Graco 332562B Repair Parts Manual

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Graco 332562B Repair Parts Manual | Manualzz

Operation

ProMix® PD2K Electronic

Proportioner

332562B

EN

Positive displacement proportioning of 2-component materials helps reduce waste. Manual system with

Advanced Display Module. For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual and in your PD2K

Installation and Repair/Parts manuals.

Save these instructions.

See page 3 for model part numbers and approvals information.

PROVEN QUALITY. LEADING TECHNOLOGY.

2

Contents

Models............................................................... 3

Related Manuals ................................................ 6

Warnings ........................................................... 7

Important Isocyanate (ISO) Information................ 10

Glossary of Terms .............................................. 12

Overview............................................................ 13

Usage ......................................................... 13

Component Identification and

Definition........................................ 13

Advanced Display Module ................................... 16

ADM Display................................................ 16

USB Download Procedure ............................ 16

USB Upload Procedure ................................ 17

ADM Keys and Indicators ............................. 18

Soft Key Icons ............................................. 19

Navigating the Screens ................................ 21

Screen Icons ............................................... 21

Booth Control ..................................................... 22

Booth Control Display................................... 22

Booth Control Keys and Indicators ................ 23

Operation........................................................... 24

Pre-operation Checklist ................................ 24

Flush Before Using Equipment...................... 24

Power On .................................................... 24

Initial System Setup ..................................... 25

Prime and Fill the System............................. 25

Spraying...................................................... 26

Purging ....................................................... 27

Pressure Relief Procedure............................ 29

Valve Settings.............................................. 30

Shutdown .................................................... 30

Run Mode Screens ............................................. 31

Splash Screen ............................................. 31

Home Screen .............................................. 31

Spray Screen............................................... 34

Fill Screen ................................................... 35

Usage Screen.............................................. 36

Jobs Screen ................................................ 37

Errors Screen .............................................. 37

Events Screen ............................................. 37

Setup Mode Screens .......................................... 38

Password Screen......................................... 38

System Screen 1 ......................................... 39

System Screen 2 ......................................... 40

System Screen 3 ......................................... 42

Information for Systems with Multiple

Guns.............................................. 43

System Screen 4 ......................................... 44

Recipe Screen ............................................. 45

Flush Screen ............................................... 47

Pump Screen 1............................................ 48

Pump Screen 2............................................ 49

Pump Screen 3............................................ 50

Calibrate Screen 1 ....................................... 51

Calibrate Screen 2 ....................................... 51

Calibrate Screen 3 ....................................... 52

Maintenance Screen 1 ................................. 53

Maintenance Screen 2 ................................. 53

Maintenance Screen 3 ................................. 53

Maintenance Screen 4 ................................. 54

Advanced Screen 1...................................... 55

Advanced Screen 2...................................... 56

Advanced Screen 3...................................... 56

Advanced Screen 4...................................... 56

Calibration Checks.............................................. 57

Pump Pressure Check ................................. 57

Pump Volume Check.................................... 58

Solvent Meter Calibration ............................. 59

Color Change ..................................................... 60

Single Color Systems ................................... 60

Multiple Color Systems................................. 60

System Errors .................................................... 61

Maintenance ...................................................... 74

Preventive Maintenance Schedule ................ 74

Flushing ...................................................... 74

Cleaning the ADM........................................ 74

Technical Data ................................................... 75

Graco Standard Warranty.................................... 76

332562B

Models

Models

See Figs. 1–7 for component identification labels, including approval information and certification.

Part No.

Series Maximum Air Working

Pressure

Maximum Fluid Working

Pressure

Location of PD2K and

Electrical Control Box

(ECB) Labels

MC0500

MC1000

MC2000

A

A

A

100 psi (0.7 MPa, 7.0 bar)

With lowpressure pumps:

300 psi (2.068 MPa,

20.68 bar)

With highpressure pumps:

1500 psi (10.34 MPa,

103.4 bar)

100 psi (0.7 MPa, 7.0 bar) 300 psi (2.068 MPa,

20.68 bar)

100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa,

103.4 bar)

0359

II 2 G

Figure 1 Model MC1000 (Low Pressure) Identification

Label

Figure 2 24M672 Control Box Identification Label

332562B

Continued on the next page.

3

Models

Figure 3 Model MC2000 (High Pressure)

Identification Label

Figure 4 Model MC0500 Identification Label

Figure 5 Non-Intrinsically Safe Color Change Control

(Accessory) Identification Label

4 332562B

Models

Figure 6 Intrinsically Safe Color Change Control

(Accessory) Identification Label

Figure 7 Booth Control Identification Label

Figure 8 Pump Expansion Kit (Accessory)

Identification Label

332562B 5

Related Manuals

Related Manuals

Manual No.

Description

3A2800

332457

PD2K Proportioner Repair-Parts

Manual, Manual Systems

PD2K Proportioner Installation

Manual, Manual Systems

3A2801

332339

332454

Mix Manifold Instructions-Parts

Manual

Pump Repair-Parts Manual

Color Change Valve Repair-Parts

Manual

Manual No.

Description

332455 Color Change Kits Instructions-

Parts Manual

332456

334512

3rd and 4th Pump Kits

Instructions-Parts Manual

PD1K Pump Expansion Kits

Instructions-Parts Manual

6 332562B

Warnings

Warnings

The following warnings are for the setup, use, grounding, maintenance and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these

Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

FIRE AND EXPLOSION HAZARD

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

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

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

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

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

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are antistatic or conductive.

• Stop operation immediately if static sparking occurs or you feel a shock, Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

ELECTRIC SHOCK HAZARD

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

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing or installing equipment.

• Connect only to grounded power source.

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

332562B 7

8

Warnings

WARNING

INTRINSIC SAFETY

Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe equipment will create a hazardous condition and can cause fire, explosion, or electric shock.

Follow local regulations and the following safety requirements.

• Be sure your installation complies with national, state, and local codes for the installation of electrical apparatus in a Class I, Group D, Division 1 (North America) or Class I, Zones 1 and 2 (Europe) Hazardous Location, including all of the local safety fire codes (for example,

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

• To help prevent fire and explosion:

• Do not install equipment approved only for a non-hazardous location in a hazardous location. See model ID label for the intrinsic safety rating of your model.

• Do not substitute system components as this may impair intrinsic safety.

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

Safety. This includes DC voltage meters, ohmmeters, cables, and connections. Remove the unit from the hazardous area when troubleshooting.

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

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

• Do not put your hand over the spray tip.

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

• Follow the Pressure Relief Procedure when you stop spraying/dispensing and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

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

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

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

332562B

332562B

Warnings

WARNING

TOXIC FLUID OR FUMES

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

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

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

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

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:

• Protective eyewear, and hearing protection.

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

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

9

Important Isocyanate (ISO) Information

Important Isocyanate (ISO) Information

Keep Components A and B Separate

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

Isocyanate Conditions

Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates.

Read 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.

Material Self-ignition

Some materials may become self-igniting if applied too thick. Read material manufacturer’s warnings and material MSDS.

Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination:

• Never interchange component A and component

B wetted parts.

• Never use solvent on one side if it has been contaminated from the other side.

Moisture Sensitivity of Isocyanates

Exposure to moisture (such as humidity) will cause

ISO to partially cure; forming small, hard, abrasive crystals, which become suspended in the fluid.

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

NOTICE

Partially cured ISO will reduce performance and the life of all wetted parts.

• Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere.

Never store ISO in an open container.

• Keep the ISO pump wet cup or reservoir (if installed) filled with appropriate lubricant. The lubricant creates a barrier between the ISO and the atmosphere.

• Use only moisture-proof hoses compatible with

ISO.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Always lubricate threaded parts with an appropriate lubricant when reassembling.

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

10 332562B

Changing Materials

NOTICE

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

• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

• When changing between epoxies and urethanes or polyureas, disassemble and clean all fluid components and change hoses. Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the A (resin) side.

Important Isocyanate (ISO) Information

332562B 11

Glossary of Terms

Glossary of Terms

Advanced Display Module (ADM) - the user interface for the system. See

Advanced Display Module, page 16

.

Enhanced Fluid Control Module (EFCM) - the fluid controller for the system.

Grand Total - a non-resettable value that shows the total amount of material dispensed through the system.

Idle - if the gun is not triggered for a user-settable value, the system enters Idle mode. Trigger the gun to resume operation.

Intrinsically Safe (IS) - refers to the ability to locate certain components in a hazardous location.

Job Total - a resettable value that shows the amount of material dispensed through the system for one job.

A job is complete when the user presses the Job

Complete key on the Booth Control or ADM.

Mix - when cross-linking of the resin (A) and catalyst

(B) occurs.

Potlife Time - the amount of time before a material becomes unsprayable.

Potlife Volume - the amount of material that is required to move through the mix manifold, hose, and applicator before the potlife timer is reset.

Pump Calibration Factor - the amount of material dispensed per revolution of the motor.

Purge - when all mixed material is flushed from the mix manifold, hose, and gun.

Purge Time - the amount of time required to flush all mixed material from the gun.

Run Screens - The Run screens provide a graphical depiction of system operation and current status.

See

Run Mode Screens, page 31 .

Setup Screens - The Setup screens allow the user to define the system, setup recipes, and establish system operating parameters. See

Setup Mode Screens, page 38 .

Standby - refers to the status of the system.

12 332562B

Overview

Overview

Usage

This electronic two-component paint proportioner can blend most two-component paints, including quick-setting paints (those with a pot life of 5 minutes and greater).

• The system dispenses Material A, monitors fluid flow, and continually dispenses Material B at ratio.

Component Identification and Definition

• Can proportion at ratios from 0.1:1 to 50.0:1

(depending on material, flow rate, pump size selection, and mix point).

• Will display the last 200 jobs, 200 errors, and 200 events with date, time, and description.

Component

Electrical Control Box

Fluid Components

Advanced Display Module

Booth Control

Description

• Enhanced Fluid Control Module (EFCM)

• 24 V Power Supply for the barrier board and the EFCM

• 48 V Power Supply for pump motors

• Solenoid Valves for solvent valve and gun flush box (if present)

• Air Flow Switch

• Relay

• Optional Pressure Switch for gun flush box (if present)

• Pump Control Modules (2), one for each pump

• CAN Isolation Board

• Intrinsically Safe Power Barrier Board

• Mix manifold (accessory), which can be attached to the operator’s belt.

• Color/catalyst valve stacks, including pneumatically operated valves for

Material A and B, as well as solvent valves.

• Solvent Flow Switch

• Pumps

• Pressure transducers

Use to set up, display, operate, and monitor the system. Use for daily painting functions including choosing recipes, reading/clearing errors, and placing the system in Spray, Standby, or Purge mode. Locate in the non-hazardous area.

Use for daily painting functions including choosing recipes, reading/clearing errors, and placing the system in Spray, Standby, or

Purge mode. Locate in the hazardous area.

332562B 13

Overview

Typical Installation (MC1000, MC2000)

HAZARDOUS (CLASSIFIED) LOCATION NON-HAZARDOUS LOCATION ONLY

Figure 9

B★

C★

D★

E★

F★

Component Description

★ Components A through F are included with the base unit.

A★ Material A (Color) Pump

Material B (Catalyst) Pump

Solvent Valve

Booth Control

Electrical Control Box

Advanced Display Module

G

H

J

Component Description

Components G through K are included in optional color change kits.

Color Change Valves (accessory)

Color Change Module (accessory)

K

Catalyst Change Valves

(accessory)

Catalyst Change Module

(accessory)

P

R

M

N

Components L through S are accessories and must be ordered separately.

L Fluid/Air hose Bundle (accessory)

Mix Manifold (accessory)

Air Spray Gun (accessory)

Gun Air Hose (accessory)

Intrinsically Safe CAN Cable (to connect booth control to electrical control box)

S Gun Fluid Hose (accessory)

14 332562B

Overview

Typical Installation (MC0500)

HAZARDOUS (CLASSIFIED) LOCATION NON-HAZARDOUS LOCATION ONLY

Figure 10

Component Description

★ Components D, E, and F are included with the base unit.

D★ Booth Control

E★

F★

Electrical Control Box

Advanced Display Module

Component Description

★ Pumps A and B are required but are sold separately for system design flexibility.

A★ Material A (Color) Pump

B★ Material B (Catalyst) Pump

G

H

J

Component Description

Components G through K are included in optional color change kits.

Color Change Valves (accessory)

Color Change Module (accessory)

K

Catalyst Change Valves

(accessory)

Catalyst Change Module

(accessory)

P

R

M

N

Components L through S are accessories and must be ordered separately.

L Fluid/Air hose Bundle (accessory)

Mix Manifold (accessory)

Air Spray Gun (accessory)

Gun Air Hose (accessory)

Intrinsically Safe CAN Cable (to connect booth control to electrical control box)

S Gun Fluid Hose (accessory)

332562B 15

Advanced Display Module

Advanced Display Module

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 31

, or

Setup Mode Screens, page 38

.

Keys are used to input numerical data, enter setup screens, navigate within a screen, scroll through screens, and select setup values.

NOTICE

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

1 2 3

4 5 6

7 8 9

0 .

Figure 11 Advanced Display Module

USB Download Procedure

Use the USB port on the ADM to download or upload data.

1. Enable USB downloads. See

Advanced Screen 3, page 56

.

2. Remove the cover from the USB port on the bottom of the ADM. Insert the USB drive.

3. During the download, USB BUSY appears on the screen.

4. When the download is complete, USB IDLE appears on the screen. The USB drive may then be removed.

NOTE: If the download operation takes longer than 60 seconds, the message disappears. To determine if the USB is busy or idle, check the

Error Status bar on the screen. If idle, remove the USB.

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

6. The USB flash drive window automatically opens.

If it does not, open the USB flash drive from within Windows® Explorer.

7. Open Graco folder.

8. Open system folder. If downloading data from more than one system, there will be more than one folder. Each folder is labeled with the corresponding serial number of the ADM. (The serial number is on the back of the ADM.)

9. Open DOWNLOAD folder.

10. Open LOG FILES folder labeled with the highest number. The highest number indicates the most recent data download.

11. Open log file. Log files open in Microsoft®

Excel® by default if the program is installed.

They also can be opened in any text editor of

Microsoft® Word.

NOTE: All USB logs are saved in Unicode

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

Microsoft Word, select Unicode encoding.

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

16 332562B

Advanced Display Module

USB Upload Procedure

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

1. If necessary, follow the USB Download

Procedure, to automatically generate the proper folder structure on the USB flash drive.

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

3. The USB flash drive window automatically opens.

If it does not, open the USB flash drive from within Windows Explorer.

4. Open the Graco folder.

5. Open the system folder. If working with more than one system, there will be more than one folder within the Graco folder. Each folder is labeled with the corresponding serial number of the ADM. (The serial number is on the back of the module.)

6. If installing the system configuration settings file, place SETTINGS.TXT file into UPLOAD folder.

7. If installing the custom language file, place

DISPTEXT.TXT file into UPLOAD folder.

8. Remove the USB flash drive from the computer.

9. Install the USB flash drive into the USB port of the ProMix PD2K system USB port.

10. During the upload, USB BUSY displays on the screen.

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

NOTE: If the custom language file was installed, users can now select the new language from the

Language drop-down menu in the Advanced Setup

Screen 1.

332562B 17

Advanced Display Module

ADM Keys and Indicators

NOTICE

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

Table 1 : ADM Keys and Indicators

Key Function

Startup/Shutdown

Key and Indicator

Press to startup or shutdown the pump/motor.

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

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

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

Press to immediately stop the system and remove motor power.

Stop

Soft Keys

Press to select the specific screen or operation shown on the display directly next to each key. The top left soft key is the Edit key, which allows access to any settable fields on a screen.

Left/Right Arrows:

Use to move from screen to screen.

Up/Down Arrows:

Use to move among fields on a screen, items on a dropdown menu, or multiple screens within a function.

Navigation Keys

Numeric Keypad Use to input values. See

ADM Display, page 16 .

Use to cancel a data entry field.

Cancel

Press to enter or exit Setup mode.

Setup

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.

Enter

18 332562B

Advanced Display Module

Soft Key Icons

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

Table 2 : Soft Key Functions

Key

Enter Screen

NOTICE

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

Function

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 exit screen after editing.

Exit Screen

Press to accept calibration value.

Accept

Press to cancel or reject calibration value.

Cancel

Press to start a pump priming procedure.

Prime Pump

Press to start a line fill procedure.

Line/Fill/Run

Press to start a spray procedure.

Mix

Press to start a gun purge procedure.

Purge

332562B 19

Advanced Display Module

Key

Standby

Stop

Pressure Check

Volume Check

Job Complete

Counter Reset

Move Cursor to Left

Move Cursor to Right

Erase All

Backspace

Upper Case/Lower Case

Function

Press to stop all pumps and put system in Standby.

Press to start a pump pressure check.

Press to start a pump volume check.

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.

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.

Appears on the User ID Keyboard screen. Use to erase one character at a time.

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

20 332562B

Navigating the Screens

There are two sets of screens:

• The Run screens control mixing operations and display system status and data.

• The Setup screens control system parameters and advanced features.

Press on any Run screen to enter the Setup screens. If the system has a password lock, the

Password screen displays. If the system is not locked

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

Press on any Setup screen to return to the

Home screen.

Advanced Display Module

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

Potlife

Recipe Number

Job Number

Target Ratio

Flow Rate

Press the Enter soft key function on any screen.

to activate the editing Pressure Volume

Press the Exit soft key to exit any screen.

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

Material A

Material A+B

Material B

Solvent

Time Calendar

Alarm/Advisory

Deviation

332562B 21

Booth Control

Booth Control

Booth Control Display

The booth control is the main control device used by the operator for daily painting functions including: changing recipes, signaling job complete, reading/clearing alarms, and placing the system in

Standby, Mix, or Purge mode. It is typically mounted inside the booth or near the painter.

The booth control displays the recipe in the following formats:

• R-xx (active recipe)

• P-xx (recipe loaded in the pumps)

• G-xx (recipe loaded in the gun)

The booth control display circulates through the recipe and error status:

• Displays the recipe number (R-xx) when ready to spray (the pumps and gun are loaded with the same recipe). If the display is on steady and does not show recipe 0 or 61, the system is ready to spray. (Recipe 61 indicates an unknown material.)

• If the gun is loaded with one recipe (G-xx) and the pumps with another (P-xx), the display will alternate between the two recipes.

• If an alarm occurs, the alarm code is displayed and the red Alarm indicator will flash until acknowledged. After the alarm is acknowledged, the LED will be on steady and the recipe number will alternate with the code.

Press and hold the Standby key to turn the pumps on or off.

for 2 seconds

To select a new recipe, scroll Up or Down to the desired recipe, then press Enter

If Enter is not pressed within 5 seconds, the system will revert to the existing recipe.

.

Figure 12 Booth Control

22 332562B

Booth Control

Booth Control Keys and Indicators

Key/Indicator

Alarm Reset Key and

Indicator

Standby Mode Key and Indicator

Mix Mode Key and

Indicator

Job Complete Key

Pressure Control Key and Indicator

Purge Mode Key and

Indicator

Up Key

Definition and Function

• Red LED is solid when an alarm condition is present.

• Red LED blinks when an event requiring user acknowledgement occurs at any level.

• Press key to acknowledge. LED shuts off after alarm is cleared.

• Starts Standby mode.

• Green LED remains lit while in Standby mode.

• Green LED blinks when the system is on and is not mixing or purging. In Idle mode, the Standby LED and the Mix LED both blink.

• Green LED blinks during pump maintenance checks.

• Press and hold the key to startup or shutdown the pumps.

• Starts Mix mode.

• Green LED remains lit while in Mix mode.

• Green LED blinks during a mix fill. If there is no fluid flow for 30 sec after starting mix fill, the process must be restarted.

• In Idle mode, the Mix LED and the Standby LED both blink.

• Signals that job is complete, and resets A, B, and solvent totalizers.

• Press to display the current job number on the booth control. Press a second time to log the current job and increment to the next job number. Times out after 5 seconds of inactivity.

• Starts Pressure Change mode.

• Green LED blinks while in Pressure Change mode.

• To change the pressure, press the Pressure Control key and use the Up/Down keys to select the desired pressure. Pressure Change mode times out after 5 seconds of inactivity. Stored recipe is only updated at the end of a spray mode.

• Starts Purge mode.

• Green LED remains lit while in Purge mode.

• Green LED blinks when gun needs to be purged and is waiting for purge to begin.

• Scrolls recipe numbers up.

• Scrolls pressure value up in Pressure Change mode.

• Scrolls recipe numbers down.

• Scrolls pressure value down in Pressure Change mode.

Down Key

• Enters selected recipe and starts color change sequence.

• Accepts pressure value change.

Enter Key

332562B 23

Operation

Operation

Pre-operation Checklist

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

✔ Checklist

System grounded

Verify all grounding connections were made. See Grounding in the

Installation manual.

All connections tight and correct

Verify all electrical, fluid, air, and system connections are tight and installed according to the Installation manual.

Fluid supply containers filled

Check component A and B and solvent supply containers.

Dose valves set

Check that dose valves are set

1–1/4 turns open. Start with the settings recommended in

Valve Settings, page 30 , then adjust

as needed.

Fluid supply valves open and pressure set

The recommended component A and

B fluid supply pressures are 1/2 to 2/3 of the target spray pressure.

NOTE: Low pressure systems may be set within a range of ± 100 psi (0.7

MPa, 7 bar); high pressure systems may be set within a range of ± 300 psi

(2.1 MPa, 21 bar). If the inlet pressure is higher than the outlet pressure, ratio accuracy may be affected.

Solenoid pressure set

85-100 psi inlet air supply (0.6-0.7

MPa, 6-7 bar).

Flush Before Using Equipment

The pump fluid section was tested with lightweight oil, which is left in the fluid passages to protect parts.

To avoid contaminating your fluid with oil, flush the equipment with a compatible solvent before using the equipment.

Power On

1. Turn the AC Power Switch ON (I = ON, 0 = OFF).

2. The Graco logo will display while the system initializes, followed by the Home screen.

3. Press the Start key . The system status will change from “System Off” to “Startup.” Once the pumps are powered and are in the Home position, the system status will change from

“Startup” to “Standby.”

Figure 13 Power Switch

24 332562B

Operation

Initial System Setup

1. Change optional setup selections to desired parameters, as described in

Setup Mode Screens, page 38

.

2. Set recipe and flush information as described in

Recipe Screen, page 45

and

Flush Screen, page 47

.

Prime and Fill the System

NOTE: See

Run Mode Screens, page 31 , for further

screen information, if needed.

NOTE: Be sure the mix manifold is set to the SPRAY position.

NOTE: You must prime the input lines to the pumps or the inputs to the color change valves before priming the pump and filling the entire system.

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

ADM. Make sure that the system is in Standby mode.

5. Verify that the recipes and the flush sequences are programmed correctly by checking the

Recipe Screen, page 45

and the

Flush Screen, page 47 .

6. Go to the

Fill Screen, page 35 .

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

Pump key . The color will load the pump through the color stack and out the outlet stack dump valve.

NOTE: In a single color system, skip step 7 and prime the pump out to the gun.

8. Press the Fill Line key to run color out to the mix manifold. The pump will run until you press the Stop key to stop the pump.

9. Trigger the gun into a grounded metal pail until the line is full, then press the Stop key

10. Repeat for all material lines.

.

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 use less than 85 psi (0.6 MPa, 6.0 bar).

3. If this is the first time starting up the system, or if lines may contain air, purge as instructed under

Purging, page 27

. The equipment was tested with lightweight oil, which should be flushed out to avoid contaminating your material.

332562B 25

Operation

Spraying

To spray in a multiple color system, also see

Multiple Color Systems, page 60

.

NOTE: See

Run Mode Screens, page 31

, for further

screen information, if needed.

1. Set the desired mix manifold to the SPRAY position.

2. Press Mix . The system will load the correct mixed material volume. The Mix Mode

LED and the recipe display on the booth control will blink during the mix fill. If the gun is loaded with one recipe (G-xx) and the pumps with another (P-xx), the display will alternate between the two recipes. When the mix fill is completed, the display will show R-xx, and the system will go into Standby Mode.

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 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 2, page 40 .

3. Press Mix again. The Mix Mode

LED will turn on solid to indicate the system is mixing. Adjust the flow rate by changing the target pressure. The fluid flow rate shown on the

Spray screen is the combined total of component

A and B out of the gun.

• If the fluid flow rate is too low: increase the spray pressure setting on the Spray screen or booth control.

• If the fluid flow rate is too high: decrease the spray pressure setting on the Spray screen or booth control.

NOTE: If spray pressure is adjusted at the ADM or booth control while spraying, it is not saved in the recipe until the system is put in Standby. This changes the pressure in the desired recipe.

4. Turn on atomizing air to the gun. Check the spray pattern as instructed in your spray gun manual.

NOTE: Do not use the first 4-5 oz. (120-150 cc) of material as it may not be thoroughly mixed due to errors while priming the system. The Spray LED must be on.

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.

26 332562B

Operation

Purging

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

Color Change, page 60 .

Flush Mixed Material

There are times when you only want to purge the mix manifold and gun, such as:

• end of potlife

• breaks in spraying that exceed the potlife

• overnight shutdown or end of shift

• before servicing the mix manifold, hose or gun.

1. Press Standby .

2. If you are using a high pressure gun or an electrostatic gun, shut off the atomizing air.

If you are using a high pressure gun, engage the trigger lock. Remove the spray tip and clean it separately.

3. Trigger the gun to relieve pressure.

4. Set the solvent supply pressure regulator at the lowest pressure possible, to avoid splashing or an injection injury. Generally a setting of 25–50 psi (0.18–0.35 MPa, 1.8–3.5 bar) is sufficient.

5. Set the mix manifold to the FLUSH position.

6. Press Purge . Trigger the gun into a grounded metal pail until the purge sequence is complete. When done purging, the system automatically switches to Standby mode, signalling the user to release the trigger.

7. If the system is not completely clean, repeat.

NOTE: For optimal efficiency, adjust purge sequence times so only one cycle is required.

8. Trigger the gun to relieve pressure. Engage the trigger lock.

9. If the spray tip was removed, reinstall it.

10. Adjust the solvent supply regulator back to its normal operating pressure.

NOTE: The mix manifold and gun remain full of solvent after purging.

If using an electrostatic gun, shut off the electrostatics before flushing the gun.

332562B 27

Operation

Flush the System

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 29

.

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, to avoid splashing or an injection injury. Generally a setting of 25–50 psi (0.18–0.35 MPa, 1.8–3.5 bar) is sufficient.

4. Set the mix manifold to the SPRAY position.

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

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

6. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun until clean solvent dispenses.

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

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

8. Relieve the pressure. See

Pressure Relief Procedure, page 29

Color Change System

1. Relieve the pressure. See

Pressure Relief Procedure, page 29 .

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, to avoid splashing or an injection injury. Generally a setting of 25–50 psi (0.18–0.35 MPa, 1.8–3.5 bar) is sufficient.

4. Set the mix manifold to the SPRAY position.

5. On the ADM, go to the Fill screen. Select Color

(A). Enter the color number in the box to the right.

6. Select the Flush Line box.

7. If the solvent is not already loaded, press the

Prime softkey . The system will prime solvent into the selected pump and out the outlet dump valve.

8. Press the Fill softkey . The system will flush the selected Color (A) line with solvent until the user presses Stop .

9. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun until clean solvent dispenses.

10. Repeat for each color line.

11. Relieve the pressure. See

Pressure Relief Procedure, page 29 .

28 332562B

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

Operation

With Color Change

NOTE: The following procedure relieves all fluid and air pressure in the system.

1. Turn off the supply pumps. Open the drain valve on the supply line fluid filter to relieve pressure in the supply lines. Do this for each color.

NOTE: If your system does not include a drain valve on the supply line, set the mix manifold to

SPRAY and press . Cycle the A and

B dosing pumps a couple of times to drain the pumps. Repeat for each color.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the

Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

Without Color Change

NOTE: The following procedure relieves all fluid and air pressure in the system.

1. Turn off the supply pumps. Open the drain valve on the supply line fluid filter to relieve pressure in the supply line.

NOTE: If your system does not include a drain valve on the supply line, set the mix manifold to SPRAY and press . Cycle the A and B dosing pumps a couple of times to drain the pumps.

2. Press Standby relieve pressure.

. Trigger the gun to

3. Set the mix manifold to FLUSH.

Flush the mix manifold and gun. See

Flush Mixed Material, page 27

.

4. Shut off the solvent supply pump. To relieve pressure, press Purge and trigger the gun. Press Standby when pressure is relieved, to avoid getting a Purge

Incomplete alarm.

NOTE: If pressure remains in the solvent line between the solvent supply pump and the solvent valve, VERY SLOWLY loosen a fitting to relieve pressure gradually.

If you are using a high pressure gun, engage the trigger lock. Remove the spray tip and clean it separately.

If using an electrostatic gun, shut off the electrostatics before flushing the gun.

2. Set the mix manifold to SPRAY. Trigger the gun to relieve pressure. Repeat for each color.

3. Press Purge . Repeat for each color.

Hold the gun trigger open after the solvent valve shuts off to relieve all pressure.

4. Set the system to Recipe 0 to flush the system from the pumps to the gun. When flushing is complete the system will go to Standby.

5. Shut off the solvent supply pump. To relieve pressure, press Purge and trigger the gun. Press Standby when pressure is relieved, to avoid getting a Purge

Incomplete alarm.

NOTE: If pressure remains in the solvent line between the solvent supply pump and the solvent valve, VERY SLOWLY loosen a fitting to relieve pressure gradually.

332562B 29

Operation

Valve Settings

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

Shutdown

1. Flush out the mixed material to avoid potlife errors and fluid setup in the lines. See

Purging, page 27

.

2. Follow the

Pressure Relief Procedure, page 29

.

3. Close the main air shutoff valve on the air supply line and on the control box.

4. Press on the Display Module to turn off power to the pumps.

5. Shut off system power (0 position).

Figure 14 Valve Adjustment

30 332562B

Run Mode Screens

Run Mode Screens

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

Splash Screen

At power up, the Graco logo will display for approximately 5 seconds, followed by the Home screen.

Figure 15 Splash Screen

Home Screen

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

To view pump flow rates and pressures

(as shown), select “Diagnostic Mode” on

System Screen 1, page 39

.

Figure 16 Home Screen, in Mix Mode with

Diagnostics On

332562B 31

Run Mode Screens

Home Screen Key

Key

A

B

Description

Date and Time

Menu Bar

C

D

Status Bar

Error Status

Details

See

Advanced Screen 1, page 55

, to set.

Run Screens. Use left and right arrow keys to scroll through the different Run screens:

• Home (shown in Diagnostic Mode)

• Spray (see

Spray Screen, page 34

)

• Fill (see

Fill Screen, page 35

)

• Potlife (present only when “Multiple Guns is selected on

System Screen 3, page 42 . See also

Information for Systems with Multiple Guns, page 43 .

• Usage (see

Usage Screen, page 36

)

• Jobs (see

Jobs Screen, page 37

)

• Errors (see

Errors Screen, page 37

)

• Events (see

Events Screen, page 37

)

System Status: Displays the current mode of operation:

• Pump Off • Change Recipe

• Standby

• Startup

• Mix

• Fill

• Purge

• Shutdown

Displays any active error code.

• Idle

• Prime Pump

• Calibrate

• Stall Test

• Maintenance Test

32 332562B

Run Mode Screens

W

X

U

V

Y

Z

S

T

M

N

P

H

J

K

L

F

G

Key

E

Description

Pump Animation and

Diagnostic Information

Pump Number (1–4)

Material (A or B)

Available Colors

Pump Inlet Color

Pump Inlet Pressure

Pump Flow Rate

Pump Outlet Color

Pump Outlet Pressure

Pump Indicator Light

• Clear = power off

• Yellow = standby

• Green = active

Solvent Flow Rate

Gun Animation

Details

Active Recipe ( )

Current Ratio ( )

Potlife Time Remaining ( )

Total Volume for the Current

Job ( )

Current Flow Rate ( )

Current Pressure ( )

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

Shows mixed material in gun and displays active recipe at gun.

Gun animation changes to show:

(Mix Fill)

(Mix With Air Flow)

(Recipe Standby)

(Purge)

• (Gun Purge in GFB)

• (Purged Gun in

Standby, in GFB)

(Solvent Standby)

(Mix With No Air Flow)

332562B 33

Run Mode Screens

Spray Screen

The Spray screen displays the following information:

• Active Recipe (can be changed on this screen)

• Target Ratio

• Actual Ratio

• Target Pressure (can be changed on this screen)

• Actual Pressure

• Actual Flow

• Potlife Remaining

• Gun Animation

Figure 18 Spray Screen, in Mix Mode

Figure 17 Spray Screen, in Standby Mode

Figure 19 Spray Screen, in Idle Mode

34 332562B

Run Mode Screens

Fill Screen

The Fill screen displays the following information for the pump assigned to the current color:

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

The pump animation at the top of the screen will show the selected material. If solvent is selected, enter the pump number in the box to the right.

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

Select this box if you want to flush the specified material line with solvent. The system uses flush sequence 1.

To prime the pumps and fill the lines, first read

Prime and Fill the System, page 25

.

Figure 20 Fill Screen, Color (A) Selected

1. Press the Edit softkey for editing.

to open the screen

2. Select Color (A).

3. Enter the color number in the box to the right.

4. If the selected material is not already loaded, press the Prime softkey . The system will prime Color (A) into the selected pump through the selected color valve and out the outlet dump valve.

5. Press the Fill softkey . The system will attempt to fill the Color (A) lines until the user presses Stop container.

. Trigger the gun into a waste

6. Repeat for Catalyst (B).

To flush the system (pump and fluid lines), see

Flush the System, page 28

.

To flush only the pump:

Figure 21 Fill Screen, Solvent Selected

1. Press the Edit softkey for editing.

to open the screen

2. Select Solvent.

3. Enter the pump number in the box to the right.

4. Press the Prime softkey . The system will flush solvent through the selected pump and out the dump valve.

332562B 35

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). The second Usage screen displays the total volume pumped for all available materials.

1. Press the Edit softkey for editing.

to open the screen

2. To enter or change the User ID ( ), select the field to open the User ID Keyboard screen, and enter the desired name (10 characters maximum).

3. To log the current job, press the Job Complete softkey . This will clear the current usage fields and increment to the next job number.

The Grand Totals cannot be cleared. See the

Jobs Screen, page 37

, to review past jobs.

Figure 23 User ID Keyboard Screen

4. Press the Edit softkey to close the screen.

Figure 24 Usage Log

Figure 22 Usage Screen

36 332562B

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.

Run Mode Screens

Errors Screen

The Errors screen displays the 200 most recent Error

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

Figure 25 Jobs Screen

Figure 26 Errors Screen

Events Screen

The Events screen displays the 200 most recent

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

Figure 27 Events Screen

332562B 37

Setup Mode Screens

Setup Mode Screens

Press screens.

on any Run screen to enter the Setup

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

If the system has a password lock, the Password screen displays. See

Password Screen, page 38

.

Password Screen

Figure 28 Password Screen

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

Setup screens.

Entering an incorrect password clears the field.

Reenter the correct password.

To assign a password, see

Advanced Screen 1, page 55

.

38 332562B

Setup Mode Screens

System Screen 1

System screen 1 includes the following fields which define your system.

Figure 29 System Screen 1, During Standby

Figure 30 System Screen 1, During Idle

Diagnostic Mode

Select this box to display flow rate and pressure for each pump on the

Home Screen, page 31

.

Color Pumps

Enter the number of color pumps in your system.

Catalyst Pumps

Enter the number of catalyst pumps in your system.

Non-Mix Pressure

Enter a lower pressure for use when not mixing and spraying (for example during fill or flushing).

NOTE: Low pressure systems may be set 100 psi

(0.7 MPa, 7 bar) lower than target pressure; high pressure systems may be set 300 psi (2.1 MPa, 21 bar) lower than target pressure.

Solvent Meter

Select this box if your system uses a solvent meter.

The Solvent K-Factor field will then become active.

Solvent K-Factor

Enter the solvent meter K-Factor.

Select Gun Flush Box

Select this box if your system uses a gun flush box.

The Autodump function will then become selectable.

Autodump

Select this box to activate the Autodump function.

332562B 39

Setup Mode Screens

System Screen 2

System screen 2 sets the following system operating parameters.

Figure 31 System Screen 2, in Standby Mode

Figure 32 System Screen 2, in Mix 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%.

Mix Idle Timeout

The air flow switch (AFS) detects air flow to the gun and signals that the gun is triggered. If you are not using an air flow switch, the system does not know if the gun 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

Air Flow Switch (AFS) Function, page 61

.

Mix No Flow Timeout

The air flow switch (AFS) detects air flow to the gun and signals that the gun is triggered. If the air flow switch indicates that the gun is triggered, but there is no fluid flow through a pump, you could spray pure resin or catalyst without knowing. The Mix No Flow

Timeout will cause the system to shutdown after the designated period of time. The default is 5 seconds.

Enter the desired shutdown time in this field.

See

Air Flow Switch (AFS) Function, page 61

.

40 332562B

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 51 .

Maximum Leak Rate

Enter the maximum allowable leak rate for a pump stall test.

Setup Mode Screens

Mix Fill Set Point

Set a higher pressure for use while mix filling.

This higher pressure decreases the time needed to fill the gun. Once the gun is filled, the system uses the recipe’s target pressure setpoint (set on

Recipe Screen, page 45

) for mixing.

The default value is 0. When set to 0, the system ignores the Mix Fill Set Point and instead uses the

Non-Mix Pressure (set on

System Screen 1, page 39 )

while mix filling.

332562B 41

Setup Mode Screens

System Screen 3

System screen 3 sets the following system operating parameters.

Gun Hose Length

Enter the length of the hose from the mix manifold to the gun.

Gun Hose Diameter

Enter the diameter of the hose from the mix manifold to the gun. The minimum diameter is 1/8 in. (3 mm).

Mix At Wall

Select this box if a remote mix manifold is used in your system.

Figure 33 System Screen 3

Multiple Guns

Enable this option if multiple guns will be loaded with mixed material at the same time. This feature will track the pot life of up to 60 different guns. See

Information for Systems with Multiple Guns, page 43 .

NOTE: If Multiple Guns is enabled, the Gun Hose

Length, Gun Hose Diameter, and Mix at Wall fields are disabled.

Figure 35

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.

NOTE: These fields are enabled only if Mix at Wall is enabled.

Figure 34

42 332562B

Setup Mode Screens

Information for Systems with Multiple Guns

The Multiple guns feature enables the ability to simultaneously track up to 60 different mixed material recipes, each loaded into a dedicated gun. This feature is enabled on

System Screen 3, page 42 .

Recipe Screen

Because the system has a dedicated gun for each recipe, the associated hose length and diameters could be unique. Therefore, these parameters are disabled on

System Screen 3, page 42

, and now appear on the

Recipe Screen, page 45 . Enter the

hose length and diameter for a gun that will spray a particular recipe.

Changing Recipes or Purging

When Multiple Guns is enabled, the Spray Screen allows the user either to change the active recipe

(the recipe that is loaded in the pumps) or to purge a particular gun (recipe). Select either Recipe or

Purge from the dropdown menu and enter the recipe number. Use the Purge soft key to purge the active recipe.

These actions also can be done using the Booth

Control. Use the normal procedure to change the active recipe or to purge the active gun. See

Booth Control, page 22 . To purge a gun that is not

active currently, scroll Up or Down to the desired recipe. Then press Purge . If

Purge is not pressed within 5 seconds, the system will revert to the active recipe number.

Figure 36

Potlife Screen

In Run mode, the Potlife Screen appears in the menu bar between Fill and Usage. This screen displays how much time remains in the potlife of any given recipe (gun). Recipes are highlighted and show remaining potlife time only if that gun is filled with mixed material and has a non-zero potlife.

Figure 38

Figure 37

332562B 43

Setup Mode Screens

System Screen 4

System screen 4 sets the following system operating parameters. This screen is needed only for systems that use AWI.

Figure 39 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.

Check this box to enable the selected Gateway so that the PLC can communicate with it.

DHCP

Select this box if your system has a Dynamic Host

Configuration Protocol (DHCP). This protocol assigns unique IP addresses to devices, then releases and renews these addresses as devices leave and rejoin the network. If selected, the IP Address, Subnet, and

Gateway fields will not be editable and will display the addresses supplied by the DHCP.

TCP/IP

Use the remaining fields to set the IP address, subnet mask, Gateway, DNS1, and DNS2.

44 332562B

Setup Mode Screens

Recipe Screen

Figure 40 Valid Recipe Screen

Recipe

Enter the desired recipe number (1-60).

Recipe 0

Use Recipe 0 to flush the system.

• 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 booth control, in addition to the

ADM. The booth operator can then quickly select a desired recipe, without scrolling through all 60.

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 41 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 hard to flush colors, select a longer sequence. 1 is the default, and should be designated for the longest, most thorough flush duration.

If Mix at Wall is enabled on System Screen 3, enter the desired flush sequence (105) 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 47

. 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. Flush 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.

332562B 45

Setup Mode Screens

Pressure Low Limit

Enter the lowest target pressure which the operator is allowed to enter from the Spray screen or booth control. The default is 5 psi (.035 MPa, 0.35 bar).

Target Pressure

Enter the desired target spray pressure. This is the pressure the pumps will maintain at the outlet. The default is 20 psi (0.14 MPa, 1.4 bar).

Pressure High Limit

Enter the highest target pressure which the operator is allowed to enter from the Spray screen or booth control. The default is 300 psi (2.1 MPa, 21.0 bar).

NOTE: If you enter an invalid pressure for your system’s parameters, the field will be highlighted and the recipe is invalid. For example, if you enter 1500 psi (10.5 MPa, 105 bar) in a low pressure system, the field will be highlighted and the recipe becomes invalid.

46 332562B

Setup Mode Screens

Flush Screen

Figure 42 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 gun purge time (0 to 999 seconds).

Initial Flush

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

Final Flush

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

Wash Cycles

A Wash Cycle activates the pump with the valves closed, to use pumping motion to thoroughly clean the pump. Enter the desired number of wash cycles

(0 to 99). Entering a number will make the Strokes per Cycle field active.

Strokes per Wash Cycle

Enter the desired pump strokes per wash cycle (0 to 99). Default is 1.

332562B 47

Setup Mode Screens

Pump Screen 1

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

Information for each pump is accessible under a separate tab in the menu bar at the top of the screen.

Select the tab for the desired pump. Each pump has three screens. Only the screens for Pump 1 are shown here, but the same fields appear on all.

Pump screen 1 includes the following fields which define the pump.

Figure 43 Pump Screen 1 — Resin Pump

Figure 44 Pump Screen 1 — Catalyst Pump

Pump Size

Select 35cc or 70cc, as appropriate.

Inlet Pressure

Select one of the following:

• Disabled

• Monitor, to track inlet pressure

Select Color Change

Select this box if your system uses color change.

Materials

Enter the number of materials used in your system.

Each color change module controls 8 colors.

Total 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.

Pump Hose Diameter

Enter the diameter of the supply and output hoses.

Valve Mapping

Remote Valve Map

NOTE: This valve mapping dropdown menu displays if the pump is a resin pump with Color Change selected on this screen and Mix at Wall enabled on

System Screen 3, page 42 .

Select whether to use the standard color change valve mapping or one of two alternate color change valve mappings for the remote valve stack. See the

Color Change and Remote Mix Manifold manual

333282 for more information.

Valve Map

NOTE: This valve mapping dropdown menu displays if the pump is a catalyst pump with Color Change selected on this screen.

Select whether to use the standard color change valve mapping or the alternate color change valve mapping for the catalyst pump(s). See the Color

Change and Remote Mix Manifold manual 333282 for more information.

Available Colors

The module displays the number of colors available in your system. This field is not editable.

48 332562B

Setup Mode Screens

Pump Screen 2

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

Figure 45 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.

• Inlet Offset Factor: This field is only used if Inlet

Pressure in

Pump Screen 1, page 48

is set to

Monitor; it is grayed out if set to Disabled. The valid range is -01.20 to +01.20 mV/V.

• Inlet Sensitivity Factor: This field is only used if

Inlet Pressure in

Pump Screen 1, page 48

is set to Monitor; it is grayed out if set to Disabled. The valid range is 18.80 to 21.20 mV/V.

• Outlet Offset Factor: The valid range is -01.20 to

+01.20 mV/V.

• Outlet Sensitivity Factor: The valid range is 18.80

to 21.20 mV/V.

Figure 46 Pump Screen 2, Default Settings Disabled

332562B 49

Setup Mode Screens

Pump Screen 3

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

When Inlet Pressure in

Pump Screen 1, page 48

is set to Disabled, the inlet limit fields are grayed out and only the outlet limit fields are active. See

Pressure Alarm and Deviation Limits, page 50 .

Figure 47 Pump Screen 3, Pressure Monitoring

Disabled

When Inlet Pressure in

Pump Screen 1, page 48

is set to Monitor, all fields are active. See

Pressure Alarm and Deviation Limits, page 50 .

Figure 48 Pump Screen 3, Pressure Monitoring

Enabled

Pressure Alarm and Deviation Limits

Inlet fields are only active if Inlet Pressure in

Pump Screen 1, page 48

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.

50 332562B

Calibrate Screen 1

Calibrate Screen 1 initiates a pump pressure check

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

Stall Test screen will appear.

The pump and lines must be primed with color or catalyst before doing the stall test. See

System Screen 2, page 40

to set test parameters.

See

Pump Pressure Check, page 57

for complete test instructions.

To initiate the test, press the Pressure Check button for the desired pump. The pump will build pressure in the line to a minimum of the Stall Test

Pressure. The pump will then move to the center stroke position and stall test the upstroke, followed by the downstroke.

NOTE: The Last Passed log can only be reset by successfully completing the test.

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

Setup Mode Screens

Calibrate Screen 2

Calibrate Screen 2 initiates a volume test for the selected pump. During the test, the Volume Check screen will appear.

The pump and lines must be primed with color or catalyst before doing the Volume Check. See

Pump Volume Check, page 58

for complete test instructions.

To initiate the test, press the Volume Check button for the desired pump.

The screen displays the volume dispensed. Press to end the test.

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

for 1-2

Figure 49 Calibrate Screen 1

Figure 51 Calibrate Screen 2

Figure 50 Stall Test Screen

332562B

Figure 52 Volume Check Screen

51

Setup Mode Screens

Calibrate Screen 3

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

Verification screen will appear.

The meter and lines must be primed with solvent before doing the calibration. See

Solvent Meter Calibration, page 59

for complete instructions.

To initiate the calibration, press the Volume Check button.

The screen displays the volume dispensed. Enter the amount of solvent dispensed in the Measured

Volume field, or press to end the test.

After the Measured Volume is entered, the Accept

Calibration window will appear. Press to accept the calibration. Press to cancel the calibration and retain the previous K-factor.

Figure 54 Enter Measured Volume of Solvent

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

for 1-2

Figure 55 Accept Calibration

Figure 53 Calibrate Screen 3

52 332562B

Maintenance Screen 1

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

NOTE: The Pump Stall Test cannot be disabled. You must enter a value other than 0.

Setup Mode Screens

Maintenance Screen 3

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

Press and hold the Reset button for 1-2 seconds to clear the alarm and reset the counter.

NOTE: The Pump Stall Test can only be reset by successfully completing the test.

Figure 56 Maintenance Screen 1, Interval Settings

Maintenance Screen 2

Maintenance screen 2 shows the current interval status of the solvent meter, fluid filter, and air filter.

Press and hold the Reset button for 1-2 seconds to clear the alarm and reset the counter.

Figure 58 Maintenance Screen 3, Current Pump

Status

Figure 57 Maintenance Screen 2, Current Status

332562B 53

Setup Mode Screens

Maintenance Screen 4

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

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

for 1-2

If the system is in Standby, valves can be opened or closed by selecting or deselecting the box for the corresponding valve.

NOTE: Gun valves are available only if Mix at Wall is enabled on

System Screen 3, page 42 .

Figure 60 Maintenance Screen 4, Solvent Valve

Resets

NOTE: When Solvent is selected in the Material field, the number to the right of “Solvent” is the pump number, not the material number.

Figure 59 Maintenance Screen 4, Color Valve Resets

54 332562B

Setup Mode Screens

Advanced Screen 1

Advanced screen 1 sets the following display parameters.

Figure 61 Advanced Screen 1

Language

Defines the language of the screen text. Select:

• English (default)

• Spanish

• French

• German

• Japanese

• Chinese

• Korean

• Dutch

• Italian

• Portuguese

• Swedish

• Russian

Date Format

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

Date

Enter the date, using the format selected. Use two digits for the month, day, and year.

Time

Enter current time in hours (24 hour clock) and minutes. Seconds are not adjustable.

Password

The password is only used to enter Setup mode.

The default is 0000, which means no password is required to enter Setup. If a password is desired, enter a number from 0001 to 9999.

NOTE: Be sure to write down the password and keep it in a secure location.

Screen Saver

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

5 is the default. Select zero (0) to disable the screen saver.

Silent Mode

Select Silent Mode to disable the alarm buzzer and audible feedback.

332562B 55

Setup Mode Screens

Advanced Screen 2

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

Figure 62 Advanced Screen 2

Display Units

Select the desired display units:

• Grand Total Volume (US gallon or liter)

• Pressure (psi, bar, or MPa)

• Length (ft or m)

Advanced Screen 3

Advanced screen 3 enables USB downloads and uploads.

Enable USB Downloads/Uploads

Select this box to enable USB downloads and uploads. Enabling USB activates the Download

Depth field.

Download Depth

Enter the number of days for which you want to retrieve data. For example, to retrieve data for the previous week, enter 7.

Log 90% Full Advisory Enabled

This selection is enabled by default. When enabled, the system will issue an advisory if the memory log has reached 90% of capacity. Perform a download to avoid loss of data.

Advanced Screen 4

Advanced screen 4 displays the software part numbers and versions for the system components.

This is not an editable screen.

Figure 64 Advanced Screen 4

Figure 63 Advanced Screen 3

56 332562B

Calibration Checks

Calibration Checks

Pump Pressure Check

NOTE: Enter the transducer calibration data before doing the pressure check.

Perform the pressure check:

• The first time the system is operated.

• Whenever new materials are used in the system, especially if the materials have viscosities that differ significantly.

• At least once per month as part of regular maintenance.

• Whenever a pump is serviced or replaced.

During each pressure test, the dose valve will close during an up stroke and a down stroke (in either order). This test is to verify that the valves are seating properly and not leaking. If leaking occurs, the system will alarm after the test for that particular pump direction.

NOTE: Do not trigger the gun during the pressure check.

1. Set the mix manifold to the SPRAY position.

2. The pump and lines must be primed with color or catalyst before doing the Pressure Check. See

Prime and Fill the System, page 25

.

3. If the display is on a Run Mode screen, press to access setup screens.

4. Scroll to Calibrate to display

Calibrate Screen 1, page 51 .

5. Press the Pressure Check button for the desired pump. The pump will build pressure in the line to a minimum of the Stall Test Pressure.

The pump will then move to the center stroke position and stall test the upstroke, followed by the downstroke.

6. 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 40 . 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.

332562B 57

Calibration Checks

Pump Volume Check

1. Set the mix manifold to the SPRAY position.

2. The pump and lines must be primed with color or catalyst before doing the Volume Check. See

Prime and Fill the System, page 25 .

3. If the display is on a Run Mode screen, press to access setup screens.

4. Scroll to Calibrate in the menu bar.

5. Scroll to

Calibrate Screen 2, page 51

.

6. Press the soft key to check.

for the pump you want

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 the line or pressure that is too high may cause incorrect values.

7. Press the Reset key will reset to 0.

. The volume counter

8. Trigger the gun into a graduated cylinder.

Dispense a minimum of 500cc of material.

9. The volume that the unit measured displays on the screen.

10. 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 the A and B pump positions are not reversed.

NOTE: Stop triggering the gun and press to cancel the test.

58 332562B

Calibration Checks

Solvent Meter Calibration

1. Set the mix manifold to the FLUSH position.

2. The meter and lines must be primed with solvent before doing the calibration. See

Prime and Fill the System, page 25 .

3. If the display is on a Run Mode screen, press to access setup screens.

4. Scroll to Calibrate in the menu bar.

5. Scroll to

Calibrate Screen 3, page 52

.

6. Press the soft key to initiate the calibration.

NOTE: For maximum accuracy, use a gravimetric

(mass) method to determine the actual volumes dispensed.

NOTE: Verify that the fluid line is filled and at the proper pressure before calibrating. Air in the line or pressure that is too high may cause incorrect calibration values.

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 calibration process.

10. Enter the amount of solvent dispensed in the

Measured Volume field on the screen.

11. After the measured volume is entered, the controller calculates the new solvent meter

K-factor and displays it on the screen. The standard meter K-factor is 0.021 cc/pulse.

12. Press to accept the calibration. Press to cancel the calibration and retain the previous

K-factor.

332562B 59

Color Change

Color Change

Color Change Module Kits are available as an accessory. See manual 332455 for complete information.

Single Color Systems

1. Follow the procedure under

Flush the System, page 28

.

2. Load the new color. See

Prime and Fill the System, page 25 .

3. Press the Mix key to start spraying.

Multiple Color Systems

1. Press Standby .

2. Set the current mix manifold to FLUSH.

3. Select the new recipe at the Booth Control or on the

Spray Screen, page 34 . This will change

colors in the pump and initiate a gun purge. The

Standby and Purge indicators should be blinking.

NOTE: The booth control only displays enabled recipes. If an invalid recipe is entered, the display will show 4 dashes (— — — — ). See

Recipe Screen, page 45

to enable a recipe.

NOTE: If Mix at Wall is enabled on

System Screen 3, page 42

, the system will purge Material B first, then Material A out of the gun. Each material will purge for the amount of time designated by the Flush

Sequence selected for that material on the

Recipe Screen, page 45 .

4. Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun. Make sure there is enough flow to open the solvent flow switch.

5. Release the trigger when the solvent flow stops and the Purge indicator stops blinking.

NOTE: If you are using quick-disconnects at the mix manifold, disconnect the gun from the purged mix manifold and connect it to the new color line.

6. Wait for the color change to complete (the

Standby indicator is on solid).

7. Set the mix manifold to SPRAY.

8. Press the Mix key on the booth control. The Mix indicator will be blinking.

9. Trigger the gun to complete the Mix Fill.

NOTE: There is a 30 second delay without flow before the system will fault.

10. Wait for atomizing air and for the Mix indicator to be on solid, then resume spraying.

60 332562B

System Errors

System Errors

System errors alert you of a problem and help prevent off-ratio spraying. There are three types:

Advisory, Deviation, and Alarm.

An Advisory records an event in the system, and will clear itself after 60 seconds.

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 the three types occur:

• Alarm buzzer sounds (unless in silent mode).

• Alarm popup screen shows the active alarm code

(see

Error Codes, page 62 ).

• Status bar on the Advanced Display Module shows the active alarm code.

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

To Clear Error and Restart

NOTE: When a deviation or alarm occurs, be sure to determine the error code before resetting it. If you forget which code occurred, go to the

Errors Screen, page 37

, to view the last 200 errors, with date and time stamps.

If an alarm has occurred, correct the cause before resuming operation.

To acknowledge a deviation or clear an alarm, press on the Advanced Display Module or on the Booth Control.

Air Flow Switch (AFS) Function

The air flow switch (AFS) detects air flow to the gun and signals the controller when the gun is triggered.

The gun icon on the Advanced Display Module shows spray when the AFS is activated.

If a pump fails, pure resin or catalyst could spray indefinitely if the unit does not detect the condition and intervene, which is why the AFS is so important.

If the unit detects through the AFS 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.

332562B 61

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 37

to view the last 200 errors, with date, time, and description.

Purge Errors

Code Type Description Problem

F7P1 Alarm Air Flow

Switch On

The air flow switch is indicating unexpected atomizing air flow.

SPD1 Alarm Gun Purge

Incomplete

The system timed out without reaching the user-specified volume of solvent for a purge.

Cause

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.

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

Solution

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

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

Set manifold to flush position.

Mix Errors

Code

F7S1

Type Description Problem

Alarm Flow

Detected

Solvent

Gun

The solvent flow switch is indicating unexpected solvent flow.

QPD1 Alarm, then

Deviation

SND1 Alarm

Potlife

Expired

Mix Fill

Incomplete

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

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.

Spray gun was not triggered.

Restrictions in mixer, manifold, or spray gun.

Solution

Clean or replace switch.

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.

62 332562B

System Errors

Pumping Errors

NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable component number, which can vary. The unit’s display will show the applicable number as the last digit in the code. For example, the F1S# code listed in this table will be displayed as F1S1 if the affected component is pump 1, F1S2 for pump 2, and so on.

Code

DA0#

DE0#

Type Description Problem

Alarm Exceeded

Maximum

Flow Pump

#

Pump was driven to its maximum allowed speed.

Alarm Leak

Detected

Pump #

This is a manual stall test failure when the pump cannot build pressure to the target

“Stall Test Pressure.”

Will fault after 30 seconds.

Cause

System has a leak or open valve that is allowing unrestricted 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 material in the pump or line.

Leak in the system.

Solution

Inspect system for leaks.

Verify that the pump is being supplied with material.

Reduce nozzle size to create more restriction.

Reduce paint pressure to lower the flow rate.

Reduce the pressure or the Flow Setpoint.

DF0#

DG0#

Alarm No Stall Up

Pump #

Alarm 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.

Valve failure, seal failure, worn rod or cylinder.

Make sure the pump and down stream color line are loaded with material.

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.

Replace inlet and outlet valve and seal for up stroke. Replace piston and throat seals. Replace rod and cylinder as necessary.

Replace inlet and outlet valve and seal for down stroke. Replace piston and throat seals. Replace rod and cylinder as necessary.

332562B 63

System Errors

Code

DK0#

EBH#

EF0#

EF1#

Type

Record

Description

DH0# Alarm No Stall

Pump #

Alarm Position

Pump #

Home

Complete

Pump #

Alarm Timeout

Startup

Pump #

Alarm Timeout

Shutdown

Pump #

Problem

Pump failed the stall test; did not stall on either the upstroke or the downstroke.

Pump was detected to be out of position.

Cause

Valve failure, seal failure, worn rod or cylinder.

Solution

Replace inlet and outlet valve and seal for up and down strokes.

Replace piston and throat seals. Replace rod and cylinder as necessary.

Re-enable pump power to reset pump. Make sure inlet supply pressure is not too high.

No action required.

Record of pump homing is complete.

Pump tried but was not able to move to the home position within a specified amount of time.

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

Pump dose valves did not actuate.

Pump tried but was not able to move to the park position within a specified amount of time.

Motor could not drive pumps and linear actuator.

Pump stroke length is shortened by mechanical system tolerance.

Pump dose valves did not actuate.

Pump is filled with thick paint and could not drive piston to end of stroke. Motor or drive is worn or damaged.

Verify air pressure to solenoid valves.

Verify the valves are actuating.

Verify motor is driving the pump.

Verify correct assembly of linear actuator and pump piston rods. See pump manual.

Visually inspect valves to ensure they are operating properly; verify they have air pressure above 85 psi

(0.6 MPa, 6.0 bar).

Observe motor and drive assembly to verify that the motor is generating force.

64 332562B

System Errors

Code

F1F#

F1S#

F7D#

F8D1

F9D#

SAD1

Type Description Problem

Alarm Flow Low

Fill Pump #

There has been no flow or low flow during a pump fill operation.

Cause

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

Thick viscosity paint requires more pressure to pump.

Solution

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

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

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

Alarm Flow Low

Purge Pump

#

There has been no flow or low flow during a pump purge operation.

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.

Alarm Flow

Detected

Pump #

Alarm Flow Not

Detected

Alarm Flow

Unstable

Pump #

Alarm Atomizing

Solvent

The pump flow exceeded 20 cc/min flow coming into Idle mode.

No flow while mixing.

The pump flow rate did not stabilize while entering Idle mode.

Air flow switch is active while solvent, diluted material, or an unknown material is in the gun.

There is a leak in the system or the gun was open when the system went into Idle mode.

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

Potential leak in the system.

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

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.

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.

332562B 65

System Errors

Pressure Errors

NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable component number, which can vary. The unit’s display will show the applicable number as the last digit in the code. For example, the P6F# code listed in this table will be displayed as P6F1 if the affected component is pump 1, P6F2 for pump 2, and so on.

Code

F6F#

P1F#

Type Description Problem

Alarm Press.

Sens.

Removed

Inlet #

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

Alarm Pressure

Low Inlet

Pump #

Cause

Disconnected transducer.

Solution

Verify transducer is connected properly.

Replace if reconnecting does not eliminate the alarm.

Increase inlet pressure.

P2F#

P3D#

P3F#

P4D#

P4F#

P6D#

P9D#

Deviation

Deviation

Deviation

Pressure

Low Inlet

Pump #

Pressure

High Outlet

Pump #

Pressure

High Inlet

Pump #

Alarm Pressure

High Outlet

Pump #

Alarm Pressure

High Inlet

Pump #

Alarm Press.

Sens.

Removed

Outlet #

Alarm Press.

Sens.

Failed

Outlet #

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.

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

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

The outlet pressure on pump # is greater than the user entered alarm limit.

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

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.

Increase inlet pressure.

Relieve system pressure.

Decrease inlet pressure.

Relieve system pressure.

Decrease inlet pressure.

Verify transducer is connected properly.

Replace if reconnecting does not eliminate the alarm.

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

66 332562B

System Errors

Code

P9F#

QADX

QBDX

Type Description

Alarm Press.

Sens.

Failed Inlet

#

Alarm Differential

Pressure A

Over B

Alarm Differential

Pressure B

Over A

Problem

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

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

There is a leak on the

B side.

The B side pump is cavitating.

There is a leak on the

A side.

The A side pump is cavitating.

Solution

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 paint supply on the B side, increase paint supply pressure.

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.

332562B 67

System Errors

System Errors

Code

EB00

Type

Record

Description

Stop Button

Pressed

Problem

Record of a stop button press.

EC00

EL00

EM00

EMIX

Record

Record

Record

Advisory

Setup

Value(s)

Changed

System

Power On

System

Power Off

Pump Off

Record of changing setup variables.

Record of power cycle

(ON).

Record of power cycle

(OFF).

The pumps are not powered and are unable to move.

Cause

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 power was turned off or an error occurred.

Solution n/a n/a n/a n/a

Start pumps by pressing pump start key on Advanced

Display module.

n/a ES00 Advisory

Factory

Defaults

Record of defaults being loaded.

Communication Errors

NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable component number, which can vary. The unit’s display will show the applicable number as the last digit in the code. For example, the CAC# code listed in this table will be displayed as CAC1 if the affected component is color change board 1, CAC2 for board 2, and so on.

Code

CA0X

CAC#

CADX

Type

Alarm

Alarm

Alarm

Description

Comm. Error

ADM

Comm. Error

Color Change

#

Comm. Error

Fluid Module

Problem

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

This communication error indicates that the Network has lost communication with the Advanced Display

Module.

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

Module #.

This communication error indicates that the Network has lost communication with the EFCM.

Solution

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.

68 332562B

System Errors

Code

CAGX

CDC#

Type

Alarm

Alarm

CDDX Alarm

Description

Comm. Error

Gateway

Duplicate

Color Change

#

Duplicate

Fluid Module

Problem

System does not detect a CGM that was registered as being connected at power up.

System detects two or more identical Color

Change Modules.

System sees two or more identical

Enhanced Fluid

Control Modules

EFCM).

Cause

More than one Color

Change Module with the same address is connected in the system .

More than one EFCM is connected in the system.

Solution

Check the system and remove the extra color change module.

Check the system and remove the extra

EFCM.

332562B 69

System Errors

USB Errors

Code Type Description Problem

EAUX

EBUX

EQU0

EQU1

EQU2

Advisory

Record

Advisory

Record

Record

USB Busy

USB Drive

Removed

USB Idle

USB Sys.

Settings

Downloaded

USB Sys.

Settings

Uploaded

USB Custom

Lang.

Downloaded

USB Custom

Lang.

Uploaded

USB drive is inserted, download is in progress.

USB drive was removed while downloading or uploading.

USB download completed, drive may be removed.

Settings were downloaded to USB drive.

Settings were uploaded from USB drive.

EQU3

EQU4

EQU5

Record

Record

Record

MMUX Advisory

USB Logs

Downloaded

Maint. USB

Logs Full

Custom language was downloaded to USB drive.

Custom language was uploaded from USB drive.

Data logs were downloaded to USB drive.

EVUX Advisory USB Disabled USB drive has been inserted, downloading is disabled.

USB memory is more than 90% full.

WSUX Advisory

WXUU Advisory

USB Config.

Err.

WXUD Advisory USB Download

Err.

USB Upload

Err.

USB configuration file does not match expected; checked on startup.

An error occurred while downloading to the USB drive.

An error occurred while uploading from the USB drive.

Cause

Indicates USB port is uploading or downloading data.

Downloading/uploading data on USB was interrupted by the USB device being removed.

Data transfer is completed to the

USB device.

User installed USB device in ADM USB port.

User installed USB device in ADM USB port.

User installed USB device in ADM USB port.

User installed USB device in ADM USB port.

User installed USB device in ADM USB port.

Configuration of system is blocking data transfer.

Configuration parameter on system is enabled to generate this advisory.

A software update was not completed successfully.

Solution

Wait for USB Idle.

Replace the USB device and begin process again.

Remove USB device from ADM.

n/a n/a n/a n/a n/a

Change configuration to enable USB download function.

Complete download to ensure no data is lost.

Reinstall software.

User installed incompatible USB device in ADM USB port.

User installed incompatible USB device in ADM USB port.

Repeat process with compatible USB device.

Repeat process with compatible USB device.

70 332562B

System Errors

Miscellaneous Errors

NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable component number, which can vary. The unit’s display will show the applicable number as the last digit in the code. For example, the B9D# code listed in this table will be displayed as B9D1 if the affected component is pump 1, B9D2 for pump 2, and so on.

Code

B9A0

B9AX

B9B0

B9BX

B9D#

B9S0

B9SX

WX00

Type

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Alarm

Description

Volume

Rollover A

Current

Volume

Rollover A

Lifetime

Volume

Rollover B

Current

Volume

Rollover B

Lifetime

Volume

Rollover

Pump #

Volume

Rollover

Solvent

Current

Volume

Rollover

Solvent

Lifetime

Software

Errors

Problem

Batch counter for material A rolled over.

Grand total counter for material A rolled over.

Batch counter for material B rolled over.

Grand total counter for material B rolled over.

Grand total counter for pump # rolled over.

Batch counter for solvent rolled over.

Grand total counter for solvent rolled over.

An unexpected software error has occurred.

Cause

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

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

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

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

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

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

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

Solution n/a n/a n/a n/a n/a n/a n/a

Call Graco technical support.

332562B 71

System Errors

Calibration Errors

NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable component number, which can vary. The unit’s display will show the applicable number as the last digit in the code. For example, the ENT# code listed in this table will be displayed as ENT1 if the affected component is pump 1, ENT2 for pump 2, and so on.

Code

END#

ENS0

ENT#

Type

Record

Record

Record

Name

Calibration Pump #

Calibration Solvent Meter

Calibration Stall Test Pump

#

Description

A calibration test was run on the pump.

A calibration test was run on the solvent meter.

A stall test was completed successfully on pump #.

72 332562B

System Errors

Maintenance Errors

NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable component number, which can vary. For example, the MAD# code listed in this table will be displayed as MAD1 if the affected component is pump 1, MAD2 for pump 2, and so on.

Because some components are assigned a 2–digit number, the last digit of the code is displayed as an alphanumeric character. The second table below correlates the alphanumeric digit to its component number.

For example, code MEDZ represents outlet valve 30.

Code

MAD#

MAT#

MEB#

MED#

MEF#

MEG#

MES#

MFF#

MFS0

MGH0

MGP0

Type

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Name

Maint. Outlet Pump # Maintenance is due on pump.

Maint. Stall Test

Pump #

Maint. Valve Catalyst

(B) #

Description

Maintenance stall test is due on pump.

Maintenance is due on catalyst valve.

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

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

Maint. Valve Gun #

Maint. Valve Solvent

#

Maintenance is due on gun valve.

Maintenance is due on solvent valve.

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

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

Maint. Filter Fluid

Maint. Filter Air

Maintenance is due on fluid filter.

Maintenance is due on air filter.

Alphanumeric Last Digits

A

B

C

D

E

F

8

9

6

7

2

3

4

5

Alphanumeric Digit

1

Component Number

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Alphanumeric Digit

G

H

J

K

L

M

N

P

R

T

U

V

W

Y

Z

Component Number

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

332562B 73

Maintenance

Maintenance

Preventive Maintenance Schedule

The operating conditions of your particular system determine how often maintenance is required.

Establish a preventive maintenance schedule by recording when and what kind of maintenance is needed, and then determine a regular schedule for checking your system.

Flushing

• Flush before changing fluids, before fluid can dry in the equipment, at the end of the day, before storing, and before repairing equipment.

• Flush at the lowest pressure possible. Check connectors for leaks and tighten as necessary.

• Flush with a fluid that is compatible with the fluid being dispensed and the equipment wetted parts.

Cleaning the ADM

Use any alcohol-based household cleaner, such as glass cleaner, to clean the ADM.

74 332562B

Technical Data

Technical Data

Positive Displacement

Proportioner

Maximum fluid working pressure:

MC0500 Systems with

Low-Pressure Pumps

MC0500 Systems with

High-Pressure Pumps

MC1000 Air Spray Systems

MC2000 Air-Assisted Spray

Systems

Maximum working air pressure:

Air supply:

Air filter inlet size:

Air filtration for air logic

(user-supplied):

Air filtration for atomizing air

(user-supplied):

Mixing ratio range:

Fluids handled:

Viscosity range of fluid:

Fluid filtration (user-supplied):

Maximum fluid flow:

Fluid outlet size:

External power supply requirements:

Operating temperature range:

Storage temperature range:

Weight (approximate):

Sound data:

Wetted parts:

U.S.

300 psi

1500 psi

300 psi

1500 psi

100 psi

85–100 psi

3/8 npt(f)

Metric

2.1 MPa, 21 bar

10.5 MPa, 105 bar

2.1 MPa, 21 bar

10.5 MPa, 105 bar

0.7 MPa, 7.0 bar

0.6–0.7 MPa, 6.0–7.0 bar)

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

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

0.1:1 — 50:1, ±1% one or two component:

• solvent and waterborne paints

• polyurethanes

• epoxies

• acid catalyzed varnishes

• moisture sensitive isocyanates

20–5000 centipoise

100 mesh minimum

800 cc/minute (depending on material viscosity)

1/4 npt(m)

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

15 amp maximum circuit breaker required

8 to 14 AWG power supply wire gauge

36 to 122°F 2 to 50°C

–4 to 158°F

195 lb

–20 to 70°C

88 kg

Less than 75 dB(A)

17–4PH, 303, 304 SST, Tungsten carbide (with nickel binder), perfluoroelastomer; PTFE, PPS, UHMWPE

332562B 75

Graco Standard Warranty

With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

free of charge any defective parts. The equipment will be returned to the original purchaser transportation made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost

Any action for breach of warranty must be brought within two (2) years of the date of sale.

FOR GRACO CANADA CUSTOMERS drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com.

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

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

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

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

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

Original Instructions. This manual contains English. MM 332562

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

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

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

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