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

+ 74 hidden pages

Graco 332564B 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