Graco 332564B User Manual

Operation

ProMix® PD2K Pr

Automatic Spr

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 approvals information.

for model part numbers and

ay Applications

oportioner for

332564B

PROVEN QUALITY. LEADING TECHNOLOGY.

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

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

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

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

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

Advanced Di

ADM Display USB Downloa USB Upload P ADM Keys an Soft Key Ic Navigatin Screen Ico

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

Operat

Prime a Sprayi Purgin Shutd

Operation Using a Programmable Logic

Network Communications and Discrete

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

Communication Gateway Module (CGM)

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

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

Network Communication - Dynamic

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

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

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

splay Module (ADM) ........................ 11

................................................ 11

d Procedure............................ 11

rocedure ................................ 12

d Indicators ............................. 13

ons ............................................. 14

g the Screens ................................ 16

ns ............................................... 16

ion Using Automatic Display Module

(ADM)................................................... 2

nd Fill the System............................. 20

ng...................................................... 21

g ....................................................... 22

own.................................................... 23

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

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

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

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

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

ation Checks.............................................. 84

Calibr

Pump Pr Pump Vo Solven

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

tenance .................................................... 102

Main

Prev Flu Cle

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

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

essure Check ................................. 84

lume Check.................................... 85

t Meter Calibration ............................. 86

entive Maintenance Schedule .............. 102

shing .................................................... 102

aning the ADM...................................... 102

332564B

Related Manuals

Current manua

Manual No. Description

332709

332458

332339 Dosing Pumps, Instructions/Parts

332454

ls are available at www.graco.com.

ProMix PD2K Proportioner for Automatic Spray Applications, Repair-Parts

ProMix PD2K Proportioner for Automatic Spray Applications, Installation

Color/Catalyst Dispense Valves, Instructions/Parts

Manual No. Description

332455

333282

332456 Pump Expansion Kits,

Color Change Kits, InstructionsParts

Color Change and Remote Mix Manifold Kits, Instructions-Parts

Instructions-Parts

332564B 3

Models

See Figs. 1–6 f

Part No.

AC1000

AC2000

0359

or component identiﬁcation labels, including approval information and certiﬁcation.

Series

Maximum Air Wo

Pressure

100 psi (0.7

7.0 bar)

100 psi (0.7 MPa,

7.0 bar)

MPa,

II 2 G

rking

Maximum Fluid

Pressure

300 psi (2.0

1500 psi (10.34 MPa,

68 MPa, 20.68 bar)

103.4 bar)

Working

Location of PD2K and

Electrical Control Box

(ECB) Labels

Figure 1 Model AC1000 (Low Pressure) Identiﬁcation Label

Figure 2 24M672 Control Box Identiﬁcation Label

Continued on the next page.

332564B

Figure 3 Model AC2000 (High Pressure) Identiﬁcation Label

Models

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

The following exclamation p risks. When th Warnings. Pr the body of th

warnings are for the setup, use, grounding, maintenance and repair of this equipment. The oint symbol alerts you to a general warning and the hazard symbol refers to procedure-speciﬁc

ese symbols appear in the body of this manual or on warning labels, refer backtothese

oduct-speciﬁc hazard symbols and warnings not covered in this section may appear throughout

is manual where applicable.

WARNING

FIRE AND EX

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

• 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

• 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

PLOSION HAZARD

area free of debris, including solvent, rags and gasoline.

grounded hoses.

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

• Connect only to grounded power source.

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

6 332564B

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

icing or installing equipment.

serv

and regulations.

INTRINSIC SAFETY

Warnings

WARNING

Intrinsical equipment wi Follow local

• 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 prev

•Equipment Safety. T unit from

SKIN INJECTION HAZARD

High-pr skin. Th immedia

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

•Donotp

• 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

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

ly safe equipment that is installed improperly or connected to non-intrinsically safe

ll create a hazardous condition and can cause ﬁre, explosion, or electric shock.

regulations and the following safety requirements.

ent 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.

that comes in contact with the intrinsically safe terminals must be rated for Intrinsic

his includes DC voltage meters, ohmmeters, cables, and connections. Remove the

the hazardous area when troubleshooting.

essure ﬂuid from dispensing device, hose leaks, or ruptured components will pierce

is may look like just a cut, but it is a serious injury that can result in amputation. Get

te surgical treatment.

ut your hand over the ﬂuid outlet.

en all ﬂuid connections before operating the equipment.

332564B

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

TOX Tox inh

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

•St

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

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

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

equi

IC FLUID OR FUMES

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

aled, or swallowed.

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

idelines.

equipment.

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

• 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 in all equ informat

• 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 manufac

• 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

• 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

• Comply with all applicable safety regulations.

yewear, and hearing protection.

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

ipment manuals. Read ﬂuid and solvent manufacturer’s warnings. For complete

ion about your material, request MSDS from distributor or retailer.

uipment daily. Repair or replace worn or damaged parts immediately with genuine

turer’s replacement parts only.

ipment only for its intended purpose. Call your distributor for information.

hildren and animals away from work area.

8 332564B

Important Isocy

anate (ISO) Information

Important Iso

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

cyanate (ISO) Information

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.

Eventually a ﬁlm will form on the surface and the ISO will begin to gel, increasing in viscosity.

NOTICE

Partially c the life of a

• 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.

ured ISO will reduce performance and

ll wetted parts.

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.

Chang

Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime.

•When

•Alw

•Che

•Wh

ing Materials

NOTIC

changing materials, ﬂush the equipment

tiple times to ensure it is thoroughly clean.

mul

ays clean the ﬂuid inlet strainers after hing.

ﬂus

ck with your material manufacturer for

mical compatibility.

che

en changing between epoxies and urethanes

polyureas, disassemble and clean all ﬂuid

mponents and change hoses. Epoxies often

ve amines on the B (hardener) side. Polyureas

tenhaveaminesontheA(resin)side.

332564B 9

General Informa

tion

General Infor

• 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.

mation

• 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 Displa

yModule(ADM)

Advanced Disp

lay 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. Enable USB dow

Advanced Scr

2. Remove the co bottom of the

3. During the d screen.

4. When the dow appears on t be removed

NOTE: If th than 60 sec determine Error Sta the USB.

5. Insert th the compu

6. The USB ﬂ If it doe within W

een 3, page 83.

ver from the USB port on the

ADM. Insert the USB drive.

ownload, USB BUSY appears on the

nload is complete, USB IDLE

he screen. The USB drive may then

e download operation takes longer

onds, the message disappears. To

if the USB is busy or idle, check the

tus bar on the screen. If idle, remove

e USB ﬂash drive into the USB port of

ter.

ash drive window automatically opens.

s not, open the USB ﬂash drive from

indows® Explorer.

nloads. See

1 2 3 4 5 6 7 8 9

0 .

Figure 7 Advanced Display Module

USB Download Procedure

the USB port on the ADM to download or upload

Use

dat

7. Open Gra

8. Open sy more th one fol corres serial

9. Open D

10. Open L numbe recen

11. Open Exce They Micr

NOT (UT Mic

12. Alw the

an one system, there will be more than

der. Each folder is labeled with the

ponding serial number of the ADM. (The

number is on the back of the ADM.)

OWNLOAD folder.

OG FILES folder labeled with the highest

r. The highest number indicates the most

t data download.

logﬁle. LogﬁlesopeninMicrosoft®

l® by default if the program is installed.

also can be opened in any text editor of

osoft® Word.

E: All USB logs are saved in Unicode

F-16) format. If opening the log ﬁle in

rosoft Word, select Unicode encoding.

ays reinstall the USB cover after removing USB, to keep the drive free of dirt and dust.

co folder.

stem folder. If downloading data from

332564B

Advanced Displa

yModule(ADM)

USB Upload Pro

Use this procedure to install a system conﬁguration ﬁle and/or a custom language ﬁle.

1. If necessary Procedure, t folder struc

2. Insert the US the compute

3. The USB ﬂash If it does no within Win

4. Open the Gr

5. Open the sy than one sy folder wi labeled w the ADM. ( the modul

, follow the USB Download o automatically generate the proper

ture on the USB ﬂash drive.

t, open the USB ﬂash drive from

dows Explorer.

aco folder.

stem folder. If working with more

stem, there will be more than one

thin the Graco folder. Each folder is

ith the corresponding serial number of

The serial number is on the back of

e.)

cedure

B ﬂash drive into the USB port of

drive window automatically opens.

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.

332564B

ADM Keys and Indicators

NOTICE

Advanced Displa

yModule(ADM)

To prevent dam press the butt plastic card

Table 1 : ADM Keys and Indicators

Key Function

Startup/Shutdown

Key and Indicator

Stop

Soft Key

age to the softkey buttons, do not

ons with sharp objects such as pens,

s, or ﬁngernails.

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.

Press to immediately stop the system and remove motor power.

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.

Left/Right Arrows:

•

Use to move from screen to screen.

Navigation Keys

Numeric Keypad

Cance

Setu

Ent

Up/Down Arrows:

• menu, or multiple screens within a function.

Use to

Use to cancel a data entry ﬁeld.

Press to enter or exit Setup mode.

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.

input values. See ADM Display, page 11.

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

332564B 13

Advanced Displa

Soft Key Icons

yModule(ADM)

The following icons appear in the ADM display, directly to the left or right of the soft key which activates that operation.

Table 2 : Soft Key Functions

Key Function

Enter Screen

Exit Screen

To prevent damage to the softkey buttons, do not press the buttons with sharp objects such as pens, plastic cards, or ﬁngernails.

Press to enter screen for editing. Highlights editable data on a screen. Use Up/Down arrows to move between data ﬁelds on the screen.

Press to e

Press to accept calibration value.

Press to cancel or reject calibration value.

NOTICE

xit screen after editing.

Cancel

Prime Pump

Line/Fill/Run

Mix

Purge

Press to start a pump priming procedure.

Press to start a line ﬁll procedure.

Press to start a spray procedure.

Press to start a purge procedure.

332564B

Key Function

Advanced Displa

yModule(ADM)

Standby

Stop

Pressure Check

Volume Check

Job Complete

Counter Reset

Press to stop all pumps and put system in Standby.

Presstostartapumppressurecheck.

Press to st

Press to log the material usage and increment the job number.

Press to reset the current usage counter.

Appears on the User ID Keyboard screen. Use to move cursor to the left.

art a pump volume check.

Move Cu

Move Cursor to Right

Upper Case/Lower Case

rsor to Left

Erase All

Backspace

Appears on the User ID Keyboard screen. Use to move cursor to the right.

Appears on the User ID Keyboard screen. Use to erase all characters.

ears on the User ID Keyboard screen. Use to

App

se one character at a time.

era

Appears on the User ID Keyboard screen. Use to change case (upper/lower).

332564B 15

Advanced Displa

yModule(ADM)

Navigating th

There are two sets of screens:

• The Run screen display syst

•TheSetupscr advanced fea

Press 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 Home screen.

Press the Enter soft key function on any screen.

Press the Exit soft key

Use the other softkeys to select the function adjacent to them.

e Screens

s control mixing operations and

em status and data.

eens control system parameters and

tures.

on any Run screen to enter the Setup

on any Setup screen to return to the

to activate the editing

to exit any screen.

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 Rat

Recipe Number Flow Rate

Pressure Volume

Material B

Material A

Material A+B

Solven

Calendar Time

Alarm/Advisory

Deviation

16 332564B

Pre-Operation T

asks

Pre-Operatio

Pre-operatio

Go through the Pre-Operation Checklist daily, before each use.

✔

n Checklist

Checklist

System grou

Verify all grounding connections were made. See Grounding in the Installation manual.

All connections tight and correct

Verify all system co installe manual.

Fluid supply containers ﬁlled

Check co solvent

nTasks

nded

electrical, ﬂuid, air, and

nnections are tight and

daccordingtotheInstallation

mponent A and B and

supply containers.

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 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.”

. The system status will

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.

supply valves open and

Fluid

ure set

press

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).

Figure 8 Power Switch

332564B

Pre-Operation T

asks

Initial Syste

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.

m Setup

Flush Before Using Equipment

The pump ﬂui oil, which To avoid co equipment the equipm

d section was tested with lightweight

is left in the ﬂuid passages to protect parts.

ntaminating your ﬂuid with oil, ﬂush the with a compatible solvent before using ent.

Valve Setting

Dose valves and purge valves are factory set with the hex nut (E) 1-1/4 turns out from fully closed.

Figure 9 Va

lve Adjustment

18 332564B

Pressure Relief

Procedure

Pressure Reli

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.

ef Procedure

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.

With Color Change

NOTE: The fol air pressure

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 electrost

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.

lowing procedure relieves all ﬂuid and

in the system.

electrostatic gun, shut off the

atics before ﬂushing the gun.

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

pres

• Loos

SLOWLY loosen a ﬁtting to relieve

sure gradually.

en the ﬁtting completely.

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

pres

• Loos

7. Ver pum

E: If pressure remains in the solvent line

NOT

ween the solvent supply pump and the solvent

bet

ve,VERYSLOWLYloosenaﬁttingtorelieve

val

essure gradually.

SLOWLY loosen a ﬁtting to relieve

sure gradually.

en the ﬁtting completely.

ify on the ADM Home Screen that neither

p is showing any pressure.

332564B 19

Operation Using

Automatic Display Module (ADM)

Operation Usi

Prime and Fill

NOTE: See Run Mode Screens, page 58, for further screen information, if needed.

NOTE: You mus or the input priming the

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.

s to the color change valves before

pump and ﬁlling the entire system.

the System

t prime the input lines to the pumps

ng Automatic Display Module (ADM)

4. If the system is powered down, press 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 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 the remote mix manifold. The pump will run until

you press the Stop key

. The color will load the pump

to run color out to

to stop the pump.

on the

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

Spraying

Operation Using

Automatic Display Module (ADM)

To spray in a multiple color system, also see

Multiple Color Systems, page 87.

NOTE: See Run screen infor

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.

Mode Screens, page 58,forfurther

mation, if needed.

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

Operation Using

Purging

Automatic Display Module (ADM)

To purge one co

Color Change,

Flush Mixed Ma

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.

lor and ﬁll with a new color, see

page 87.

terial

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

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.

To reduce risk of ﬁre and explosion, if using an electrostatic gun, shut off the electrostatics before ﬂushing the gun.

332564B

Flush the System

Operation Using

Automatic Display Module (ADM)

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

Color Change S

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 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.

ystem

. The system

Material to Color (A). Press 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 system will pump solvent through pump B all the way to the gun.

8. Relieve the pressure. See

Pressure Relief Procedure, page 19

. The system

.The

7. Relieve the pressure. See

Pressure Relief Procedure, page 19

down

Shut

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 power to the pumps.

5. Shut off system power (0 position).

on the Display Module to turn off

332564B 23

Operation Using

a Programmable Logic Controller (PLC)

Operation Usi

ng 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

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 Cont

point (s

• Gun Trig

when the

NOTE: Th user to (PLC) i run all signal mode of Overri avoid the au

rol – Means of adjusting the control set

ee Flow Control Set Point below).

ger – Means of signaling the ProMix PD2K

spray device is triggered.

e Manual Override check box enables a

operate the system before the automation

s available. Manual Override can be used to

functions of the system if a proper gun trigger

is provided. It is not intended to be the main

control. Graco recommends that Manual de be disabled during normal operation to driving the system in a way that conﬂicts with

tomation sequence.

Discrete I/O

The ProMix PD Discrete I/ is necessar with the PLC connection strips on t inside the

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

Gun Trigger Input

lSet

Contro Point

Safety Interlock Input

2K does not supply power for

O. A clear understanding of these inputs

y to properly integrate the ProMix PD2K

or networking device. Input and output

s are made at the Discrete I/O terminal

he Enhanced Fluid Control Module (EFCM)

control box.

EFCM Connector

61,2

Pins Type

Normally Open Contact

1,2 4-20 mA Input

11,12

Normally Open Contact

332564B

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).

• In Flow Cont cc/min, a 4m is 500 cc/mi

• In Pressur 500 psi, a 4 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.

rol Mode: If the Max Set Point is 500

A signal is 0 cc/min and a 20mA signal

e Control Mode: If the Max Set Point is

mA signal is 0 psi and a 20mA signal

Examples

PD2K Discrete Input

e10

Figur

4–20 mA

Flow Control Set Point Input

PLC (4–20 MA Signal)

O = Output R=Return

332564B 25

Operation Using

Figure 11

a Programmable Logic Controller (PLC)

Discrete I/O Connections on EFCM

KEY

C1 Safety Interlock Input

Gun Trigger Input

og Set Point Input

Anal

26 332564B

Operation Using

a Programmable Logic Controller (PLC)

Communicatio

n 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 fo ﬁles are ava

• EDS ﬁle: DeviceNet or Ethernet/IP ﬁeldbus networks

• GSD ﬁle: PROFIBUS ﬁeldbus networks

• GSDML ﬁle: PROFINET ﬁeldbus networks

llowing system network conﬁguration

ilable at www.graco.com.

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.

CGMDNO

CGMEPO

CGMPBO PROFIBUS

CGMPNO PROFINET

24W462

Fieldbus Manual

DeviceNet 312864

EtherNet/

Modbus TCP

312864

334183

332564B

Operation Using

a Programmable Logic Controller (PLC)

Network Commu

nication 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

OUTPUT REGIS

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

Number

TER 00: Current System Mode

Operation Mode

Pump Off

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

Recipe Change: PurgeAThe system is purging material A as part of a recipe change.

Recipe C B

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

hange: Purge

Description

The pumps a operation

The syst

manifold with material as part of a recipe change.

em is purging material B as part of a recipe change.

provide various system and component status, measurement, and set point values. See

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

re currently powered down and the system is not in

6MixFil

8MixI

9 Purge A

10 Purge B

Mix The system is currently mixing/spraying material.

dle

Standby: Mix Ready

andby: Fill Ready

Standby: Mix Not Ready

Standby: Alarm

The system is mixing material at ratio through the mix manifold and out the gun.

The system has paused mix operation due to the absence of a gun trigger signal.

system is purging material A while in Standby.

The

The system is purging material B while in Standby.

e system has a valid recipe loaded out to the gun.

The system has a valid recipe loaded in the pumps, but not in the gun.

he system requires that a recipe change operation be completed.

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 indicates the be used for gen or as an indica operations.

Pump Command

Table4PumpS

Nu-

Pump

State

ber

Off

Standby

2 Busy The pump i

3 Flushing

s registers contain a number that

state of Pumps 1 — 4. This status can

eral monitoring of the pump state,

tor for driving independent pump

See INPUT REGISTER 02: Flush/Prime

, page 36.

tates for Output Registers 01–04

Description

The pump is powered down or not enabled.

The pump is powered but not currently active.

s currently in arecipec operatio

The pump is currently ﬂushing with solvent

hange or mixing

OUTPUT REGISTER 07: Actual Mix Potlife Remaining

The Actual Pot the current am recipe’s potl

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 number of th

• 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 Activ number of the curre

life Remaining register contains

ount of time remaining in the active

ife in seconds.

ecipe Number register contains the

eactiverecipe(1–60).

e Recipe Material A register contains the

the Color (1 – 30) that is associated with

nt recipe.

4 Priming The pump

with mat

OUTPUT REGISTER 05: Actual Mix Flow

The Act insta

NOTE: This register is valid only during a mix operation.

OUTPUT REGISTER 06: Actual Mix Ratio

The A inst

• The value reported is the ratio antecedent

Example

(Material A to Material B)

•Ift

This register is valid only during a mix operation.

ual Mix Flow register reports back the

ntaneous mixing ﬂow rate in cc/min.

ctual Mix Ratio register contains the

antaneous calculated mix ratio.

multiplied by 100. The ratio consequent is always

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

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

lue will be 0.

is currently priming

erial.

• 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 Act the num with t

• This value is 0 if the system was ﬂushed.

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

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

OUTPUT REGISTER 11: Active Recipe Material A Flush Sequence

The reg (1 – cur

If the current recipe is invalid this value reﬂects the Flush Sequence associated with Material A pump of recipe 0.

ive Recipe Material B data register contains

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

he current recipe.

initial startup.

recipe).

Active Recipe Material A Flush Sequence

ister contains the number of the Flush Sequence

5) that is associated with the Color pump of the

rent recipe.

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

Example

(Material A to Material B)

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

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

recipe)

OUTPUT REGISTER 19: Actual Pump 1 Fluid Pressure

OUTPUT REGIST Pressure

OUTPUT REGISTER 21: Actual Pump 3 Fluid Pressure

OUTPUT REGISTER 22: Actual Pump 4 Fluid Pressure

These regis pressure on

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 triggere

•Thevalue triggere

This data register is valid only for systems conﬁgured to use the discrete input for the Gun Trigger.

d).

Gun Trigger Signal, page 71

OUTPUT REGISTER 24: Gun 2 Trigger Input Status

ER 20: Actual Pump 2 Fluid

ters contain the instantaneous ﬂuid

the outlet of pumps 1–4 in PSI.

s0iftheinputisOPEN(gunnot

is 1 if the input is CLOSED (gun

See

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

OUTPUT REGISTER 26: Gun 4 Trigger Input Status

These registers are not used.

OUTPU Statu

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

See

OUTPUT REGISTERS 28 – 36: DCS Command Structure

See Dynamic Command Description, page 47.

T REGISTER 27: Safety Interlock Input

Stop).

Safety Interlock in Digital Inputs, page 25

30 332564B

Operation Using

a Programmable Logic Controller (PLC)

OUTPUT REGISTER 37: Time

TheTimeregis since the Unix

• 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.

ter contains a count of total seconds

Epoch (January 1, 1970).

OUTPUT REGISTER 38 – 40: Software Version

The Software V “minor,” and “

These registers are NOT currently available with the Modbus Communications Gateway Module.

ersion registers contain the “major,”

build” revisions of the ADM software.

332564B 31

Operation Using

Notes

a Programmable Logic Controller (PLC)

32 332564B

Operation Using

Network Output Data Map (Read Only)

a Programmable Logic Controller (PLC)

Network Output ID

00 40100

Modbus Register

Parameter Name Data Type Units Range

uint32

Current Syste Mode

NONE

1=PumpOff

2 = Recipe Change

3 = Recipe Change: Purge A

4=RecipeCh Purge B

5 = Recipe Change: Fill

6=MixFil

7=Mix

8=MixIdle

9=Purge

10 = Purge B

11 = Sta

12 = Standby: Fill Ready

13 = Standby: Mix Not Ready

14 = S

ange:

ndby: Mix Ready

tandby: Alarm

01 40102

02 40104

03 40106

Pump 1 Status

ump 2 Status

Pump 3 Status

uint32

NONE

ONE

NONE

0=Off

1 = Standby

2=Busy

Flushing

4 = Priming

=Off

1 = Standby

2=Busy

3 = Flushing

4 = Priming

0=Off

1 = Standby

2=Busy

3 = Flushing

4 = Priming

332564B 33

Operation Using

a Programmable Logic Controller (PLC)

04 40108

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

06 40112 Actual Mix Ratio uint32

07 40114

08 40116 Active Re

09 40118 Active Recipe

10 40120 Active Recipe

11 40122 Active

12 40124 Active Recipe

Pump 4 Status

Actual Mix Potlife Remaining

cipe

Number

Material A

Material B

Recipe

al A Flush

Materi Sequen

Material B Flush Sequence

uint32

NONE

sec

NONE

0=Off

1 = Standby

2=Busy

3 = Flushing

4 = Priming

0 - 5000

0 – 59940

0-61

1-30,61

31 - 34, 61

1-5

13 40126 Active Recipe

Ratio Set Point

0140

134

14 4012

15 40130 Actual Pump 1

16 40132 Actual Pump 2

17 40

18 40136 Actual Pump 4

19 40138 Actual Pump 1

21 40142 Actual Pump 3

22 40144 Actual Pump 4

ve Recipe

Acti

ife Time Set

Potl

Poin

Flow Rate

tual Pump 3

ow Rate

Flow Rate

Fluid Pressure

ctual Pump 2

A Fluid Pressure

Fluid Pressure

uint32

uint

uint32 cc/min 0 - 800

nt32

uint32 cc/min 0 - 800

uint32

int32

uint32

NONE

min 0 - 99

/min

PSI

0 - 5000

800

0 - 1500

-1500

0 - 1500

34 332564B

Operation Using

a Programmable Logic Controller (PLC)

23 40146

24 40148

25 40150

26 40152

27 40154

28 40200

29 40202

30 402

Gun 1 Trigger Input Status

Gun 2 Trigger Input Status

Gun 3 Trigge Input Stat

Gun 4 Trigger Input Status

Safety Interlock Input Status

Comman Acknow

Command Return 0

Command Return 1

ledge

uint32

uint32 N/A N/A

t32

uin

NONE

N/A N/A

0 = Gun not triggered

1 = Gun trigger

0 = Gun not triggered

1 = Gun triggered

0=Gunnottr

1 = Gun triggered

0 = Gun not triggered

1=Guntri

0=Open

1 = Closed

0:=NOP

1=BUSY

2=ACK

3=NAK

4=ER

iggered

ggered

31 40206

32 40208

33 40210

34 40212

35 40214

36 40216

37 N/A Time uin32

38 N/A

39 N/A

40 N/A

mmand Return

Co 2

Command Return 3

Command Return 4

Command Return 5

Command Return 6

Command Return 7

Software Version –Major

Software Version –Minor

Software Version – Build

uint32 N/A N/A

uint32

sec

NONE

0 – 4,294,967,295

0–99

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

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 M to initiate Figures 5 –

Number

2 Power Pumps

6Mix Thesy

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

these registers for Read status, other than to conﬁrm data that has been written and accepted.

ode Command register accepts a number that represents a command to the PD2K system

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

9 for details).

Operation Mode

No OP

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

Recipe

Mix Fill

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

Change

Descripti

The system takes no action.

The system powers on or powers off the pumps.

pumps.

The sys

The system ﬁlls the mix manifold and gun with material at ratio for a valid recipe.

tem initiates a recipe change. (See also Register 7.)

stem initiates a mix/spray cycle.

Standby 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

ThePumpFlush register is us Pump Command r below) to inde 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 REG

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).

Sequence/Prime Material Selection

ed in conjunction with the Flush/Prime

egister (see INPUT REGISTER 02

pendently prime or ﬂush an inactive

ISTER 02: Flush/Prime Pump Command

INPUT REGISTER 03: Mix (Pump 1) Control Set Point

The Mix Contro adjust the mix as the ﬂuid con a1Krecipe. It system will i

• 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 REG

INPUT REGISTER 05: Pump 3 Control Set Point

INPUT REGISTER 06: Pump 4 Control Set Point

l Set Point register is used to set and

ing ﬂuid control set point. It also is used

trol set point for pump 1 when running

can be changed at any time, and the

mmediately adjust to the new set point.

ISTER 04: Pump 2 Control Set Point

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: inact conti the s is co mode oper

If two pumps are currently mixing and an ive pump is commanded to ﬂush or prime it will nue its operation to completion without affecting

ystem mode status. When the mixing operation

mplete, the system status will reﬂect Standby

while the ﬂushing/priming pump completes its

ation.

These r

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 chan

egisters are not used.

: Writing to this register does not trigger a recipe

ge.

See Color Change Sequence, page 44.

332564B 37

Operation Using

a Programmable Logic Controller (PLC)

INPUT REGISTER 08: Clear Active Alarm

The Clear Acti acknowledge a may resume ope condition has register to ac more than one recent alarm should be per alarms. See ﬁ

ve Alarm register is used to

n alarm remotely so that the system

ration. Be sure that the alarm

been alleviated. Write a 1 to this

knowledge the latest active alarm. If

alarm is currently active only the most

will be acknowledged. A repeated write

formed to clear any remaining active

gure 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 REG

ISTER 09: Job Complete

The Job Complete register is used to log the current job remotely. Write a ‘1’ to the register to command theProMixPD2Ktoﬂagajobcomplete.

INPUT REGISTER 10: Gun 1 Trigger

TheGun1Trigg ProMix PD2K wh triggered. Th spray device i provides timi the ﬂow contr

er register is used to signal the

en the automatic spray device is

is signal should be sent any time the

s triggered. The state of this register

ng for alarm functions and also drives

ol 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 is set to ‘N If it is se gun trigg

Digital I

critical provide a

etwork’ via System Screen 5 on the ADM.

t to ‘Discrete’ this register is ignored and

er is handled via the discrete input. See

nputs, page 25.

NOTE: Because timing is so

for ﬂow control Graco recommends that users

discrete input to minimize latency effects.

(See Usage Screen, page 64 for more information on Job Logs and Job Complete.)

NOTE: Th PD2K. A is writ automa other t

is register is not polled by the ProMix

job is logged only when a value of ‘1’

ten to this register. It is recommended the

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

imes to avoid inadvertently logging a job.

Input Register 10

Gun Trigger

Discrete Signal

ProMix PD2K

Gun Trigger State

e 12 Gun Trigger Timing (Network and Discrete

Figur

ls Shown

Signa

10 1 0

INPUT REGISTER 11: Gun 2 Trigger

INPUT REGISTER 12: Gun 3 Trigger

T REGISTER 13: Gun 4 Trigger

INPU

These registers are not used.

INPUT REGISTERS 14 – 21: DCS Command Structure

e Dynamic Command Description, page 47.

38 332564B

Notes

Operation Using

a Programmable Logic Controller (PLC)

332564B 39

Operation Using

a Programmable Logic Controller (PLC)

Network Input Data Map (Write/Read)

Network Input ID

00 40156

01 40158

02 40160

Modbus Register

Parameter Name Data

Type

System Mode Co

Pump Flu Materia

Flush/Prime Pump Command

sh Sequence #/Prime

mmand

uint32

Units Range

NONE

0=No

1=PowerPump

2=RemoteStop

3 = Recipe Change

4 = Mix Fill

5=Mix

6=PurgeA

7=PurgeB

8 = Standby

1 - 5, 1 - 34

0=NoOP

1=Flus

2=PrimePump1

3=FlushPump2

4=Pri

hPump1

me Pump 2

03 40162

0170

164

04 40

05 40166

06 40168

08 40172

09 40174

10 40176

11 40178

(Pump 1) Control Set Point

Mix

Pump 2 Control Set Point

Pump 3 Control Set Point

ump 4 Control Set Point

Go to Recipe Number

Clear Active Alarm

Job Complete

Gun 1 Trigger

Gun 2 Trigger

uint32 cc/min or

PSI

nt32

uint32 cc/min or

int32

uint32

/min or

PSI

NONE

NONE 1 = Clear Active Alarm

NONE

5=FlushPump3

6=PrimePump3

ush Pump 4

7=Fl

8=PrimePump4

1 - 1600

1600

1 - 1600

,1-60

1 = Trigger job complete

0 = Gun not triggered

1 = Gun triggered

0 = Gun not triggered

1 = Gun triggered

40 332564B

Operation Using

a Programmable Logic Controller (PLC)

12 40180

13 40182

14 40184

15 40186

16 40188

17 40190

18 40192

19 40194

20 40196

21 40198

These

Gun3Trigger

Gun4Trigger

Command Arg

Command Argument 1

Command Argument 2

Command A

Command Argument 4

Command Argument 5

Comman

DCS Command

registers are not used.

rgument 3

dArgument6

ument 0

uint32

NONE

NONE See Command Table

DCS Register

0 = Gun not triggered

1 = Gun trigger

0 = Gun not triggered

1 = Gun triggered

N/A

332564B

Operation Using

a Programmable Logic Controller (PLC)

Operation Flo

w Charts

Purge Mode Sequence

Purge A System Command Write ‘6’ to Input Register 00

Is system in Standby or

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.

Pumps Off?

YES

NOTE: Purge B command works similarly with the catalyst lines and solvent flow switch 2.

No action taken.

Either pumps are currently

running or an alarm condition

exists.

Purge time set according to the flush sequence assigned to

System Mode = Standby: Mix Not Ready

System closes color solvent valve at remote stack.

material A in recipe.

Is solvent flow switch 1 ON?

YES YES

Purge time expired?

YES

(Output Register 00 = ‘13’)

Purge no flow timeout expired?

No solvent flow detected.

Generate alarm.

332564B

Operation Using

Inactive Pump Flush and Prime Sequences

a Programmable Logic Controller (PLC)

Write Flush Sequence #

(1-5) to Output Register 01

Write

Flush Pump Command

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

Is requested pump

status* = Standby?

(Output Register* = ‘1’)

YES YES

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

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.

Invalid request.

No action taken.

NONO

Write Prime Material #

(1-34) to Output Register 01

Write

Prime Pump Command

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

Is requested pump

status* = Standby?

(Output Register* = ‘1’)

Is selected material valid

for requested pump?

Pump is flushed using

assigned sequence number.

Pump Status = Flushing

(Output Register* = ‘3’)

NO NO

Is Flush complete? Is Prime complete?

Pump is returned to Standby.

Pump Status = Standby

(Output Register* = ‘1’)

YES

Pump is primed using

assigned material.

Pump Status = Priming

(Output Register* = ‘4’)

YESYES

332564B 43

Operation Using

a Programmable Logic Controller (PLC)

Color Change Sequence

Write Goto Recipe Number

(0,1 - 60) to Input Register 07

Recipe Change System

Command

Write ‘3’ to Input Register 00

System Mode = Recipe

(Output Register 00 = ‘2’)

Purge Material B out gun.

(Output Register 00 = ‘4’)

Pump will flush then prime.

Change

Is Material B

changing?

YES

System Mode = Recipe

Change: Purge B

Is Material A

changing?

YES

Is system in Standby

with no alarm conditions?

Is purge complete and

are pumps primed?

Fill material out to mix

manifold.

System Mode = Recipe

Change: Fill

(Output Register 00 = ‘5’)

YES

No action taken.

Either pumps are currently

running or an alarm condition

Mix material out to gun.

System Mode = Mix Fill

(Output Register 00 = ‘6’)

exists.

Is mix fill complete?

YES YES

Purge Material A out gun.

System Mode = Recipe

Change: Purge A

(Output Register 00 = ‘3’)

Pump will flush then prime.

Is material filled out to

mix manifold?

YES

System Mode = Standby:

Mix Ready

(Output Register 00 = ‘11’)

332564B

Mixing Sequence

Mix System Command

Write ‘5’ to Input Register 00

Operation Using

a Programmable Logic Controller (PLC)

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.

Stem Mode =

Standby: Mix Ready?

System Mode = Mix

(Output Register = ‘7’)

YES

Gun Trigger = ON?

YESYES

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.

Mix Idle Timeout

expired?

YES

NOTE: System will remain in Mix mode until a STANDBY command is issued or an alarm condition exists.

No gun trigger signal for

longer than Mix Idle Timeout.

System Mode = Mix Idle

(Output Register = ‘8’)

332564B 45

Operation Using

a Programmable Logic Controller (PLC)

Alarm Clearing Sequence

NOTE: If an alarm condition is active the System Mode will either be Pump Off or Standby: Alarm. (Output Register 00 = ‘1’ or ‘14’)

Clear Active Alarm

Write ‘1’ to Input Register 08

Clear most recent active

alarm.

Remaining alarm(s) still

active.

NOTE: If more than 1 active alarm exists a repeated write of ‘1’ to Input Register 08 is required for each.

YES

Is there an active

alarm?

YES

Is there more than 1

active alarm?

No action taken.

Clear active alarm.

46 332564B

Operation Using

a Programmable Logic Controller (PLC)

Network Commu

nication - 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 foll

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.

ProMix PD2K Inputs (PLC Outputs)

INPUT REGISTER 14

owing sequence for the DCS.

[arg_0]

INPUT REGISTER 14+n [arg_n]

INPUT REGISTER 21

ProMix PD2K Outputs (PLC Inputs)

OUTPUT REGISTER 28

OUTPUT REGISTER 29

OUTPUT REGISTER 29+n

13 Dynamic Command Structure Timing

Can be written together

or sequentially.

[id]

ACK = 2

[rtn_0]

[rtn_n]

Figure

332564B

Operation Using

a Programmable Logic Controller (PLC)

List of DCS Commands

Table 5 Dynamic Commands with Command ID

1 Write User ID

2WriteRecip

10 Read User ID

11 Read Reci

Write

The W more as th

Command

No OP

Write Flush Sequence

Write Fluid Control Mode

Read Flush Sequence

Read Fluid Control Mode

Read Jo

Read Alarm Info

Read Event Info

bInfo

User ID

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

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

ree 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

DCS Command

gument 0

rgument 1

Argument 2 User ID characters [9:8]

Acknowledge

Return 0 User ID characters [3:0]

Return 1 User ID characters [7:4]

Return 2 User ID characters [9:8]

Parameter Description Data

te User ID

Wri

er ID characters [3:0]

SCII)

ser ID characters [7:4]

ASCII)

(

(ASCII)

Command Acknowledged

(ASCII)

Type

t32

uin

nt32

int32

uint32

Units Value Range

NONE

NONE 0x6E686F4A = [‘n’,

NONE 0x656F4420 = [‘e’,

NONE

NONE 2 = ACK

NONE

10-1

’h’, ’o’, ’J’]

’o’, ’D’, ’ ‘]

0x0 = [null] N/A

0x6E686F4A N/A

0x656F4420 N/A

0x0 N/A

0-4

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 reci

Example: Conﬁgure Recipe 6 for

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

DCS Register

DCS Command

Argument 0 Recipe Number uint32

Argument 1 Material A uint32

Argument 2 Material B uint32

Argument 3

Argumen

Argument 5

Argument 6

wledge

Ackno

Return 0 Recipe Number uint32

pe must be enabled via the ADM before it can be loaded for mixing.

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

Parameter Description Data

Type

Write Recipe uint32

uint32

uint32 min 10 0 - 999

uint3

Material A Flush Sequence

Material B Flush Sequence

Mix Rat

Potlife Time Set Point

Command Acknowledged

io Set Point

Units Value Range

NONE

NONE 2 = ACK

NONE

20-16

60-60

20–30

31 0, 31 – 34

21-5

31-5

150 = 1.50:1 0 - 5000

0-4

60-60

Return 1 Material A uint32

urn 2

Ret

Return 3

Return 4

eturn 5

Return 6

erial B

Mat

terial A Flush Sequence

Material B Flush Sequence

Mix Ratio Set Point

Potlife Time Set Point

t32

uin

uint32

int32

uint32 min 10 0 - 999

NONE

20–30

- 5000

1–34

31 0, 3

21–5

31–5

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: Con Flush Volume

DCS Register

DCS Command

Argument 0

Argument 1

Argument 2 Initial Flush Volume uint32

Argument 3 Final Flush Volume uint32

Argumen

Argument 5

Acknowledge

Retur

Return 1

Return 2 Initial Flush Volume uint32

Return 3 Final Flush Volume uint32

ﬁguring Flush Sequence 4 for Gun Purge Time = 10 sec, Initial Flush Volume = 125 cc, Final = 250 cc, Wash Cycles = 1, Strokes per Cycle = 2.

scription

ime

Data Type

uint32

uint3

uint32

Parameter De

Write Flush Sequence

Flush Sequence #

Gun Purge T

#WashCycles

sperWashCycle

Stroke

Command Acknowledged

Flush Sequence #

urge Time

Gun P

Units Value Range

NONE

sec

NONE

NONE 2 = ACK

NONE

sec

30-16

41-5

10 0 - 999

125 0 - 9999

250 0 - 9999

10-99

20-99

41-5

10 0 - 999

125 0 - 9999

250 0 - 9999

0-4

urn 4

Ret

Return 5

#WashCycles

rokes per Wash Cycle

t32

uin

uint32

NONE

10-9

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 Flui powered off.

d Control mode should be changed only when the system is in Standby or when the pumps are

Do not change Fluid Control modes during a mix operation.

Example: Change to Flow Control mode.

DCS Register

DCS Command

Acknowle

dge

Parameter Description Data

Type

Write Fluid

Fluid Control Mode

Command Acknowledged

Fluid Co

Control Mode

ntrol Mode

uint32

Units Value Range

NONE

NONE 2 = ACK

NONE

40-16

0 = Flow Mode

0=FlowArgument 0

1=Pressure

0-4

0=FlowReturn 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.

Examp

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

DCS Register

DCS Command

owledge

Ackn

Return 0 User ID characters [3:0]

Return 1 User ID characters [7:4]

eturn 2

Param

Read User ID uint32

Command Acknowledged

(ASCII)

U (

eter Description

ser ID characters [9:8]

ASCII)

Data Type

uint

uint32

int32

Units Value Range

NONE

NONE 2 = ACK

NON

NONE 0x656F4420 = [‘e’,

NONE

10 0 - 16

E686F4A = [‘n’,

0x6

,’o’,’J’]

’h’

’o’, ’D’, ’ ‘]

x0 = [null]

0-4

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 Sequence = 1, C

DCS Register

DCS Command

Argument 0

Acknowledge

Return 0

Return 1 Material

Return 2 Material B uint32

Return 3

Return

Return 5

Return 6

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

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

knowledged

scription

Data Type

uint32

uint32 min 35 0 - 999

Parameter De

Read Recipe uint32

Recipe #

Command Ac

Recipe #

Material A Flush Sequence

Material B Flush Sequence

Mix Ra

Potlife Time Set Point

tio Set Point

Read Flush Sequence

Units Value Range

NONE

NONE 2 = ACK

NONE

11 0 - 16

3 0 - 30, 61

32 0, 31 - 34, 61

11-5

41-5

325 0 - 5000

0-60

0-4

0-60

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

DCS Command

rgument 0

Acknowledge

Return 0

Return 1

Return 2 Initial Flush Volume uint32

Return 3 Final Flush Volume uint32

Return 4

Return 5

Parameter Description Data

Type

nt32

Read Flush Sequence

Flush Sequence #

Command Acknowledged

Flush Sequence #

Gun Purge Time

#WashCycles

Strokes per Wash Cycle

int32

uint32

Units Value Range

NONE

NONE 2 = ACK

NONE sec

NONE

12 0 -

11-5

20 0 - 999

00-9999

500 0 - 9999

20-99

10-99

-5

0-4

52 332564B

Read Fluid Control Mode

Operation Using

a Programmable Logic Controller (PLC)

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.

DCS Register

DCS Command

Acknowledge

Parameter Description Data

Type

Read Fluid Control Mode

Command Ac

Fluid Control Mode

knowledged

uint32

Example: Read Fluid Control as currently set to Pressure mode.

Units Value Range

NONE

NONE 2 = ACK

NONE

13 0 - 16

0-4

1 = Pressure

0=FlowReturn 0

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 200thmost recent.

The date is ret month, day, an

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 S

urnedasfour-bytepacketwitheachbyteholdingatwo-digitvaluefor(from MSB to LSB) year,

d day of the week (Monday = 01).

creen, 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

DCS Command

Argument 0 Job Index uint32

Acknowledge

Return

Parameter Description Data Type Units Value Range

Read Job Info

Command Acknowledged

Job Dat

uint32

uint32 [YY:MM

NONE

NONE 2 = ACK

:DW]

:DD-

14 0 - 16

00–199

0-4

0x0E05 [14:05

1D04 =

:29:04]

N/A

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

:SS]

Return 2 Job Number uint32

Return 3

rn 4

Retu

Return 5

turn 6

Return 7

Recipe #

olume

A+B V

User ID [3:0] (ASCII)

User ID [7:4] (ASCII)

er ID [9:8] (ASCII)

uint32

uint

uint32

nt32

uint32

NONE

NONE 0x6E686F4A = [‘n’,

NONE 0x656F4420 = [‘e’,

0x0B160E = [11:22:14]

25 0 - 9999

20-60

1234 N/A

’h’, ’o’, ’J’]

’o’, ’D’ ‘ ’]

0N/A

N/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 the 200

most recent.

chronological index

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

The date is ret month, day, a

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 E

An example decoding algorithm is provided below.

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

nd day of the week (Monday = 01).

rrors, page 88, for more details on these Event Types.

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.

Parameter Description Data

DCS Regis

DCS Command

Argument 0 Alarm Index uint32

Acknowledge

Return

ter

Type

Read Alarm Info

Command Acknowledged

Alarm D

ate

uint32

uint32 [YY:MM

Units Value Range

NONE

NONE 2 = ACK

:DD:DW]

15 0 - 16

10-199

0-4

0x0E06 [14:06

0302 =

:03:02]

N/A

Return 1 Alarm Time uint32

Return 2

ple ASCII Character String Decode Algorithm:

Exam

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’;

m Code Char[3:0]

Alar

uint32

[xx:HH:MM:SS]

NONE 0x31

0x080B0B = [08:11:11]

’0’,

304B44 = [‘1’,

’K’, ’D’]

N/A

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 199 is the 200

most recent.

chronological index

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

Thedateisret month, day, a

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

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

nd day of the week (Monday = 01).

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

DCS Command

Argument 0 Event Number uint32

Acknowl

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

edge

Parameter Description Data

Type

Read Even

Command Acknowledged

tInfo

uint32

Units Value Range

NONE

NONE 2 = ACK

:DW]

16 0 - 16

40-199

0-4

0x0E060302 = [14:06:03:02]

N/A

Retur

Return 2

Time

Event

Event Code Char[3:0]

uint3

uint32

[xx:HH:MM:SS]

NONE 0x30304345 = [‘0’,

B0B =

0x080

1:11]

[08:1

’0’, ’C’, ’E’]

N/A

56 332564B

Operation Using

a Programmable Logic Controller (PLC)

Flow Control S

ystem

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 con controll Point.

recommen controll

driven b could be timing.

trol system relies on two main inputs for

ing ﬂow rate: Gun Trigger and Control Set

TE: These inputs are timing critical. Graco

ds that users wire them discretely to the

er.

Alternatively these two inputs can be

y the network communications, but latency

an issue for systems requiring precise

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.

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.

ystem is considered to be stable when the

The s

sure readings do not ﬂuctuate and the ﬂow rate

pres

intained. While the system is considered stable

is ma

ll store (“learn”) the associated pump pressures

it wi

table that is used if the gun trigger signal is lost

to a

emoved.

or r

The gun o algori too hig exampl trigge to the p for th

Syste

The pr the t ProM beca new p (dep

n/off prediction is used in the ﬂow control

thmtopreventtheﬂuidpressurefrombecoming

h or too low due to a system disturbance. For

e, if a gun off prediction occurs while the gun

r input is high, the system will begin to control

ressure value last stored in the pressure table

e current ﬂow set point.

m Startup and Defaults

essuretableisstoredinvolatilememory,so

able values will be lost after a power cycle of the

ix PD2K controller. This issue is not signiﬁcant

use the system generally is able to recalculate

ressure table values within a few seconds

ending on the stability of the ﬂuid system).

332564B 57

Run Mode Screens

RunModeScree

NOTE: Selection ﬁelds and buttons that are grayed-out on the screens are not currently active.

Opening Screen

At power up, approximat screen.

the Graco logo will display for

ely 5 seconds, followed by the Home

Home Screen

The Home screen displays the current status of the system. The following table details the information shown.

Figure 14 Opening Screen

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

Home Screen Key

Key Description Details

Run Mode Screens

A Date and Time

B Menu Bar

C Status Ba

See Advanced Screen 1, page 82,toset.

Run Screens. U different Ru

• 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 St

•PumpOff

• Standby

•Startup

•Mix

• Fill

se left and right arrow keys to scroll through the

n screens:

atus: Displays the current mode of operation:

• Change Recipe

•Idle

• Prime Pump

• Calibrate

•StallTest

• Purge

• Shutdown

Error Status

ays any active error code.

Displ

• Maintenance Test

332564B 59

Run Mode Screens

Key Description Details

E Pump Animation and

Diagnostic Information

G Material (A or B)

L Pump Flow Rate

P Pump Indi

SSolven

Pump Number (1

Available Colors

Pump Inlet C

Pump Outle

Pump Outlet Pressure

• Clear = power off

• Yellow = standby

•Green=active

Spray Device Animation

olor

tColor

cator Light

tFlowRate

–4)

Shows s

Shows mixed material in the spray device and displays active recipe at the spray device. Gun animation changes to show:

•

olvent ﬂow rate, if a solvent meter is attached.

•

(Mix Fill)

•

(Mix With Gun Triggered)

•

(Recipe Standby)

(Purge)

•

• (Solvent Standby)

• Gun Not Triggered)

(Mix With

60 332564B

Key Description Details

Run Mode Screens

Active Recipe (

Current Ratio (

Potlife Time

Total Volume for the Current Job (

Current Fl

Current Pressure (

)

ow Rate (

)

Remaining (

)

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 sc

• 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:

reen includes the following information:

Press to put the system in Standby.

Press to spray mixed material.

Figure 16 Spray Screen, in Standby Mode

e 17 Spray Screen, in Mix Mode

Figur

Press to purge the gun.

Figure 18 Spray Screen, in Idle Mode

62 332564B

Fill Screen

NOTE: This screen is visible only if manual override is enabled on System Screen 5, page 71.

Run Mode Screens

The Fill scre the pump assi

• 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

for editing.

2. Select Color (A).

3. If the selected material is not already loaded,

press th prime C the sel valve.

en displays the following information for

gned to the current color:

to open the screen

e Prime softkey

olor (A) into the selected pump through

ected color valve and out the outlet dump

. The system will

Figure 19 Fill Screen, Color (A) Selected

4. Press the Fill softkey

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

pres cont

5. Repe

ses Stop

ainer.

at for Catalyst (B).

. Trigger the gun into a waste

. The system will

e 20 Fill Screen, Solvent Selected

Figur

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 for editing.

2. To enter or change the User ID ( 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 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

. This will clear the current usage

to open the screen

), select the

to close the screen.

Figure 22 User ID Keyboard Screen

e 23 Usage Log

Figur

Figure 21 Usage Screen

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 Scree

SetupModeScr

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 screen disp

has a password lock, the Password

lays. See Password Screen, page 66.

eens

Password Screen

Figure 27 Password Screen

Enter the 4 digit password, then press screen 1 will open, allowing access to the other Setup screens.

.System

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 Scree

System Screen

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 (0.7 MPa, pressur bar) low

Solvent

pressure systems may be set 100 psi

7 bar) lower than target pressure; high

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

er than target pressure.

Meter

Select t The Sol

Solven

Enter

his box if your system uses a solvent meter.

vent K-Factor ﬁeld will then become active.

tK-Factor

the solvent meter K-Factor.

332564B 67

Setup Mode Scree

System Screen

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.

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

Mix No Flow

The Gun Tri triggered gun is tri pump, you knowing. system to time. The shutdow

See Digital Inputs, page 25.

Inputs, page 25.

Timeout

gger Input signals that the gun is

. If the Gun Trigger Input indicates that the

ggered, but there is no ﬂuid ﬂow through a

could spray pure resin or catalyst without

The Mix No Flow Timeout will cause the

shutdown after the designated period of

default is 5 seconds. Enter the desired

ntimeinthisﬁeld.

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

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 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 Scree

System Screen

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 Scree

System Screen

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 that the PLC

ox to enable the selected Gateway so

can communicate with it.

DHCP

Select thi Conﬁgurat unique IP a renews the the netwo Gateway ﬁ the addre

s box if your system has a Dynamic Host

ionProtocol(DHCP).Thisprotocolassigns

ddresses to devices, then releases and

se addresses as devices leave and rejoin

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

elds will not be editable and will display

sses supplied by the DHCP.

TCP/IP

Use the r mask, Ga

emaining ﬁelds to set the IP address, subnet

teway, DNS1, and DNS2.

70 332564B

Setup Mode Scree

System Screen

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

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 — t hard-wired

•Network—th other netw

Flow Contr

Select the ﬂow rate o

• 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.

he signal is sent via a direct,

connection

esignalissentviaaPC,PLC,or

orked device.

ol (Setpoint Signal)

format of the signal that indicates system

r pressure.

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.

Check this box to give users system control at the ADM. Leave the box unchecked if all system settings

332564B

Setup Mode Scree

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.

332564B

Flush Screen

Initial Flush

Setup Mode Scree

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).

Enter the init

ialﬂushvolume(0to9999cc).

Final Flush

Enter the ﬁna

l ﬂush volume (0 to 9999 cc).

Wash Cycles

AWashCycle closed, to u the pump. E (0 to 99). E per Cycle ﬁ

Strokes p

Enter the to 99). De

se pumping motion to thoroughly clean

nter the desired number of wash cycles ntering a number will make the Strokes eld active.

er Wash Cycle

desired pump strokes per wash cycle (0

fault is 1.

activates the pump with the valves

332564B 73

Setup Mode Scree

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 deﬁne the pu

Figure 36 Pump Screen 1

1 includes the following ﬁelds which

mp.

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.

Pump Size

Select 35cc or 70cc, as appropriate.

Inlet Pressure

Select one of the following:

• Disabled

• Monitor, to track inlet pressure

332564B

Pump Screen 2

Setup Mode Scree

Pump screen 2 sets the pressure transducer settings for the pump.

Figure 37 Pump Screen 2, Default Settings Enabled

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 Pressure i Monitor; i valid ran

•InletSen Inlet Pre to Monito valid ra

•OutletO +01.20 m

•OutletS to 21.2

et Factor: This ﬁeld is only used if Inlet

n Pump Screen 1, page 74 is set to

t is grayed out if set to Disabled. The

ge is -01.20 to +01.20 mV/V.

sitivity Factor: This ﬁeld is only used if

ssure in Pump Screen 1, page 74 is set

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

nge is 18.80 to 21.20 mV/V.

ffset Factor: The valid range is -01.20 to

V/V.

ensitivity Factor: The valid range is 18.80

0mV/V.

re 38 Pump Screen 2, Default Settings Disabled

Figu

332564B 75

Setup Mode Scree

Pump Screen 3

Pump screen 3 sets the pressure alarm limits for the pump.

When Inlet Pr set to Disabl out and only t

Pressure Ala

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.

essure in Pump Screen 1, page 74 is

ed, the inlet limit ﬁelds are grayed

he outlet limit ﬁelds are active. See

rm 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 Scree

Calibration S

creens

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 l or catalyst

System Scre

See Pump Pre test instru

To initiat button for pressure Pressure stroke po by the dow

NOTE: TheLastPassedlogcanonlyberesetby successfully completing the test.

The screen displays the number of days since the last stall test was passed for each pump.

e the test, press the Pressure Check

. The pump will then move to the center

sition and stall test the upstroke, followed

ines must be primed with color

before doing the stall test. See

en 2, page 68 to set test parameters.

ssure Check, page 84 for complete

ctions.

the desired pump. The pump will build

in the line to a minimum of the Stall Test

nstroke.

Figure 41 Calibrate Screen 1

332564B

e 42 Stall Test Screen

Figur

Setup Mode Scree

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 li or catalyst b

Pump Volume C

instruction

To initiate button for t

The screen displays the volume dispensed. Press

to end the test.

Press and seconds t

o reset the volume counter.

nes must be primed with color

efore doing the Volume Check. See

heck, page 85 for complete test

the test, press the Volume Check

he desired pump.

hold the Reset button

for 1-2

Figure 43 Calibrate Screen 2

Figure

44 Volume Check Screen

78 332564B

Calibrate Screen 3

Calibrate Screen 3 initiates a calibration of an accessory solvent meter. During the test, the Volume Veriﬁcation screen will appear.

Setup Mode Scree

The meter and l solvent befo

Solvent Mete

instruction

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

After the

Calibra

the cal and ret

Press and hold the Reset button seconds to reset the volume counter.

Measured Volume is entered, the Accept

tion window will appear. Press

ibration. Press

ain the previous K-factor.

ines must be primed with

re doing the calibration. See

r Calibration, page 86 for complete

to end the test.

to accept

to cancel the calibration

for 1-2

Figure 46 Enter Measured Volume of Solvent

Figure 45 Calibrate Screen 3

Figure

47 Accept Calibration

332564B 79

Setup Mode Scree

Maintenance S

creens

Maintenance Screen 1

Use this screen to set maintenance intervals. Set to 0 to disable the alarm.

NOTE: The Pum must enter a

Figure 48 Maintenance Screen 1, Interval Settings

p Stall Test cannot be disabled. You

value other than 0.

Maintenance Screen 3

Maintenance screen 3 shows the current interval status of the pump maintenance tests.

Press and hold the Reset button seconds to clear the alarm and reset the counter.

NOTE: ThePumpStallTestcanonlyberesetby successfully completing the test.

for 1-2

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 seconds to clear the alarm and reset the counter.

gure 49 Maintenance Screen 2, Current Status

for 1-2

Figure 50 Maintenance Screen 3, Current Pump Status

80 332564B

Maintenance Screen 4

Maintenance screen 4 displays cycle counts for a selected color, catalyst, or solvent valve.

Setup Mode Scree

Press and hold the Reset button seconds to reset the counter.

If the system or closed by correspond

Figure 51 Maintenance Screen 4, Color Valve Resets

is in Standby, valves can be opened

selecting or deselecting the box for the

ing valve.

for 1-2

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 Scree

Advanced Scre

Advanced screen 1 sets the following display parameters.

Figure 53 Advanced Screen 1

en 1

Language

Deﬁnes the language of the screen text. Select:

• English (default)

• Spanish

•French

•German

• Japanese

• Chinese

• Korean

•Dutch

• Italian

uguese

•Port

•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 it in a s

Screen

Select 5isth saver

Silen

Sele audi

sure to write down the password and keep

ecure location.

Saver

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

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

tMode

ct Silent Mode to disable the alarm buzzer and

ble feedback.

82 332564B

Setup Mode Scree

Advanced Scre

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

Figure 54 Advanced Screen 2

en 2

Display Units

Select the desired display units:

• Grand Total Volume (US gallon or liter)

• Pressure (psi, bar, or MPa)

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.

• Length (ft or m)

Advanced Screen 3

Advanced screen 3 enables USB downloads and uploads.

Figure 55 Advanced Screen 3

Figure 56 Advanced Screen 4

332564B 83

Calibration Che

cks

Calibration C

Pump Pressure

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.

hecks

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 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.

button for the

84 332564B

Calibration Che

cks

Pump Volume Ch

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 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.

eck

for the pump you want

6. Press the Reset key 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.

. The volume counter

332564B 85

Calibration Che

cks

Solvent Meter

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

NOTE: For maximum accuracy, use a gravimetric (mass) method to determine the actual volumes dispensed.

Calibration

to initiate the calibration.

6. Trigger the gu Dispense a min

7. The volume tha the screen.

8. Compare the a amount in the

NOTE: If the repeat the c

9. Enter the am Measured V

10. After the m controlle K-factor a standard m

11. Press to cance K-facto

value is substantially different,

alibration process.

ount of solvent dispensed in the

olume ﬁeld on the screen.

easured volume is entered, the

r calculates the new solvent meter

nd displays it on the screen. The

eter K-factor is 0.021 cc/pulse.

l the calibration and retain the previous

n into a graduated cylinder.

imum of 500cc of material.

t the unit measured displays on

mount on the screen to the

graduated cylinder.

accept the calibration. Press

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.

86 332564B

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 Col

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..

or Systems

332564B 87

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 r clear itself

A Deviation 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 th

• 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.

ecords an event in the system, and will

after 60 seconds.

e three types occur:

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 acknowl

may acknowledge and clear errors via a network device. INPUT REGISTER 08: Clear Active Alarm in

ProMix PD2K Network Inputs, page 36.

edge a deviation or clear an alarm, press

on the Advanced Display Module. Users also

Gun Trigger Input Function

The Gun T the gun i Display Input i

rigger Input signals the controller when

s triggered. The gun icon on the Advanced

Module shows spray when the Gun Trigger

s 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

F7P1 Alarm Air Flow

SPD1

Type Description Problem

Switch On

Alarm

Gun Purge Incomplete

The air ﬂow switch is indicating unexpected atomizing air ﬂow.

Thesystemtimedout without reaching the user-speciﬁed volume of solvent for a purge.

Cause Solution

Air ﬂow switch is stuck in ﬂow position.

Leak downstream in air line or ﬁtting.

Air supply pressure ﬂuctuation.

Solvent ﬂow switch not working.

Solvent ﬂow is too low to actuate the solvent switch.

Gun is not triggered. Operator must continue

Mix manifold was not set to ﬂush position, blocking solvent ﬂow to the spray gun.

Clean or replace switch.

Check for leaks and tighten ﬁttings.

Eliminate pressure ﬂuctuations.

Replace switch.

Increase solvent pressure to drive a high purge ﬂow rate

ﬂushing for conﬁgured time, until the booth control indicates purge is completed.

Setmanifoldtoﬂush position.

Mix Errors

Code

QPD1

SND1

Type Description Problem

Alarm Flow

Detected Solvent Gun

Alarm, then Deviation

Alarm Mix Fill

Potlife Expired

Incomplete

The solvent ﬂow switch is indicating unexpected solvent ﬂow.

Potlife time has expired before the system has moved the required amount of material (potlife volume) through the mixed material line.

The system timed out before the mix ﬁll cycle loaded the gun with mixed material.

Cause Solution

Solvent ﬂow switch is stuck in ﬂow position.

There is a leak through the solvent cutoff valve.

Purge process was not completed.

Solvent supply shut off or empty.

Mix manifold not set to spray position.

Spraygunwasnot triggered.

Restrictions in mixer, manifold, or spray gun.

Clean or replace switch.F7S1

Check for leaks and repair valve.

Make sure purge process is completed.

Verify solvent supply is available and on, supply valves are open.

Set manifold to spray.

Allow ﬂow through gun during ﬁll process until the ﬁll complete LED stops ﬂashing.

Fix restrictions.

332564B 89

System Errors

Pumping Errors

NOTE: In some e applicable co last digit in t component is p

Code

DA0#

DE0#

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

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

ump 1, F1S2 for pump 2, and so on.

Type Description Problem

Alarm Exceeded

Alarm Leak

rror codes listed below, a # symbol is shown as the last digit. This symbol represents the

Cause Solution

Maximum Flow Pump #

Detect Pump #

Pump was driven to its maximum allowed speed.

This is test fa pump ca pressu “Stal Will f secon

a manual stall

ilure when the

nnot build

re to the target

l Test Pressure.”

ault after 30

ds.

System has a l or open valve allowing un ﬂow.

Pump is cavitating, cycling without restriction.

Viscosity of material is too thin for nozzle size.

System pressure or Flow Setpoint is too high (causing the pump to work too hard).

No mate or line

Leak in the system.

rial in the pump

eak

that is

restricted

Inspect syst leaks.

Verify that the pump is being supplied with material.

Reduce noz create mo Reduce pa to lower t

Reduce the pressure or the Flow Setpoint.

Make su and dow line ar materi

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.

em for

zlesizeto

re restriction.

int pressure

he ﬂow rate.

re the pump

n stream color eloadedwith al.

DF0#

DG0#

Ala

Alarm

No Stall Up Pump #

No Stall Down Pump #

Pump failed the stall test; did not stall on the upstroke.

Pump failed the stall test; did not stall on the downstroke.

Valve failure, seal failure, worn rod or cylinder.

lace inlet and outlet

Rep

ve and seal for

val

stroke. Replace

ston and throat

als. Replace rod and

linder as necessary.

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

DH0#

DK0#

EBH#

EF0#

Type Description Problem

Alarm

Alarm Position

Record

Alarm Timeout

No Stall Pump #

Pump #

Home Complete Pump #

Startup Pump #

Pump failed th test; did not s either the ups the downstrok

Pump was dete be out of pos

Record of pump homing is complete.

Pump tried but was not abletomovetothe home position within a speciﬁed amount of time.

estall tall on troke or

cted to

ition.

Cause Solution

Valve failure failure, worn cylinder.

An indication on the display that the pump completed the home function

Pump dose valves did not actuate.

Motor could not drive pumps and linear actuator.

, seal

rod or

Replace inlet and outlet valve and seal for up and down strokes. Replacepistonand throat seals. Replace rod and cylinder as necessary.

Re-enable pu to reset pum sure inlet s pressure is high.

No action required.

Verify ai to soleno Verify t actuati

Verify motor is driving the pump.

mp power

p. Make

upply

not too

rpressure

id valves.

he valves are

ng.

EF1#

Alarm Timeout

Shutdown Pump #

Pump tried but was not abletomovetothe park position within a speciﬁed amount of time.

Pump stroke length is shortened by mechanical system tolerance.

Pump dose valves did not actuate.

p is ﬁlled with thick

Pum

nt and could not

pai

ve piston to end of

dri

oke. Motor or drive

str

orn or damaged.

is w

correct assembly

Verify

ar actuator and

of line pump p pump m

Visually inspect valves to ensure they are operating properly; verify they have air pressure above 85 psi (0.6 MPa, 6.0 bar).

Obs dri ver gen

iston rods. See

anual.

erve motor and

ve assembly to

ify that the motor is

erating force.

332564B 91

System Errors

Code

F1F#

F1S#

F7D#

Type Description Problem

Alarm Flow Low

Fill Pump #

Alarm Flow Low

Purge Pump #

Alarm Flow

Detecte Pump #

There has been or low ﬂow duri pump ﬁll opera

There has b or low ﬂow pump purg

Thepumpﬂow exceeded 20 cc/min ﬂowcomingintoIdle mode.

no ﬂow

ng a

tion.

eennoﬂow

during a

e operation.

Cause Solution

There is a restriction on the outlet side of the pump or color stack.

Thick viscos requires mor to pump.

The pumps do not have to move for the system to build enough pressure to meet the setpoint.

Restriction in the outlet side of the pump or color stack resulting in the solvent ﬂow being too low.

There is system o open whe went in

ity paint

e pressure

a leak in the r the gun was

n the system

to Idle mode.

Make sure there are no restrictions in the color stack and that the dump valve is actuating.

Increase non pressure if n to create ﬂow the ﬁll funct

Increase non-mix pressure if necessary to create ﬂow during the ﬁll function.

Make sure there are no restrictions in the system. Increase non-mix pressure if necessary to create ﬂow during the purge function.

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.

-mix

ecessary

during

ion.

F8D1 Alarm Flow Not

Detected

F9D#

SAD

Alarm Flow

Alarm Atomizing

able

Unst Pump

Solvent

No ﬂow

Thepumpﬂowrate did not stabilize while entering Idle mode.

Air act dil unk the

while mixing.

ﬂow switch is

ive while solvent,

uted material, or an

nown material is in

gun.

Restriction in the outlet side of the pump or color stack.

tial leak in the

Poten

em.

syst

Atomizing air supply was not shut off before purging or ﬁlling spray gun.

Make sure there are no restrictions in the system.

Check the system for leaks and run manual stall test.

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

Pressure Errors

System Errors

NOTE: In some e applicable co last digit in t component is p

Code

F6F#

P1F#

P2F#

P3D#

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

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

ump 1, P6F2 for pump 2, and so on.

Type Description Problem

Alarm Press.

Alarm Pressure

Deviation

rror codes listed below, a # symbol is shown as the last digit. This symbol represents the

Cause Solution

Disconnected transducer.

Verify trans connected pr Replace if r does not eli alarm.

Increase inlet pressure.

Relieve pressur

ducer is

operly.

econnecting

minate the

system

Sens. Removed Inlet #

Low Inlet Pump #

Pressure Low Inlet Pump #

Pressur High Out Pump #

No inlet pressure transducer is detected when the system is expecting one.

The inlet pressure on pump # is less than the user-entered alarm limit.

The inlet pressure on pump # is less than the user-entered deviation limit.

et pressure

user entered

on limit.

let

The outl on pump # than the deviati

is greater

P3F#

P4D#

P4F#

P6D#

P9D#

Deviation

Alarm Pressure

Alar

Alarm Press.

arm

Pressure High Inlet Pump #

High Outlet Pump #

sure

Pres

Inlet

High

Pump

Sens. Removed Outlet #

ess.

ns.

iled

tlet #

The inlet pressure on pump # is greater than the user-entered deviation limit.

Theoutletpressureon pump # is greater than the user entered alarm limit.

nlet pressure on

The i

# is greater than

pump

ser-entered alarm

the u

limi

No outlet pressure transducer is detected when the system is expecting one.

Outlet pressure transducer has failed.

Disconnected transducer.

Outlet pressure transducer has failed or the pressure is above the readable range.

Decrease inlet pressure.

Relieve system pressure.

ease inlet

Decr

sure.

pres

Verify transducer is connected properly. Replace if reconnecting does not eliminate the alarm.

lieve system

essure. Verify

nnections, or replace

reconnecting does

ot eliminate the alarm.

332564B 93

System Errors

Code

P9F#

QADX

QBDX

Type Description Problem

Alarm Press.

Sens. Failed Inlet #

Alarm

Differential Pressure A Over B

Differential Pressure B Over A

Inlet pressure transducer has failed.

Low differential pressure. This alarm is active only during Mix mode.

High differential pressure. This alarm is active only during Mix mode.

Cause Solution

Inlet pressure transducer has failed or thepressureisabove the readable range.

There is a lea B side.

The B side pump is cavitating.

There is a leak on the A side.

The A sid

ing.

cavitat

konthe

epumpis

Relieve system pressure. Verify connections, or replace if reconnecting does not eliminate the alarm.

Check the system for internal and external leaks on all catalyst manifolds and plumbing.

Check pain the B side, paint supp

Check the system for internal and external leaks on all color manifolds and plumbing.

Check paint supply on the A side, increase paint supply pressure.

t supply on

increase

ly pressure.

94 332564B

System Errors

Code

EB00 Rec-

EC00

EL00 Rec-

EM00 Rec-

EMIX Advi-

ES00

Commun

Type Description Problem

ord

Record

ord

sory

Advisory

ication Errors

Stop Button Pressed

Setup Value(s) Changed

System Power On

System Power Off

Pump Off

Factory Defaults

Recordofastopbutton press.

Record of cha setup variab

Record of power cycle (ON).

Record of p (OFF).

The pumps powered a unable to

Record o being lo

nging

les.

ower cycle

are not

nd are

move.

f defaults

aded.

Cause Solution

Indicates system stop key on ADM was pressed.

Indicates date and time when setup values were changed.

Indicates date and time when system was started.

Indicates date and time when system was turned off.

Pump powe turned of occurred

rwas

foranerror

n/a

Start pumps by pressing pump start key on Advanced Display module.

n/a

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

CA0X

CAC#

CADX

Type Description Problem

Alarm

arm

Comm. Error ADM

Comm. Error Color Change #

Comm. Error Fluid Module

System does not detect the Advanced Display Module (ADM).

System does not detect the Color Change Module #.

System does not see the Enhanced Fluid Control Module (EFCM).

Cause Solution

ommunication

This c

r indicates that

erro

etwork has lost

the N

unication with

comm

dvanced Display

the A

le.

Modu

This communication error indicates that the network has lost communication with the Color Change Module #.

is communication

ror indicates that

he Network has lost

ommunication with

he EFCM.

Check CAN cable connecting ADM to the EFCM.

Check CAN cable connections to the Color Change Module # and any interconnected modules.

Check CAN cables connecting ADM to the EFCM. Replace Cable or EFCM as necessary.

332564B 95

System Errors

Code

CAGX

CDC#

CDDX

Type Description Problem

Alarm

Alarm Duplicate

Comm. Error Gateway

Color Change #

Fluid Modu

System does no detect a CGM th was registere being connect power up.

System detects two or more identical Color Change Modules.

System sees two or more identical Enhanced Fluid Control Modules EFCM).

das

ed at

Cause Solution

More than one Color Change Module with thesameaddress is connected in the system .

More than one EFCM is connected in the system.

Check the system and remove the extra color change module.

Check the system and remove the extra EFCM.

96 332564B

USB Errors

System Errors

Code

EAUX Advi-

EBUX Record

EQU0

EQU1

EQU2

EQU3

EQU4

Type Description Problem

sory

Advisory

Record

Recor

USB Busy USB drive is inserted,

download is in progress.

USB Drive Removed

USB Idle USB download

USB Sys. Settings Downloaded

USB Sys. Setting Uploade

USB Custom Lang. Downloaded

USB Custom Lang. Uploaded

USB drive was removed while downloading or uploading.

completed, drive may be removed.

Settings were downloaded to USB drive.

Setting uploade drive.

Custom language was downloaded to USB drive.

Custom language was uploaded from USB drive.

swere

dfromUSB

Cause Solution

Indicates USB port is uploading or downloading data.

Downloading ingdataonUS interrupte USB device b removed.

Data transfer is completedtothe USB device.

User installed USB device in ADM USB port.

User ins device i port.

User installed USB device in ADM USB port.

/upload-

Bwas

dbythe

eing

talled USB

n ADM USB

Wait for USB Idle.

Replace the USB device and begin process again.

Remove USB device from ADM.

n/a

EQU5

EVUX Advi-

SUX

Record

sory

vi-

Advisory

ogs

USB L

loaded

Down

USB Disabled USB drive has

Maint. USB Logs Full

SB Conﬁg.

rr.

Data logs were downloaded to USB drive.

been inserted, downloading is disabled.

USB memory is more than 90% full.

SB conﬁguration

le does not match

ﬁ expected; checked on startup.

installed USB

User

ce in ADM USB

devi

port

Conﬁguration of system is blocking data transfer.

Conﬁguration parameter on system is enabled to generate this advisory.

software update

as not completed

w successfully.

n/a

Change conﬁguration to enable USB download function.

Complete download to ensure no data is lost.

einstall software.

332564B 97

System Errors

Code

WXUD Advi-

WXUU Advi-

Type Description Problem

sory

USB Download Err.

USB Upload Err.

An error occurred while downloading to the USB drive.

An error occu while upload the USB drive

rred

ing from

Cause Solution

User installed incompatible USB device in ADM USB port.

User install incompatibl device in ADM port.

eUSB

USB

Repeat process with compatible USB device.

Repeat proce compatible U device.

ss with

98 332564B

Miscellaneous Errors

System Errors

NOTE: In some e applicable co digit in the co component is p

Code

B9A0 Advi-

B9AX Advi-

B9B0 Advi-

B9BX Advi-

B9D#

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

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

ump 1, B9D2 for pump 2, and so on.

Type Description Problem

sory

Advisory

rror codes listed below, a # symbol is shown as the last digit. This symbol represents the

Cause Solution

Volume Rollover A Current

Volume Rollover A Lifetime

Volume Rollover B Current

Volume Rollover B Lifetime

Volume

Rollov Pump #

Batch counte material A ro

Grand total counter for material A rolled over.

Batch counter for material B rolled over.

Grand to for mate over.

Grand total counter forpump#rolled over.

rfor

lled over.

tal counter

rial B rolled

The totalizer has reached maximum capable value and started over at zero.

The totaliz reached max capable va started ov

The totalizer has reached maximum capable value and started over at zero.

The tota reache capabl starte

er has

imum

lue and

er at zero.

lizer has

d maximum

e value and

doveratzero.

n/a

B9S0

B9SX

WX00 Alar

Advisory

Volume Rollover Solvent Current

Volume Rollover Solvent Lifetime

Software Errors

Batch counter for solvent rolled over.

Grand for s over

An un soft occ

total counter

olvent rolled

expected

ware error has

urred.

The totalizer has reached maximum capable value and started over at zero.

n/a

Call Graco technical support.

332564B 99

System Errors

Calibration Errors

NOTE: In some e applicable co digit in the co component is p

Code

END#

ENS0

ENT#

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

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

ump 1, ENT2 for pump 2, and so on.

rror codes listed below, a # symbol is shown as the last digit. This symbol represents the

Type Name Description

Record

Calibration

Calibration Solvent Meter

Calibratio #

Pump #

nStallTestPump

A calibration test was run on the pump.

A calibration test was run on the solvent meter.

A stall test on pump #.

was completed successfully

100 332564B

Graco 332564B User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Related Manuals

Models

Warnings

Isocyanate Conditions

Keep Components A and B Separate

Moisture Sensitivity of Isocyanates

ADM Display

USB Download Procedure

ADM Keys and Indicators

Table 1 : ADM Keys and Indicators

Soft Key Icons

Table 2 : Soft Key Functions

Screen Icons

Power On

Flush Before Using Equipment

Without Color Change

With Color Change

Spraying

Purging

Flush the System

Network Communications and Discrete I/O

Discrete I/O

Table 3 PD2K Discrete I/O Connections

Digital Inputs

Analog Inputs

CGM Overview

CGM Kits

ProMix PD2K Network Outputs

Notes

Network Output Data Map (Read Only)

ProMix PD2K Network Inputs

Notes

Network Input Data Map (Write/Read)

Purge Mode Sequence

Inactive Pump Flush and Prime Sequences

Color Change Sequence

Mixing Sequence

Alarm Clearing Sequence

Dynamic Command Description

List of DCS Commands

Table 5 Dynamic Commands with Command ID

1 Write User ID

Write Recipe

Write Flush Sequence

Write Fluid Control Mode

Read User ID

Read Recipe

Read Flush Sequence

Read Fluid Control Mode

Read Job Info

Read Alarm Info

Read Event Info

Overview

Pressure Control

Gun On/Off Prediction

Normal Flow Control

Run Mode Screens

Opening Screen

Home Screen

Spray Screen

Fill Screen

Usage Screen

Jobs Screen

Errors Screen

Events Screen

Password Screen

Diagnostic Mode

Color Pumps

Catalyst Pumps

Non-Mix Pressure

Mix Pressure Tolerance

Stall Test Pressure

Pump Stall Test

Low Flow Tolerance

Low Flow Timeout