Graco 3A4486E, ProMix® PD2K Dual Fluid PanelElectric Proportioner for Automatic Spray Applications Instructions

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Graco 3A4486E, ProMix® PD2K Dual Fluid PanelElectric Proportioner for Automatic Spray Applications Instructions | Manualzz

Operation

Electronic

Advanced

Important

Read all warnings and instructions in this manual and in your PD2K installation, repair, and associated component manuals. Save these instructions.

See page 4for model part numbers and approvals information.

3A4486E

EN

PROVEN QUALITY. LEADING TECHNOLOGY.

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

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

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

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

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

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

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

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

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

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

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

Navigating the Screens ................................ 15

Screen Icons ............................................... 15

Pre-Operation Tasks........................................... 16

Pre-operation Checklist ................................ 16

Power On .................................................... 16

Initial System Setup ..................................... 17

Flush Before Using Equipment...................... 17

Valve Settings.............................................. 17

Pressure Relief Procedure .................................. 18

Without Color Change .................................. 18

With Color Change....................................... 18

Operation Using Advanced Display Module

(ADM)................................................... 19

Prime and Fill the System ............................. 19

Pre-Fill the Pump ......................................... 19

Spraying...................................................... 19

Purging ....................................................... 20

Shutdown .................................................... 21

Operation Using a Programmable Logic

Controller (PLC) .................................... 22

Network Communications and Discrete

I/O ................................................. 22

Discrete I/O ................................................. 22

Communication Gateway Module (CGM)

Details ........................................... 25

Network Communication I/O Data Map ........... 26

Operation Flow Charts ................................. 41

Network Communication - Dynamic

Command Structure (DCS) ............. 49

PLC Diagnostic Screens............................... 58

Flow Control System .................................... 59

Run Mode Screens ............................................. 60

Opening Screen........................................... 60

Home Screen .............................................. 60

Spray Screen............................................... 63

Fill Screen ................................................... 64

Usage Screen.............................................. 65

Jobs Screen ................................................ 66

Errors Screen .............................................. 66

Events Screen ............................................. 66

Setup Mode Screens .......................................... 67

Password Screen......................................... 67

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

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

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

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

Solvent Push ............................................... 71

System Screen 5 ......................................... 73

Gateway Screen .......................................... 74

Recipe Screen ............................................. 75

Flush Screen ............................................... 78

Air/Solvent Chop .......................................... 79

Pump Screen 1 ............................................ 80

Custom Valve Mapping ................................ 81

Pump Screen 2 ............................................ 85

Pump Screen 3 ............................................ 86

Calibration Screens...................................... 87

Maintenance Screens................................... 89

Advanced Screen 1...................................... 91

Advanced Screen 2...................................... 92

Advanced Screen 3...................................... 92

Advanced Screen 4...................................... 93

Diagnostic Screens ...................................... 94

Calibration Checks.............................................. 95

Pump Pressure Check ................................. 95

Pump Volume Check.................................... 96

Solvent Meter Calibration ............................. 96

Color Change ..................................................... 97

Multiple Color Systems................................. 97

System Errors .................................................... 98

On-Screen Help ........................................... 98

To Clear Error and Restart............................ 99

Gun Trigger Input Function ........................... 99

Error Codes ............................................... 100

Maintenance .................................................... 110

Preventive Maintenance Schedule .............. 110

Flushing .................................................... 110

Cleaning the ADM...................................... 110

Appendix A: Integration with Allen Bradley

PLC.................................................... 111

Technical Data ................................................. 114

California Proposition 65 ................................... 115

2 3A4486E

Related Manuals

Current manuals are available at www.graco.com.

Manual No.

Description

332709 ProMix PD2K Proportioner for

Automatic Spray Applications,

Repair — Parts

332458 ProMix PD2K Proportioner for

Automatic Spray Applications,

Installation

332339

332454

Dosing Pumps, Instructions —

Parts

Color/Catalyst Dispense Valves,

Instructions — Parts

Manual No.

Description

333282 Color Change and Remote Mix

Manifold Kits, Instructions — Parts

332456

334183

Pump Expansion Kits, Instructions

— Parts

Modbus TCP Gateway Module,

Instructions — Parts

334494 ProMix PD2K CGM Installation

Kits, Instructions — Parts

3A4486E 3

Models

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

AC1002

AC2002

A

A

100 psi (0.7 MPa, 7.0 bar)

100 psi (0.7 MPa, 7.0 bar)

300 psi (2.068 MPa,

20.68 bar)

1500 psi (10.34 MPa,

103.4 bar)

II 2 G

Figure 1 Model AC1002 Identification Label

Figure 2 26A188 Control Box Identification Label

Continued on the next page.

4 3A4486E

Models

Figure 3 Non-Intrinsically Safe Color Change Control (Accessory) Identification Label

Figure 4 Intrinsically Safe Color Change Control

(Accessory) Identification Label

Figure 5 Pump Expansion Kit (Accessory) Identification Label

PART NO.

SERIAL NO.

DATE / SERIES

RECOGNIZED

COMPONENT

12-30 VDC

4 AMP MAX

Type 1 ENCL

4003764

Conforms to

UL STD 508

Certified to CAN/CSA

STD C22.2 No. 14

U.S. Patent Pending

Artwork No.

293656 Rev. D

Figure 6 CGM Identification Label

3A4486E 5

Warnings

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

solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

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

• Never spray or flush solvent at high pressure.

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

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

• Use only grounded hoses.

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

you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

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.

6 3A4486E

Warnings

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.

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin.

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

• Do not put your hand over the fluid outlet.

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

servicing equipment.

• Tighten all fluid connections before operating the equipment.

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

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,

3A4486E

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.

7

8

Warnings

Always wear appropriate personal protective equipment and cover all skin when spraying, servicing equipment, or when in the work area. Protective equipment helps prevent serious injury, including long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction; burns; eye injury and hearing loss. This protective equipment includes but is not limited to:

• A properly fitting respirator, which may include a supplied-air respirator, chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority.

• Protective eyewear and hearing protection.

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 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.

• 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.

3A4486E

Important Isocyanate (ISO) Information

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

Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized particulates

• Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific hazards and precautions related to isocyanates.

• Use of isocyanates involves potentially hazardous procedures. Do not spray with the equipment unless you are trained, qualified, and have read and understood the information in this manuals and in the fluid manufacturer’s application instructions and SDS.

• Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material. Equipment must be carefully maintained and adjusted according to instructions in the manual.

• To prevent inhalation of isocynate mists, vapors, and atomized particulates, everyone in the work area must wear appropriate respiratory protection. Always wear a properly fitting respirator, which may include a supplied-air respirator. Ventilate the work area according to instructions in the fluid manufacturer’s SDS.

• Avoid all skin contact with iscocyanates.

Everyone in the work area must wear chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority.

Follow all fluid manufacturer recommendations, including those regarding handling of contaminated clothing. After spraying, wash hands and face before eating or drinking.

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.

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.

• 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.

crystallization varies depending on the blend of ISO, the humidity, and the temperature.

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.

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

B wetted parts.

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

3A4486E 9

General Information

• Reference numbers and letters in parentheses in the text refer to numbers and letters in the illustrations.

• Be sure all accessories are adequately sized and pressure-rated to meet system requirements.

• To protect the screens from paints and solvents, clear-plastic protective shields (10 per pack) are available. Order Part No. 197902 for the Advanced

Display Module. Clean the screens with a dry cloth if necessary.

10 3A4486E

Advanced Display Module (ADM)

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 60

, or

Setup Mode Screens, page 67 .

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

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

1

4

7

2

5

8

0

Figure 7 Advanced Display Module

3

6

9

.

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

1.

Enable USB downloads.

See

Advanced Screen 3, page 92 .

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.

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.

(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.

3A4486E 11

Advanced Display Module (ADM)

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

1.

USB Download 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.

users can now select the new language from the

Language drop-down menu in the Advanced Setup

Screen 1.

installed, it is recommended to remove the file from the UPLOAD folder on the USB flash drive. This will prevent inadvertently overwriting any future setup changes.

12 3A4486E

Advanced Display Module (ADM)

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

Press to startup or shutdown the pump/motor.

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

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

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

Press to immediately stop the system and remove motor power.

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

The top left soft key is the Edit key, which allows access to any settable fields on a screen.

Left/Right Arrows:

Use to move from screen to screen.

Up/Down Arrows:

Use to move among fields on a screen, items on a dropdown menu, or multiple screens within a function. Also used to toggle between Mix Units on Home Screen.

Numeric Keypad Use to input values. See

ADM Display, page 11 .

Use to cancel a data entry field.

Press to enter or exit Setup mode.

Press to choose a field to update, to make a selection, to save a selection or value, to enter a screen, or to acknowledge an event.

3A4486E 13

Advanced Display Module (ADM)

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

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

14

Enter Screen

Exit Screen

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

Press to exit screen after editing.

Press to accept calibration value.

Accept

Cancel

Toggle

Prime Pump

Pre-Fill Pump

Line/Fill/Run

Mix

Press to mark pump as filled. (Only for applicable pumps.)

Press to start a line fill procedure.

Press to start a spray procedure.

Press to start a purge procedure.

Purge

Press to cancel or reject calibration value.

Press to switch between

Mix Units on the Spray and Fill screens.

Press to start a pump priming procedure.

Solvent Purge

Press to engage solvent push sequence, when applicable.

Standby

Press to stop all pumps and put system in

Standby.

Stop

Recipe Link

Press to link recipe data for a specific recipe on both Mix Units.

Press to start a pump pressure check.

Pressure Check

Press to start a pump volume check.

Volume Check

Pressure Relief

Appears on the

Maintenance screen to relieve pump pressure out the color change dump valve.

Press to log the material usage and increment the job number, for Mix Unit

#1 or Mix Unit #2.

Job Complete

Press to reset the current usage counter.

Counter Reset

Appears on the User ID

Keyboard screen. Use to move cursor to the left.

Move Cursor to Left

Move Cursor to Right

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.

Erase All

3A4486E

Backspace

Upper Case/Lower

Case

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).

Press to get more information on active system error.

Info

Troubleshooting

QR Code

Press to see troubleshooting information for system error.

Press to see QR Code for system error.

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.

Press the Enter soft key function on any screen.

to activate the editing

Press the Exit soft key to exit any screen.

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

Advanced Display Module (ADM)

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.

User ID

Potlife

Recipe Number

Pressure

Material A

Material A+B

Calendar

Alarm/Advisory

Mix Unit

Job Number

Target Ratio

Flow Rate

Volume

Material B

Solvent

Time

Deviation

3A4486E 15

Pre-Operation Tasks

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

Verify all grounding connections

Installation manual.

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

Check component A and B and solvent supply containers.

Check that dose valves are set

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

Valve Settings, page 17

, then adjust as needed.

The recommended component A and

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

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.

85-100 psi inlet air supply (0.6-0.7

MPa, 6-7 bar).

1.

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

0 = OFF).

2.

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

3.

Press the Start key

Power pop-up screen.

to display the Pump

The softkey options allow for powering a specific

Mix Unit, or both at the same time. The system status will change from “System Off” to “Startup.”

Once the pumps are powered and are in the

Home position, the system status will change from “Startup” to “Standby.”

Figure 8 Power Switch

16 3A4486E

Pre-Operation Tasks

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

1.

Change optional setup selections to desired parameters, as described in

Setup Mode Screens, page 67

.

2.

Set recipe and flush information as described in

Recipe Screen, page 75

, and

Flush Screen, page 78

.

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.

Figure 9 Valve Adjustment

3A4486E 17

Pressure Relief Procedure

whenever you see this symbol.

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.

2.

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 and before cleaning, checking, or servicing the equipment.

air pressure in the system. Use your control interface to issue the necessary commands to your system.

1.

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

2.

Command Mix Unit #1 to Standby. From

Maintenance Screen 4 on the ADM, check the box in the field labeled Gun for the color or catalyst in the pump. Trigger the spray device to relieve pressure. Repeat for each pump.

3.

Flush the remote mix manifold and spray device.

See

Flush Mixed Material, page 20

.

4.

Shut off the solvent supply pump. To relieve pressure, command Mix Unit #1 to Purge and trigger the spray device. When the pressure is relieved, command Mix Unit #1 to Standby to avoid getting a Purge Incomplete alarm.

5.

If pressure remains in the solvent line between the solvent supply pump and the solvent valve:

• VERY SLOWLY loosen a fitting to relieve pressure gradually.

• Loosen the fitting completely.

6.

Repeat for Mix Unit #2

To help prevent fire and explosion, shut off electrostatics before flushing.

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

3.

Trigger the gun to relieve pressure. From

Maintenance Screen 5on the ADM, check the box in the field labeled Gun for each color used with

Mix Unit #1, to manually open each color valve.

4.

Set the system to Recipe 0 to flush the pumps and to purge to the spray device. Hold the gun trigger open after the solvent valve shuts off to relieve all pressure. When flushing is complete

Mix Unit #1 will go to Standby.

5.

Shut off the solvent supply pump. Set Mix Unit

#1 to Recipe 0 to flush solvent from the pumps and to purge to the spray device. Command Mix

Unit #1 to Standby after just a couple of seconds, to avoid getting a Purge Incomplete alarm.

6.

If pressure remains in the solvent line between the solvent supply pump and the solvent valve:

• VERY SLOWLY loosen a fitting to relieve pressure gradually.

• Loosen the fitting completely.

7.

Verify on the ADM Home Screen that neither pump 1 nor 2 is showing any pressure.

8.

Repeat for Mix Unit #2 and pumps 3 and 4.

18 3A4486E

Operation Using Advanced Display Module (ADM)

NOTE:

Run Mode Screens, page 60

, for further screen information, if needed.

or the inputs to the color change valves before priming the pump and filling the entire system.

1.

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

2.

Adjust the main air pressure. To ensure proper operation, set the main air pressure as close to

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

Flush the System, page 20

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

4.

If on the ADM to bring up the Pump Power pop-up screen and, using the softkeys, turn on power to a specific Mix Unit or both. 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 75

, and the

Flush Screen, page 78

.

6.

Enable the manual override on System Screen 1.

7.

Go to the

Fill Screen, page 64 .

8.

Select the desired color to load. Press the Prime

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

skipped..

9.

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

10. Trigger the gun into a grounded reservoir or purge receptacle until the line is full, then press the Stop key .

11. Repeat for all material lines.

3A4486E

have color change valves and only a single material.

If a pump is filled with a material when the system is powered down, this will allow the user to change the pump’s contents, without flushing the pump, the next time power is restored.

1.

Enable the manual override on

System Screen 1, page 67

.

2.

Go to the

Fill Screen, page 64

.

3.

Press the Pre-Fill Pump key . The pump will change from material 61 to the proper color or catalyst.

To spray in a multiple color system, also see

Multiple Color Systems, page 97

.

NOTE:

Run Mode Screens, page 60

, for further screen information, if needed.

1.

Command a Mix Unit to Mix. The system will load the correct mixed material volume.

Fill if the recipe is not currently loaded into the system. The Mix Fill volume calculation includes the remote mix manifold volume and the mixed material hose volume. The mixed material hose volume is determined by the gun hose length and diameter entered in

System Screen 3, page 69

, and the remote-to-mix hose length and diameter also entered in

System Screen 3, page 69 .

2.

Adjust the flow rate by changing the target pressure (in Pressure Mode) or the target flow rate (in Flow Mode) on the Spray Screen or through the PLC. The fluid flow rate shown on the

Spray screen is the combined total of component

A and B out of the spray device.

3.

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

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.

19

Operation Using Advanced Display Module (ADM)

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

Color Change, page 97

.

To avoid fire and explosion, always ground equipment and waste container. To avoid static sparking and injury from splashing, always flush at the lowest possible pressure.

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

• end of potlife

• breaks in spraying that exceed the potlife

• overnight shutdown or end of shift

• before servicing the remote mix manifold, hose or gun.

1.

Command the Mix Unit to Standby.

2.

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

3.

To reduce the risk fire and explosion, shut off electrostatics before flushing the gun.

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

4.

Command the Mix Unit to Purge A,

Purge B, or Recipe Purge. (See

Purge Mode Sequence, page 41

.) Trigger the spray device into a grounded metal pail until the purge sequence is complete. When done purging, the Mix Unit automatically switches to

Standby mode, signalling the spray device to stop spraying.

5.

If the Mix Unit is not completely clean, repeat

Step 5.

sequence times so only one cycle is required.

of solvent after purging.

To avoid fire and explosion, always ground equipment and waste container. To avoid static sparking and injury from splashing, always flush at the lowest possible pressure.

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

1.

Relieve the pressure.

See

Pressure Relief Procedure, page 18 .

2.

Disconnect the color and catalyst supply lines from the pump inlet manifolds, and connect regulated solvent supply lines.

3.

Set the solvent supply pressure regulator at the lowest pressure possible. Generally a setting of 25–50 psi (0.18–0.35 MPa, 1.8–3.5 bar) is sufficient.

4.

Enable manual override on

System Screen 1, page 67

.

5.

On the ADM, go to the Fill screen for Mix Unit

#1. Set the Material to Color (A). Press .

The system will pump solvent through pump A all the way to the gun.

6.

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

7.

On the ADM, go to the Fill screen for Mix Unit

#1. 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 18

9.

Repeat for Mix Unit #2.

20 3A4486E

1.

Relieve the pressure.

See

Pressure Relief Procedure, page 18 .

2.

Attach regulated solvent supply lines as follows: 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.

Connect regulated solvent supply lines to the designated solvent valves on the color and catalyst valve manifolds. Do not connect solvent supply lines directly to the inlet manifolds of the pumps.

3.

Set the solvent supply pressure regulator at the lowest pressure possible. Generally a setting of 25–50 psi (0.18–0.35 MPa, 1.8–3.5 bar) is sufficient.

4.

On the ADM, go to the Fill screen for Mix Unit

#1. Select Color (A). Enter the color number in the box to the right.

5.

Select the Flush Line box.

6.

If the solvent is not already loaded, press the

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

7.

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

Operation Using Advanced Display Module (ADM)

8.

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

9.

Repeat for each color line.

10. Relieve the pressure.

See

Pressure Relief Procedure, page 18

11. Repeat for Mix Unit #2.

1.

2.

4.

5.

6.

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

Follow the

3.

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

Press

Pressure Relief Procedure, page 18

on the Display Module to turn off power to the pumps to display the following pop-up screen. Make sure that the system is in

Standby mode.

Purging, page 20

Select either Mix Unit, or both, to power off.

Shut off system power (0 position).

.

.

3A4486E 21

Operation Using a Programmable Logic Controller (PLC)

The ProMix PD2K Automatic system does not use a Booth Control module. Instead, it uses Network

Communications and has optional Discrete I/O features to drive the system remotely.

Some automation control elements of the

ProMix PD2K can be driven by a discrete input

or

network communications. These options need to be configured at the ADM (see

Gateway Screen, page 74

). The following features can be set to ‘Discrete’ or ‘Network’: when the spray device is triggered.

Screen 1 enables a user to operate the system before the automation (PLC) is available. Manual

Override can be used to run all functions of the system if a proper gun trigger signal is provided. It is not intended to be the main mode of control. Graco recommends that Manual Override be disabled during normal operation to avoid driving the system in a way that conflicts with the automation sequence.

The ProMix PD2K does not supply power for

Discrete I/O. A clear understanding of these inputs is necessary to properly integrate the ProMix PD2K with the PLC or networking device. Input and output connections are made at the Discrete I/O terminal strips on the Enhanced Fluid Control Module (EFCM) inside the control box.

Table 3 and Figure 12 show where discrete I/O connections are made on the ProMix PD2K.

I/O

Description

Gun Trigger

#1 Input

Gun Trigger

#2 Input

Control Set

Point #1

Control Set

Point #2

Safety

Interlock

Input

EFCM

Connector

6

6

7

7

5

Pins

1,2

3.4

1,2

3.4

Type

Normally Open

Contact

Normally Open

Contact

4-20 mA Input

4-20 mA Input

10,11 Normally Open

Contact

22 3A4486E

Operation Using a Programmable Logic Controller (PLC)

like a soft emergency stop button. If the ProMix

PD2K reads the input as CLOSED it interrupts system operation and removes power from the pumps regardless of the current operating mode.

If the input is read as OPEN, the system operates normally

Do not toggle this input to put the system into

Standby mode.

(maintained) contacts provide a signal to the Mix

Units to indicate whether or not a spray device is triggered. These inputs provide timing for alarm functions and also drives the flow control algorithm.

If an input is OPEN the Mix Unit operates as though the spray device is off. The input must be maintained CLOSED to signal that the spray device is triggered.

enabled individually via

System Screen 4, page 70

, on the ADM. If it is set to ‘Network’ the discrete input is ignored and the spray device trigger signal is handled via the network communications.

If enabled, it is imperative that this signal be sent any time the spray device is triggered. Without the signal, the flow control features will not work.

Figure 10 these 4-20 mA signal inputs are used to set and adjust the operating flow control set point for each

Mix Unit. The ProMix PD2K scales the set point linearly from 0 to the Max Set Point setting (see

System Screen 4, page 70 ).

Examples

, cc/min, a 4mA signal is 0 cc/min and a 20mA signal is 500 cc/min.

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

enabled individually via

System Screen 4, page 70

, on the ADM. If set to ‘Network’ the discrete input is ignored and set point adjustment is handled via the network communications.

PLC (4–20 mA Signal) Mix Unit #2

PLC (4–20 mA Signal) Mix Unit #1

PD2K Discrete Input O = Output

R = Return

3A4486E 23

Operation Using a Programmable Logic Controller (PLC)

Figure 11

A1

A2

B1

B2

C1

Gun Trigger Input #1

Gun Trigger Input #2

Analog Set Point Input #1

Analog Set Point Input #2

Safety Interlock Input

24 3A4486E

Operation Using a Programmable Logic Controller (PLC)

The CGM provides a control link between the PD2K system and a selected fieldbus. This linkage provides the means for remote monitoring and control by external automation systems.

The PD2K system does not come with a CGM; it must be purchased separately. The available CGM field bus protocols are listed in the tables.

DeviceNet, EtherNet/IP, and Modbus TCP protocols.

PROFINET protocol calls for two CGM modules with the PD2K Dual Panel application. The PROFINET kit consolidates all installation hardware as well as the two CGM modules into a single part number.

26A303

25D997

DeviceNet

EtherNet/IP

Modbus TCP

PROFINET

334494

334494

312864

Part No.

Fieldbus

CGMDN0

CGMEP0

24W462

DeviceNet

EtherNet/IP

Modbus TCP

312864

312864

334183

3A4486E 25

Operation Using a Programmable Logic Controller (PLC)

The PD2K has PLC Diagnostic Screens built into the software that assist in the system integration process. See

Setup Mode Screens, page 67 .

shown with indices for Mix Unit #1 and Mix Unit #2, respectively.

The ProMix PD2K Network Outputs are Read-Only and should be treated as inputs to a PLC or other networking device. These registers provide various system and component status, measurement, and set point values. See

Network Output Data Map (Read Only), page 30 .

16

17

18

26

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

6

7

8

9

10

11

12

13

14

15

1

2

3

4

5

Pump Off

Recipe Change

Recipe Change: Purge A

Recipe Change: Purge B

Recipe Change: Fill

Mix Fill

Mix

Mix Idle

Purge A

Purge B

Standby: Mix Ready

Standby: Fill Ready

Standby: Mix Not Ready

Standby: Alarm

Line Filling/Flushing

Pump Prime/Flush

Maintenance/Calibration

Mix: Solvent Push

The pumps are currently powered down and the Mix Unit is not in operation.

The Mix Unit is in the process of a color change sequence.

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

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

The Mix Unit is filling the hose from the remote valves to the mix manifold with material as part of a recipe change.

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

The Mix Unit is currently mixing/spraying material.

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

The Mix Unit is purging material A while in Standby.

The Mix Unit is purging material B while in Standby.

The Mix Unit has a valid recipe loaded out to the gun.

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

The Mix Unit requires that a recipe change operation be completed.

The Mix Unit has an active alarm.

The Mix Unit is filling/flushing a color change hose between the outlet valves and remote valves.

The Mix Unit is priming/flushing one of the pumps.

The Mix Unit is currently performing a calibration or maintenance procedure.

The Mix Unit is currently mixing/spraying with solvent push engaged.

3A4486E

The Event Flag register provides indication when an event (Alarm or Deviation) has occurred that requires user acknowledgement.

• The value will be 0 if there are no events requiring acknowledgement.

• The value will be 1 if there is at least one event needing acknowledgement.

Operation Using a Programmable Logic Controller (PLC)

This data register is valid only for systems configured to use the discrete inputs for the Gun Triggers.

See

Gun Trigger Signal, page 70

.

The Pump Status registers contain a number that indicates the state of Pumps 1 – 4. This status can be used for general monitoring of the pump state, or as an indicator for driving independent pump operations.

See

INPUT REGISTER 06 and 16: Flush/Prime

Pump Command, page 36

.

The Actual Mix Flow/Pressure register reports back the instantaneous mixing flow rate in cc/min or mixing pressure in PSI. This register is primarily used to reflect that the Mix Unit is on it’s target fluid control

set point. See INPUT REGISTER 03 and 13: Mix

Control Set Point, page 35

.

operation.

The Actual Mix Ratio register contains the instantaneous calculated mix ratio.

• The value reported is the ratio antecedent multiplied by 100. The ratio consequent is always 1.

Example

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

(Material A to Material B)

• If the current recipe ratio is 0:1 (1K recipe) this value will be 0.

This register is valid only during a mix operation.

0

1

2

3

4

Off

Standby

Busy

Flushing

Priming

The pump is powered down or not enabled.

The pump is powered but not currently active.

The pump is currently in a recipe change or mixing operation.

The pump is currently flushing with solvent

The pump is currently priming with material.

The Actual Potlife Remaining register contains the current amount of time remaining in the active recipe’s potlife in seconds.

initial startup this value will be 0xFFFFFFFF.

The Pump Material register values indicate what material is currently loaded in each pump.

• Colors are numbered 1 – 32.

• Catalysts are numbered 33 – 40.

• The value is 0 if the pump is filled with solvent.

• The value is 61 if the material is unknown, such as initial startup.

The Gun Trigger Input Status registers contain the status of the Gun Trigger Discrete Inputs.

• The value is 0 if the input is OPEN (gun not triggered).

• The value is 1 if the input is CLOSED (gun triggered).

3A4486E 27

Operation Using a Programmable Logic Controller (PLC)

These registers contain the instantaneous flow rate of Pumps 1–4 in cc/min.

Mix Flow

.

These registers contain the instantaneous fluid pressure on the outlet of pumps 1–4 in PSI.

The Active Recipe Number register contains the number of the active recipe (1 – 30).

• This value is 0 if the Mix Unit was flushed.

• This value is 61 if the Mix Unit does not know the current loaded recipe, if the recipe is invalid, or at initial startup.

The Active Recipe Material A register contains the number of the Color (1 – 32) that is associated with the current recipe.

• This value is 0 if the Mix Unit was flushed.

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

The Active Recipe Material B data register contains the number of the Catalyst (33 – 40) that is associated with the current recipe.

• This value is 0 if the Mix Unit was flushed.

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

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

The Active Recipe Material A Flush Sequence register contains the number of the Flush Sequence

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

If the current recipe is invalid this value reflects the

Flush Sequence associated with Material A pump of recipe 0.

The Active Recipe Material B Flush Sequence register contains the number of the Flush Sequence

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

• If the current recipe is invalid this value reflects the

Flush Sequence associated with Material B pump of recipe 0.

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

The Active Recipe Ratio Set Point data register contains the ratio set point associated with the current recipe.

• The value reported is the ratio antecedent multiplied by 100. The ratio consequent is always 1.

Example

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

(Material A to Material B)

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

28 3A4486E

Operation Using a Programmable Logic Controller (PLC)

The Active Recipe Potlife Timeout Set Point register contains the set point for the potlife time associated with the current recipe in minutes.

• This value is 0 if the potlife time is disabled for the current recipe.

The Job Solvent Volume register provides a real time volume of solvent dispensed during the current job in cc.

The Job Number register contains the number of the job currently running on the Mix Unit.

The Safety Interlock Input Status register contains the status of the Safety Interlock Discrete Input.

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

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

Stop).

See Safety Interlock in

Digital Inputs, page 23

.

The Job A Sprayed Volume register provides a real time volume of color sprayed during the current job in cc.

See

Dynamic Command Description, page 49

.

The Job B Sprayed Volume register provides a real time volume of color sprayed during the current job in cc.

3A4486E 29

Operation Using a Programmable Logic Controller (PLC)

0000

0001

0002

0003

0004

0005

0006

0007

0008

0009

30

41000 Current System Mode uint32

41002

41004

41006

41008

41010

41012

Event Flag

Pump 1 Status uint32

Actual Mix

Flow/Pressure

Actual Mix Ratio

Actual Mix Potlife

Remaining

Gun 1 Trigger Status uint32 uint32 uint32 uint32 uint32

41014 Pump 2 Status

41016

41018

Pump 1 Material

Pump 2 Material uint32 uint32 uint32

NONE 1 = Pump Off

2 = Color Change

3 = Color Change: Purge A

4 = Color Change: Purge B

5 = Color Change: Fill

6 = Mix Fill

7 = Mix

8 = Mix Idle

9 = Purge A

10 = Purge B

11 = Standby: Mix Ready

12 = Standby: Fill Ready

13 = Standby: Mix Not Ready

14 = Standby: Alarm

15 = Line Filling/Flushing

16 = Pump Prime/Flush

17 = Maintenance/Calibration

NONE

18 = Mix: Solvent Push

0 = No Events

1 = New Event cc/min

PSI

1 – 1600

NONE 0 – 5000 sec

0 – 59940

NONE

NONE

NONE

0 = Gun not triggered

1 = Gun triggered

0 = Off

1 = Standby

2 = Busy

3 = Flushing

4 = Priming

0 = Off

1 = Standby

2 = Busy

3 = Flushing

4 = Priming

NONE 0 – 40, 61

NONE 0 – 40, 61

3A4486E

Operation Using a Programmable Logic Controller (PLC)

0010

0011

0012

0013

0014

0015

0016

0017

0018

0019

0020

0021

0022

0023

0024

0025

0026

3A4486E

41020

41022

41024

41026

41028

41030

41032

41034

41036

41038

41040

41042

41044

41046

41048

41050

42000

Actual Pump 1 Flow

Rate

Actual Pump 2 Flow

Rate

Actual Pump 1 Fluid

Pressure

Actual Pump 2 Fluid

Pressure uint32 uint32 uint32 uint32

Active Recipe Number uint32

Active Recipe Material

A uint32 uint32 Active Recipe Material

B

Active Recipe Material

A Flush Sequence uint32

Active Recipe Material

B Flush Sequence

Active Recipe Ratio

Set Point uint32 uint32

Active Recipe Potlife

Time Set Point

Job Number uint32 uint32

Job A Sprayed Volume unit32

Job B Sprayed Volume unit32

Job Solvent Volume unit32

Safety Interlock Input

Status unit32

Current System Mode uint32 cc/min 0 – 800 cc/min 0 – 800

PSI 0 – 1500

PSI 0 – 1500

NONE 0 – 30, 61

NONE 1 – 32, 61

NONE 33 – 40, 61

NONE 1 – 5

NONE 1 – 5

NONE 0 – 5000 min 0 – 999

NONE 0 – 9999 cc

0 – 999999999 cc

0 – 999999999 cc

0 – 999999999

NONE 0 = Open

1 = Closed

NONE 1 = Pump Off

2 = Color Change

3 = Color Change: Purge A

4 = Color Change: Purge B

5 = Color Change: Fill

6 = Mix Fill

7 = Mix

8 = Mix Idle

9 = Purge A

10 = Purge B

11 = Standby: Mix Ready

12 = Standby: Fill Ready

13 = Standby: Mix Not Ready

14 = Standby: Alarm

15 = Line Filling/Flushing

16 = Pump Prime/Flush

17 = Maintenance/Calibration

31

Operation Using a Programmable Logic Controller (PLC)

0027

0028

0029

0030

0031

0032

0033

0034

0035

0036

0037

0038

0039

0040

0041

0042

0043

0044

0045

0046

0047

0048

0049

32

42002

42004

42006

42008

42010

42012

Event Flag uint32

Actual Mix

Flow/Pressure

Actual Mix Ratio

Actual Mix Potlife

Remaining

Gun 2 Trigger Status uint32 uint32 uint32 uint32

Pump 3 Status uint32

42014 Pump 4 Status

42016

42018

42020

42022

42024

42026

42028

42030

42032

42034

42036

42038

42040

42042

42044

42046

Pump 3 Material

Pump 4 Material

Actual Pump 3 Flow

Rate

Actual Pump 4 Flow

Rate

Actual Pump 3Fluid

Pressure

Actual Pump 4 Fluid

Pressure uint32 uint32 uint32 uint32 uint32 uint32

Active Recipe Number uint32

Active Recipe Material

A

Active Recipe Material

B uint32 uint32

Active Recipe Material

A Flush Sequence

Active Recipe Material

B Flush Sequence uint32 uint32

Active Recipe Ratio

Set Point

Active Recipe Potlife

Time Set Point uint32 uint32

Job Number uint32

Job A Sprayed Volumn unit32

Job B Sprayed Volume unit32 uint32

NONE 0 = No Events

1 = New Event cc/min or PSI

1 – 1600

NONE 0 – 5000 sec

0 – 59940

NONE

NONE

0 = Gun not triggered

1 = Gun triggered

0 = Off

1 = Standby

2 = Busy

3 = Flushing

4 = Priming

NONE 0 = Off

1 = Standby

2 = Busy

3 = Flushing

4 = Priming

NONE 0 – 40, 61

NONE 0 – 40, 61 cc/min 0 – 800 cc/min 0 – 800

PSI 0 – 1500

PSI 0 – 1500

NONE 0 – 30, 61

NONE 1 – 32, 61

NONE 33 – 40, 61

NONE 1 – 5

NONE 1 – 5

NONE 0 – 5000 min 0 – 999

NONE 0 – 9999 cc 0 – 999999999 cc

0 – 999999999

3A4486E

Operation Using a Programmable Logic Controller (PLC)

0050

0051

0052

0053

0054

0055

0056

0057

0058

0059

0060

0061

42048

42050

43000

43002

43004

43006

43008

43010

43012

43014

43016

43018

Job Solvent Volume

Safety Interlock Input

Status

Command Return 1

Command Return 2

Command Return 3

Command Return 4

Command Return 5

Command Return 6

Command Return 7

Command Return 8

Command Return 9

Command

Acknowledgment unit32 unit32 unit32 unit32 unit32 unit32 unit32 unit32 unit32 unit32 unit32 unit32 cc

NONE

0 – 999999999

0 = Open

1 = Closed

NONE N/A

NONE N/A

NONE N/A

NONE N/A

NONE N/A

NONE N/A

NONE N/A

NONE N/A

NONE N/A

NONE 0 = NOP

1 = BUSY

2 = ACK

3 = NAK

4 = ERR

DCS Registers

3A4486E 33

Operation Using a Programmable Logic Controller (PLC)

The ProMix PD2K Network Inputs are Write-Read capable, but should be treated as outputs from a PLC or other networking device. These registers allow the user to control system operation and configure system settings remotely.

Invalid values (i.e. out of bounds or not consistent with system configuration) will be ignored by the ProMix PD2K. All values must be written as integers. Floating point numbers are not supported.

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

to invalid values.

The System Mode Command register accepts a number that represents a command to the PD2K system to initiate a particular operation. Some operation modes may be initiated only under certain conditions (see Figures

5 – 9 for details).

4

7

8

9

5

6

Input Value Operation Mode

0

1

2

No OP

Power Pumps

Remote Stop

3 Recipe Change

10

Mix Fill

Mix

Purge A

Purge B

Standby

Recipe Purge

Solvent Push

The Mix Unit takes no action.

The Mix Unit powers on or powers off the pumps.

The Mix Unit stops all current operations and turns off power to the pumps.

The Mix Unit initiates a recipe change. (See also Input Register 02 and 12..)

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

The Mix Unit initiates a mix/spray cycle.

The Mix Unit purges only Material A out through the gun.

The Mix Unit purges only Material B out through the gun.

The Mix Unit puts both active pumps into Standby mode.

The Mix Unit automatically determines the purge sequence required based on the loaded recipe.

The Mix Unit initiates the solvent push sequence while mixing/spraying.

The Clear Active Alarm/Deviation register is used to remotely acknowledge a system error. The Event

Flag register indicates whether a system error requiring acknowledgement exists (see

OUTPUT

REGISTER 01 and 27: Event Flag, page 27 ). In

the case of an alarm condition, the alarm must be acknowledged and resolved before the Mix Unit is allowed to resume operation. Write a ‘1’ to this register to acknowledge the latest active system error. If more than one system error is currently active, only the most recent will be acknowledged.

A repeated write should be performed to clear any remaining active system errors.

(See

System Errors, page 98

for more information on alarms and deviations.)

PD2K. A system error is cleared only when a value of ‘1’ is written to this register. It is recommended that the automation reset this register by writing a ‘0’ to it at all other times to avoid inadvertently clearing an alarm.*

*** It is recommended to wait at least 500 msec for the

PD2K to process before resetting to ‘0’.

34 3A4486E

Operation Using a Programmable Logic Controller (PLC)

The Go to Recipe Number register is used as a queue for the next recipe to be loaded when a recipe change is initiated. A number between 0 and 30 can be written to this register. However, a recipe must be enabled via the ADM before it can be loaded. See

Recipe Screen, page 75

.

change.

See

Color Change Sequence, page 45

.

The Mix Fill Set Point register is used to set an alternate control set point during the mix fill process

(see Mix Fill Set Point on

System Screen 2, page 68

).

• If the Mix Unit is configured for Flow Control this value can be set between 5 and 1600 cc/min for a

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

See Fluid Control on

System Screen 4, page 70

.

• If the Mix Unit is configured for Pressure Control this value can be set between 1 and the maximum pump pressure in PSI. See Fluid Control on

System Screen 4, page 70

.

to ‘Network’ via System Screen 4 on the ADM.

If set to ‘Discrete’ this register is ignored and set point is handled via the discrete input. See

Analog Inputs, page 23 .

The Mix Control Set Point register is used to set and adjust the mixing fluid control set point. It can be changed at any time, and the system will immediately adjust to the new set point.

• If the Mix Unit is configured for Flow Control this value can be set between 5 and 1600 cc/min for a

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

See Fluid Control on

System Screen 4, page 70

.

• If the Mix Unit is configured for Pressure Control this value can be set between 0 and the maximum pump pressure in PSI. See Fluid Control on

System Screen 4, page 70

.

‘Network’ via System Screen 4 on the ADM. If set to ‘Discrete’ this register is ignored and set point adjustment is handled via the discrete input. See

Analog Inputs, page 23 .

The Pump Flush Sequence/Prime Material Selection register is used in conjunction with the Flush/Prime

Pump Command register (see

INPUT REGISTER 06

and 16: Flush/Prime Pump Command, page 36

) to independently prime or flush an inactive pump.

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

• Write a value between 1 and 32 if priming a Color pump.

• Write a value between 33 and 40 if priming a

Catalyst pump.

material is assigned to each pump. An invalid selection will be ignored by the ProMix PD2K.

3A4486E 35

Operation Using a Programmable Logic Controller (PLC)

The Flush/Prime Pump Command register is used in conjunction with the Pump Flush Sequence/Prime

Material Selection register (see INPUT REGISTER

05 and 15) to independently prime or flush an inactive pump. The desired pump MUST be in Standby mode. Confirm by reading the corresponding Pump

Status output register (see OUTPUT REGISTERS

06, 07, 32, and 33).

If an invalid Flush Sequence or invalid material number is written to the Pump Flush Sequence/Prime

3

4

5

0

1

2

8

9

6

7

10

Input Value Operation Mode

No OP

Flush Pump 1

Prime Pump 1

Flush Pump 2

Prime Pump 2

Flush Pump 3

Prime Pump 3

Flush Pump 4

Prime Pump 4

Fill Line

Flush Line

11 Stop Line Fill/Flush

Material Selection register then the Flush/Prime command will be ignored. The user must know what material is assigned to each pump. (See

Color Change Kits Instruction Manual 332455 for color/catalyst pump mapping.)

This register can also be used to fill or flush a specific material hose.

The system takes no action.

Flush Pump 1 using selected sequence.

Prime Pump 1 using selected material.

Flush Pump 2 using selected sequence.

Prime Pump 2 using selected material.

Flush Pump 3 using selected sequence.

Prime Pump 3 using selected material.

Flush Pump 4 using selected sequence.

Prime Pump 4 using selected material.

Run selected material from the pump and out the gun.

Run solvent through hoses for selected material from the pump and out the gun.

Stop Line Fill/Flush command.

The Job Complete register is used to log the current job remotely. Write a ‘1’ to the register to command the ProMix PD2K to flag a job complete.

(See

Usage Screen, page 65

for more information on

Job Logs and Job Complete.)

PD2K. A job is logged only when a value of ‘1’ is written to this register. It is recommended the automation reset this register by writing a ‘0’ to it at all other times to avoid inadvertently logging a job.*

*** It is recommended to wait at least 500 msec for the

PD2K to process before resetting to ‘0’.

36 3A4486E

Operation Using a Programmable Logic Controller (PLC)

The Gun Trigger register is used to signal the ProMix

PD2K when the automatic spray device is triggered.

This signal should be sent any time the spray device is triggered. The state of this register provides timing for alarm functions and also drives the flow control algorithm.

sent any time the spray device is triggered. Without it the flow control features will not work.

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

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

is set to ‘Network’ via System Screen 4 on the ADM.

If it is set to ‘Discrete’ this register is ignored and gun trigger is handled via the discrete input. See

Digital Inputs, page 23 .

Graco recommends that users provide a discrete input to minimize latency effects.

Input Register 08 1 0 1 0

Gun Trigge r

Discrete Signal

ProMix PD2K:

Mix Unit #1

Gun Trigge r S ta te

Figure 12 Gun 1 Trigger Timing (Network and

Discrete Signals Shown

The Fluid Control Mode register is used to toggle system control between Flow Control and Pressure Control (see Fluid Control on

System Screen 4, page 70

).

• A value of ‘0’ sets the Mix Unit to Flow Control.

• A value of ‘1’ sets the Mix Unit to Pressure Control.

but typical applications will not change it.

See

Dynamic Command Description, page 49

.

3A4486E 37

Operation Using a Programmable Logic Controller (PLC)

0000 41100

0001

0002

0003

0004

0005

0006

0007

0008

0009

41102

41104

41106

41108

41110

41112

41114

41116

41118

System Mode Command

Clear Active Alarm/Deviation

Goto Recipe Number

Mix Control Set Point

Mix Fill Set Point

Pump Flush Sequence #/Prime

Material #

Flush/Prime Pump Command uint32 uint32 uint32 unit32 unit32 unit32

Job Complete

Gun 1 Trigger

Fluid Control Mode uint32 unit32 unit32 unit32

NONE

NONE

NONE cc/min

PSI cc/min or

PSI

NONE

0 = No OP

1 = Power Pumps

2 = Remote Stop

3 = Color Change

4 = Mix Fill

5 = Mix

6 = Purge A

7 = Purge B

8 = Standby

9 = Recipe Purge

10 = Solvent Push

1 = Clear Active Alm/Dev

0, 1 – 30

1 - 1600

1 – 1600

1 –5, 1 – 40

NONE

NONE

NONE

NONE

0 = No OP

1 = Flush Pump 1

2 = Prime Pump 1

3 = Flush Pump 2

4 = Prime Pump 2

5 = Flush Pump 3

6 = Prime Pump 3

7 = Flush Pump 4

8 = Prime Pump 4

9 = Fill Line

10 = Flush Line

11 = Stop Line Fill/Flush

1 = Trigger job complete

0 = Gun not triggered

1 = Gun triggered

0 = Flow Control

1 = Pressure Control

38 3A4486E

Operation Using a Programmable Logic Controller (PLC)

0010 42100

0011

0012

0013

0014

0015

0016

0017

0018

0019

42102

42104

42106

42108

42110

42112

42114

42116

42118

0020

0021

0022

0023

0024

0025

3A4486E

43100

43102

43104

43106

43108

43110

System Mode Command

Clear Active Alarm/Deviation

Goto Recipe Number

Mix Control Set Point

Mix Fill Set Point

Pump Flush Sequence #/Prime

Material #

Flush/Prime Pump Command uint32 uint32 uint32 unit32 unit32 unit32

Job Complete

Gun 2 Trigger

Fluid Control Mode

Command Argument 1

Command Argument 2

Command Argument 3

Command Argument 4

Command Argument 5

Command Argument 6 uint32 unit32 unit32 unit32 unit32 unit32 unit32 unit32 unit32 unit32

NONE

NONE

NONE cc/min or

PSI cc/min or

PSI

NONE

0 = No OP

1 = Power Pumps

2 = Remote Stop

3 = Color Change

4 = Mix Fill

5 = Mix

6 = Purge A

7 = Purge B

8 = Standby

9 = Recipe Purge

1 = Clear Active Alm/Dev

0, 1 – 30

1 - 1600

1 – 1600

1 –5, 1 – 40

NONE

NONE

NONE

NONE

NONE

NONE

NONE

NONE

NONE

NONE

0 = No OP

1 = Flush Pump 1

2 = Prime Pump 1

3 = Flush Pump 2

4 = Prime Pump 2

5 = Flush Pump 3

6 = Prime Pump 3

7 = Flush Pump 4

8 = Prime Pump 4

9 = Fill Line

10 = Flush Line

11 = Stop Line Fill/Flush

1 = Trigger job complete

0 = Gun not triggered

1 = Gun triggered

0 = Flow Control

1 = Pressure Control

N/A

N/A

N/A

N/A

N/A

N/A

39

Operation Using a Programmable Logic Controller (PLC)

0026

0027

0028

0029

43112

43114

43116

43118

Command Argument 7

Command Argument 8

Command Argument 9

Command ID

DCS Registers unit32 unit32 unit32 unit32

NONE

NONE

NONE

NONE

N/A

N/A

N/A

See Command Table

40 3A4486E

Operation Using a Programmable Logic Controller (PLC)

#1. For Mix Unit #2, reference the Network Maps for corresponding register indices.

Purge A System Command

Write ‘6’ to Input Re gis te r 00

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

No action taken.

Either pumps are currently running or an alarm condition exists.

Is Mix Unit #1 in Standby or

Pumps Of f?

YES

System Mode = Purge A

(Output Register 00 = ‘9’)

System opens color solvent valve at remote stack to allow solvent flow through mix manifold and out gun.

Purge time set according to the flush sequence assigned to material A in re cipe .

NO

Is solvent flow switch 1 ON?

YES

NO Purge time expired?

YES

System Mode = Standby: Mix Not Ready

(Output Register 00 = ‘13’)

System closes color solvent valve at remote stack.

NO

NO

Purge no flow timeout expired?

YES

No solvent flow detected.

Generate alarm.

3A4486E 41

Operation Using a Programmable Logic Controller (PLC)

Purge Recipe System Command

Write ‘9’ to Input Re gis te r 00

NO

Is Mix Unit #1 in Standby or Pumps Of f?

NO

YES

No action taken.

Either pumps are currently running or an alarm condition exists.

System Mode = Purge B

(Output Register 00 = ‘10’)

System opens catalyst solvent valve at remote stack to allow solvent flow through mix manifold and out gun.

Purge time set according to the flush sequence assigned to material B in recipe.

NOTE: System will automatically skip Purge B if it is not necessary .

(i.e. working with one component recipes)

System Mode = Purge A

(Output Register 00 = ‘9’)

System opens color solvent valve at remote stack to allow solvent flow through mix manifold and out gun.

Purge time set according to the flush sequence assigned to material A in re cipe .

Is solvent flow switch 2

ON?

NO

YES

NO

Purge no flow timeout expired?

YES

Is solvent flow switch 1

ON?

NO

YES

NO

Purge no flow timeout expired?

YES

NO

Purge time expired?

No solvent flow detected.

Generate alarm.

Purge time expired?

No solvent flow detected.

Generate alarm.

YES YES

System Mode = Standby : Mix

Not Ready

(Output Register 00 = ‘13’)

System closes color solvent valve at remote stack.

42 3A4486E

3A4486E

Operation Using a Programmable Logic Controller (PLC)

Write Flush Sequence #

(1-5) to Input Register 05

Write Prime Material #

(1-40) to Input Register 05

Write

Flush Pump Command

(1,3) to Input Register 06

NOTE: Be sure to read to appropriate Output Register* for the desired pump status:

Register 06 - Pump 1

Register 07 - Pump 2

Write

Prime Pump Command

(2,4) to Input Register 06

Is requested pump status* = Standby?

(Output Register* = ‘1’)

YES

NO

Pump is either Off or Busy

(Output Register* = ‘0’ or ‘2’)

Busy refers to a pump that is currently involved in a mixing operation. No action taken.

NO

Is requested pump status* = Standby?

(Output Register* = ‘1’)

YES

Invalid request.

No action taken.

Pump is flushed using assigned sequence number

Pump Status = Flushing

(Output Register* = ‘3’)

.

NO

Is selected material valid for requested pump?

YES

Pump is primed using assigned material.

Pump Status = Priming

(Output Register* = ‘4’)

NO Is Flush complete?

YES

NO Is Prime complete?

YES

Pump is returned to Standby .

Pump Status = Standby

(Output Register* = ‘1’)

43

Operation Using a Programmable Logic Controller (PLC)

Write Material #

(1 - 40) to Input Register 05

Write Material #

(1 - 40) to Input Register 05

Write Line Flush Command

‘10’ to Input Register 06

Is Current System Mode =

Standby ?

(Output Register 00 = 1 1,

12, 13)

YES

Is corresponding pump primed with solvent?

YES

Pump begins to run solvent out the pump, through selected hose, and out the gun.

Current System Status = Line

Filling/Flushing

(Output Register 00 = ‘15’)

Write Line Fill Command

‘9’ to Input Register 06

NOTE: System must be in

Standby to flush or fill a hos e line since it will run ma te ria l from the pump all th e wa y out the gun.

NO NO

Is Current System Mode =

Standby ?

(Output Register 00 = 1 1,

12, 13)

YES

NO

NOTE: The pump mu s t be primed with the app ropria te material before comma nding to fill or flush a hos e line .

No action taken.

NO

Is corresponding pump primed with selected material?

YES

Pump begins to run material out the pump, through selected hose, and out the gun.

Current System Status = Line

Filling/Flushing

(Output Register 00 = ‘15’)

NO

Write Stop Line Fill/Flush ?

(Write ‘11’ to Input Re gis te r 06)

YES

Current System Mode is set to

Standby: Mix Not Ready .

(Output Register 00 = ‘13’)

44 3A4486E

Operation Using a Programmable Logic Controller (PLC)

NOTE: If using Cus tom Ma pping for color cha nge va lve s , a nd the Inle t s ta ck is s e t to

S ingle , the Ma te ria l Re a dy fla g ne e ds to be s e t prior to s ta rting a re cipe cha nge . If the

Ma te ria l Re a dy fla g is not s e t, the pump(s ) will not fill with the de s igna te d ma te ria l a nd the re cipe cha nge will not comple te . S e e

“Write Ma te ria l Re a dy Fla g DCS

Comma nd a nd Cus tom Va lve Ma pping” for more de ta ils .

Write Go to Re c ip e Nu m b e r

(0,1 - 30) t o Input Registe r 02

Recipe Chan g e System

Command

Write ‘3’ to Input Re gis te r 00

Syst em Mode = Re c ip e

Change

(Out put Re gis te r 00 = ‘2’)

YES

Is system in Standb y with no a la rm conditions ?

NO

No action taken.

Either pu mps a re curre ntly running or an alarm condition exists.

NO

Is Material B chang ing?

YES

Purge Material B out gun.

Syst em Mode = Re c ip e

Change: Purge B

(Out put Re gis te r 00 = ‘4’)

Pump will flus h the n prime .

Is Material A chang ing?

NO

YES

Purge Material A out gun.

Syst em Mode = Re c ip e

Change: Purge A

(Out put Re gis te r 00 = ‘3’)

Pump will flus h the n prime .

NO

Is purge com plete and are p umps primed?

YES

Fill mat erial out to mix manifold.

Syst em Mode = Recipe

Change: Fi ll

(Out put Re gis te r 00 = ‘5’)

Mix material out t o gun.

System Mode = Mix Fill

(Outpu t Register 00 = ‘6’)

NO

Is material fille d out to mix ma nifold?

YES

NO Is mix fill complete?

YES

System Mode = Stand by:

Mix Ready

(Output Register 00 = ‘11’)

3A4486E 45

Operation Using a Programmable Logic Controller (PLC)

Read Status of

Output Register 00

Output Register 00 =

‘14’?

Standby: Alarm

YES

Output Register 00 =

‘13’?

Standby: Mix Not

Ready

YES

Output Register 00 =

‘11’?

Standby: Mix Ready

YES

Output Register 00 =

‘1’?

Pump Off

YES

Clear Alarm

(See Alarm Clearing

Sequence)

Recipe Change

System Command

Write ‘3’ to Input

Register 00

NOTE: Mix Unit #1 will automatically run t hrough necessary recipe ch a nge steps based on it’ s curre nt state. If Goto Reci p e

Number has not ch a nge d, it does not have to be rewritten here.

Mix

System Command

Write ‘7’ to Input

Register 00

NOTE: System will automatically perfo rm Mix

Fill if it needs to be comple te d before transitioning dire ctly into Mix mode.

Power Pumps

System Command

Write ‘1’ to Input

Register 00

46 3A4486E

Operation Using a Programmable Logic Controller (PLC)

Mix Fill or Mix System

Command W rite ‘4’ or ‘5’ to Input Register 00

System Mode =

Standby: Mix Ready ?

(Output Register 00 = ‘1 1’)

NO

YES

No action taken.

Mix Unit #1 is not in valid state for mixing. Confirm pumps are on, a recipe is loaded, and there are no existing alarm conditions.

NO

System Mode =

Standby: Fill Ready ?

(Output Register 00 = ‘12’)

YES

NO

System Mode = Mix

(Output Register 00 = ‘7’)

NO

A re cipe is loa de d in the pumps but not yet filled out to the gun. Mixed material is pumped out to the gun.

System Mode = Mix Fill

(Output Register 00 = ‘6’)

YES

Gun Trigge r = ON?

Mix Fill Complete?

NO

No gun trigger signal for longer than Mix Idle timeout.

System Mode = Mix Idle

(Output Register 00 = ‘8’)

Mix Idle Time out expired?

YES

YES

Gun is filled, Mix Unit #1 is put into Standby .

System Mode =

Standby: Mix Ready

(Output Register 00 = ‘1 1’)

3A4486E 47

Operation Using a Programmable Logic Controller (PLC)

NOTE: If an alarm condition is active the System Mode will either be Pump Off or Standby: Alarm

(Output Register 00 = ‘1’ or ‘14’), and the Event Flag will be set

(Output Register 01 = ‘1’).

Clear Active Alarm

Write ‘1’ to Input Re gis te r 01

Is there an active alarm or deviation?

NO

YES

Event Flag set

(Output Register 01 = ‘1’)

YES

Is there more than 1 active alarm or deviation?

NO

No action taken.

Clear most recent active alarm or deviation.

Remaining alarm(s) or deviation(s) still active.

NOTE: If more than 1 active alarm or deviation exists a repeated write of ‘1’ to Input

Register 01 is required for each.

Event Flag cleared

(Output Register 01 = ‘0’)

48 3A4486E

00000000000000000000000000000000000000000000000000000000000

0000000000000000000000000000000000000000000000000000000000000000

0000000000000000000000000000000000000000000000000000000000000000

Operation Using a Programmable Logic Controller (PLC)

The Dynamic Command Structure (DCS) is used to 1) access data that requires some form of argument(s) or 2) consolidate data that requires multiple registers. The DCS uses a static set of network communication input and output registers (see

Network Input Data Map (Write/Read), page 38

and

Network Output Data Map (Read Only), page 30 .

Use the following sequence for the DCS.

1.

Write the appropriate command arguments to INPUT REGISTERS 20 – 28. These commands may be written sequentially or sent all at once.

2.

Once all arguments have been passed, write the command ID to INPUT REGISTER 29.

3.

The ProMix PD2K will respond to a valid command by writing a 2 (Acknowledge) to OUTPUT REGISTER 61.

4.

The ProMix PD2K will write appropriate return values to OUTPUT REGISTERS 52 – 60.

ProMix PD2K Inputs

(PLC Outputs)

INPUT REGISTER 20 [arg_0]

00000000000000000000000000000000000000000000000000000000000

Can be written together or sequentially .

INPUT REGISTER 20+ n

0000000000000000000000000000000000000000000000000000000000000000

[arg_ n]

0000000000000000000000000000000000000000000000000000000000000000

INPUT REGISTER 29 [id]

ProMix PD2K Outputs

(PLC Inputs)

OUTPUT REGISTER 61 ACK = 2

OUTPUT REGISTER 52 [rtn_0]

[rtn_n] OUTPUT REGISTER 52+ n

Figure 13 Dynamic Command Structure Timing

3A4486E 49

Operation Using a Programmable Logic Controller (PLC)

6

10

11

12

0

1

2

3

14

15

16

22

No OP

Write User ID

Write Recipe

Write Flush Sequence

Write Material Ready Flag

Read User ID

Read Recipe

Read Flush Sequence

Read Job Info

Read Alarm Info

Read Event Info

Read Grand Totals

The Write User ID command allows users to assign a User ID to a Job Log. See

Usage Screen, page 65 , for more

details on Job Log and User ID. The User ID can be up to ten ASCII characters in length and is packaged as three little endian segments of ASCII characters. The return registers will echo the arguments received.

Example: Write a User ID of “John Doe” to Mix Unit #1 of the ProMix PD2K.

DCS Register Parameter

DCS

Command

Argument 0

Argument 1

Argument 2

Argument 3

Write User ID

Mix Unit

User ID characters [3:0]

(ASCII)

User ID characters [7:4]

(ASCII)

User ID characters [9:8]

(ASCII) uint32 uint32 uint32 uint32 unit32

NONE 1 0 - 16

NONE 1

NONE 0x6E686F4A = [‘n’,

’h’, ’o’, ’J ‘]

NONE 0x656F4420 = [‘e’,

’o’, ’D’, ’ ‘]

NONE 0x0 = [null]

1 – 2

N/A

N/A

N/A

Acknowledge Command Acknowledged

Return 0 Mix Unit

Return 1

Return 2

Return 3

User ID characters [3:0]

(ASCII)

User ID characters [7:4]

(ASCII)

User ID characters [9:8]

(ASCII) uint32 unint32 uint32 uint32 uint32

NONE 2 = ACK

NONE 1

NONE 0x6E686F4A

NONE 0x656F4420

NONE 0x0

0 - 4

1 – 2

N/A

N/A

N/A

50 3A4486E

Operation Using a Programmable Logic Controller (PLC)

The Write Recipe command allows users to configure an entire recipe remotely. See

Recipe Screen, page 75 , for

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

Example: Configure Mix Unit # 1 Recipe 6 for

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

Sequence = 3, Mix Ratio Set Point = 1.50:1, Potlife = 10 minutes, and Mix Pressure Tolerance = 40%.

DCS Register Parameter

DCS

Command

Argument 0

Argument 1

Argument 2

Argument 3

Argument 4

Argument 5

Argument 6

Argument 7

Argument 8

Write Recipe uint32

Mix Unit

Recipe #

Material A

Material B unint32 uint32 uint32 uint32

Material A Flush Sequence uint32

Material B Flush Sequence uint32

Mix Ratio Set Point

Potlife Time Set Point

Mix Pressure Tolerance uint32 uint32 uint32

NONE

NONE

NONE

NONE

NONE

NONE

NONE

NONE min

%

2

1

6

2

33

2

3

150 = 1.50:1

10

40

0 - 16

1 - 2

0 - 30

0 – 32

0, 33 – 40

1 - 5

1 - 5

0 - 5000

0 - 999

10 - 90

Acknowledge Command Acknowledged

Return 0 Mix Unit

Return 1

Return 2

Recipe #

Material A

Return 3

Return 4

Return 5

Return 6

Return 7

Return 8 uint32 uint32 uint32 uint32

Material B uint32

Material A Flush Sequence uint32

Material B Flush Sequence uint32

Mix Ratio Set Point

Potlife Time Set Point

Mix Pressure Tolerance uint32 uint32 uint32

NONE

NONE

NONE

NONE

NONE

NONE

NONE

NONE min

%

33

2

3

150

10

40

6

2

2 = ACK

1

0 - 4

1 - 2

0 - 30

0 - 32

0, 33 – 40

1 – 5

1 – 5

0 - 5000

0 - 999

10 – 90

3A4486E 51

Operation Using a Programmable Logic Controller (PLC)

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

Flush Screen, page 78 , for more details of flush sequence parameters. The return registers will echo the arguments

received.

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

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

DCS Register Parameter

DCS

Command

Argument 0

Argument 1

Argument 2

Argument 3

Argument 4

Argument 5

Write Flush Sequence

Flush Sequence #

Gun Purge Time

Initial Flush Volume

Final Flush Volume

# Wash Cycles

Strokes per Wash Cycle uint32 uint32 uint32 uint32 uint32 uint32 uint32

NONE 3

NONE 4

NONE 10

NONE 125

NONE 250

NONE 1

NONE 2

0 - 21

1 - 5

0 - 999

0 - 9999

0 - 9999

0 - 99

0 - 99

Acknowledge Command Acknowledged

Return 0 Flush Sequence #

Return 1

Return 2

Gun Purge Time

Initial Flush Volume

Return 3

Return 4

Return 5

Final Flush Volume

# Wash Cycles

Strokes per Wash Cycle uint32 uint32 uint32 uint32 uint32 uint32 uint32

NONE 2 = ACK

NONE 4 sec

10 cc

125 cc

250

NONE 1

NONE 2

0 - 4

1 - 5

0 - 999

0 - 9999

0 - 9999

0 - 99

0 - 99

52 3A4486E

Operation Using a Programmable Logic Controller (PLC)

The Write Material Ready Flag command is used to signal to the PD2K that the upstream material management has the appropriate color/catalyst loaded at the inlet valve stack(s) of the pump(s) prior to a recipe change. This flag is only used when multiple materials for a pump are fed to the PD2K via a single valve at the inlet valve stack (i.e. a piggable system). See

Custom Valve Mapping, page 81

for more info on Single inlet valve stacks.

avoid having the wrong material being fed into the pump during a recipe change.

Example: Setting the Material Ready Flag for Mix Unit #1.

DCS Register Parameter

Write Material Ready Flag uint32 DCS

Command

Argument 0

Argument 1

Mix Unit #

Material Ready Status uint32 uint32

NONE 6

NONE 1

NONE 1

0 - 21

1 - 2

0 := Not

Ready/No OP

1 := Material

Ready

Acknowledge Command Acknowledged

Return 0 Mix Unit #

Return 1 Material Ready Status uint32 uint21 uint32

NONE 2 = ACK

NONE 1

NONE 1

0 - 4

1 - 2

0 := Not

Ready/No OP

1 := Material

Ready

The Read User ID command reads back the current User ID. See

Usage Screen, page 65 , for more details on Job

Log and User ID. The User ID can be up to ten ASCII characters in length and is packaged as three little endian segments of ASCII characters. No arguments are required.

Example: Read Mix Unit #1 User ID that is currently “John Doe”.

DCS Register Parameter

DCS

Command

Argument 0

Read User ID

Mix Unit uint32 uint32

NONE 10

NONE 1

0 - 16

1 - 2

Acknowledge Command Acknowledged

Return 0

Return 1

Mix Unit

User ID characters [3:0]

(ASCII)

Return 2

Return 3

User ID characters [7:4]

(ASCII)

User ID characters [9:8]

(ASCII) uint32 uint32 uint32 uint32 uint32

NONE

NONE

NONE

NONE

NONE

2 = ACK

1

0x6E686F4A = [‘n’,

’h’, ’o’, ’J’]

0x656F4420 = [‘e’,

’o’, ’D’, ’ ‘]

0x0 = [null]

0 - 4

1 - 2

N/A

N/A

N/A

3A4486E 53

Operation Using a Programmable Logic Controller (PLC)

The Read Recipe command returns all configured recipe parameters for a desired recipe number. The number of the recipe to be read is the only argument.

Example: Read Mix Unit #1 Recipe 5 data as it is currently configured with Color = 3, Catalyst = 2 (34), Color Flush

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

Tolerance = 30%.

DCS Register Parameter

DCS

Command

Argument 0

Argument 1

Read Recipe

Mix Unit

Recipe # uint32 uint32 uint32

NONE 11

NONE 1

NONE 5

0 - 16

1 - 2

0 - 30

Acknowledge Command Acknowledged

Return 0 Mix Unit

Return 1

Return 2

Recipe #

Material A

Return 3

Return 4

Return 5

Return 6

Return 7

Return 8

Material B uint32 uint32 uint32 uint32

Material A Flush Sequence uint32

Material B Flush Sequence uint32

Mix Ratio Set Point

Potlife Time Set Point

Mix Pressure Tolerance uint32 uint32 uint32 uint32

NONE 2 = ACK

NONE 1

NONE 5

NONE 3

NONE 34

NONE 1

NONE 4

NONE 325 min

%

35

30

0 - 4

1 - 2

0 - 30

0 - 32, 61

0, 33 - 40, 61

1 - 5

1 - 5

0 - 5000

0 - 999

10 - 90

The Read Flush Sequence command returns all configured parameters for a desired flush sequence. The number of the flush sequence to be read is the only argument.

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

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

DCS Register Parameter

Read Flush Sequence DCS

Command

Argument 0 Flush Sequence # uint32 uint32

NONE 12

NONE 1

0 - 21

1 - 5

Acknowledge Command Acknowledged

Return 0 Flush Sequence #

Return 1

Return 2

Return 3

Return 4

Return 5

Gun Purge Time

Initial Flush Volume

Final Flush Volume

# Wash Cycles

Strokes per Wash Cycle uint32 uint32 uint32 uint32 uint32 uint32 uint32

NONE 2 = ACK

NONE 1 sec

20 cc

0 cc 500

NONE 2

NONE 1

0 - 4

1 - 5

0 - 999

0 - 9999

0 - 9999

0 - 99

0 - 99

54 3A4486E

Operation Using a Programmable Logic Controller (PLC)

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

chronological index

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

The date is returned as four-byte packet with each byte holding a two-digit value for (from MSB to LSB) year, month, day, and day of the week (Monday = 01).

The time is returned as a three-byte packet with each byte holding a two-digit value. Starting from the MSB, the first byte can be ignored, then hour, minute, and second.

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

(See

Usage Screen, page 65

, for more details on Job Log)

Example: Read back the most recent job log, job 25, which ran recipe 2 for a total of 1234 cc’s of material under User

ID “John Doe”. The job was logged on Thursday May 29, 2014 at 11:22:14 AM with Mix Unit #1.

DCS Register Parameter Data Units

DCS

Command

Argument 0

Read Job Info

Job Index uint32 uint32

NONE

NONE

14

0

0 - 16

0 – 199

Acknowledge Command

Acknowledged

Return 0 Job Date

Return 1 Job Time

Return 2

Return 3

Return 4

Return 5

Return 6

Return 7

Return 8

Job Number

Mix Unit

Recipe #

A+B Volume

User ID [3:0] (ASCII)

User ID [7:4] (ASCII)

User ID [9:8] (ASCII) uint32 uint32 uint32 uint32 uint32 uint32 uint32 uint32 uint32 uint32

NONE 2 = ACK 0 - 4

[YY:MM:DD-

:DW]

[xx:HH:MM-

:SS]

NONE

NONE

NONE cc

NONE

NONE

NONE

0x0E051D04 =

[14:05:29:04]

0x0B160E =

[11:22:14]

25

1

2

1234

0x6E686F4A = [‘n’,

’h’, ’o’, ’J’]

0x656F4420 = [‘e’,

’o’, ’D’ ‘ ’]

0

N/A

N/A

0 - 9999

1 - 2

0 - 30

N/A

N/A

N/A

N/A

3A4486E 55

Operation Using a Programmable Logic Controller (PLC)

The Read Alarm Info command allows remote access to any of the last 200 alarms logged by the ProMix PD2K. The argument is the

chronological index

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

The date is returned as a four-byte packet with each byte holding a two-digit value for (from MSB to LSB) year, month, day, and day of the week (Monday = 01).

The time is returned as a three-byte packet with each byte holding a two-digit value. Starting from the MSB, the first byte can be ignored, then hour, minute, and second.

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

See

System Errors, page 98

, for more details on these Event Types.

An example decoding algorithm is provided below.

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

June 3, 2014 at 8:11 AM.

DCS Register Parameter

DCS

Command

Argument 0

Read Alarm Info

Alarm Index uint32 uint32

NONE

NONE

15

1

0 - 16

0 - 199

Acknowledge Command Acknowledged uint32

Return 0 Alarm Date uint32

Return 1

Return 2

Alarm Time

Alarm Code Char[3:0] uint32 uint32

NONE 2 = ACK

[YY:MM:DD:DW] 0x0E060302 =

[14:06:03:02]

[xx:HH:MM:SS]

NONE

0x080B0B =

[08:11:11]

0x31304B44 = [‘1’,

’0’, ’K’, ’D’]

0 - 4

N/A

N/A

N/A character_str[0] = Return_2 & 0xFF; character_str[1] = (Return_2 >> 8) & 0xFF; character_str[2] = (Return_2 >> 16) & 0xFF; character_str[3] = (Return_2 >> 24) & 0xFF; character_str[4] = ‘\0’;

56 3A4486E

Operation Using a Programmable Logic Controller (PLC)

The Read Event Info command allows remote access to any of the last 200 events logged by the ProMix PD2K.

The argument is the

chronological index

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

The date is returned as a four-byte packet with each byte holding a two-digit value for (from MSB to LSB) year, month, day, and day of the week (Monday = 01).

The time is returned as a three-byte packet with each byte holding a two-digit value. Starting from the MSB, the first byte can be ignored, then hour, minute, and second.

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

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

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

June 3, 2014 at 8:11 AM.

DCS Register Parameter

DCS

Command

Argument 0

Read Event Info

Event Number uint32 uint32

NONE

NONE

16

4

0 - 16

0 - 199

Acknowledge Command

Acknowledged

Return 0 Event Date

Event Time Return 1

Return 2 Event Code Char[3:0] uint32 uint32 uint32 uint32

NONE 2 = ACK 0 - 4

[YY:MM:DD-

:DW]

[xx:HH:MM:SS] 0x080B0B =

[08:11:11]

NONE

0x0E060302 =

[14:06:03:02]

0x30304345 = [‘0’,

’0’, ’C’, ’E’]

N/A

N/A

N/A

The Read Grand Totals command allows remote access to the material grand total volume data. No arguments are necessary for this command.

Example: Read current Grand Total usage data. A = 132 gal, B = 128 gal, A+B = 260 gal, Solvent = 11 gal

DCS Register Parameter

DCS

Command

Read Grand Totals uint32 NONE 22 0 – 22

Acknowledge Command

Acknowledged

Return 0 Grand Total A Material

Return 1 Grand Total BMaterial

Return 2

Return 2

Grand Total A+B

Grand Total Solvent uint32 uint32 uint32 uint32 uint32

NONE

Gallons

Gallons

Gallons

Gallons

2 = ACK

132

128

260

11

0 – 4

0 –

4,294,967,295

0 –

4,294,967,295

0 –

4,294,967,295

0 –

4,294,967,295

3A4486E 57

Operation Using a Programmable Logic Controller (PLC)

These screens may be used to verify PLC communications by providing a real-time status of all

Network Inputs and Outputs.

These screens show all PD2K Network Outputs with their associated register ID, Modbus TCP address, current value, and any relevant state information.

This screen encapsulates all the registers used in the Dynamic Command Structure. Arguments and Command registers are shown on the left.

Acknowledge and Return registers are shown on the right. When a valid DCS command is sent, the

Return registers will display the appropriate data on the right side of the screen. This can be used to test and verify DCS commands with the PLC.

Figure 14 PLC Diagnostic Screen 1

These screens show all PD2K Network Inputs with their associated register ID, Modbus TCP address, last value written, and any relevant state information.

show a value of 4294967295 (0xFFFFFFFF) and state as invalid.

Figure 16 PLC Diagnostic Screen 11

Figure 15 PLC Diagnostic Screen 8

58 3A4486E

Operation Using a Programmable Logic Controller (PLC)

Flow control is an optional feature that precisely regulates the flow of material to an automatic spay device, to help ensure adequate coverage and avoid sags or runs in the finish coat. The ProMix PD2K system can control fluid flow by directly controlling the proportioning pumps. The pumps accurately dispense a fixed volume of fluid during each stroke.

For this reason, the flow rate of a given pump is directly proportional to the velocity of the pump. As long as the gun is open and the system is stable, flow control is the most effective method for controlling flow rate.

The flow control system relies on two main inputs for controlling flow rate: Gun Trigger and Control Set

Point.

NOTE: recommends

These recommends that controller.

Alternatively these two inputs can be driven by the network communications, but latency could be an issue for systems requiring precise timing.

See

System Screen 4, page 70

, for more details on configuring these options for ‘Discrete’ or ‘Network’.

manual gun system.

The ProMix PD2K will directly control the speed of the pump(s) to the programmed flow control set point to maintain accurate flow rate and ratio. The flow control set point is set by Network Communications or the Discrete Input.

The system is considered to be stable when the pressure readings do not fluctuate and the flow rate is maintained. While the system is considered stable it will store (“learn”) the associated pump pressures to a table that is used if the gun trigger signal is lost or removed.

When the gun trigger signal is removed the system automatically switches to pressure control mode to avoid over pressurizing the fluid lines and to allow smooth transition to flow control if the gun trigger signal returns. It also works to maintain a consistent flow rate even though it has transitioned to pressure control mode if the gun trigger signal is inadvertently lost.

The pressure table also is used to predict if the gun has been turned on or off (without a change to the gun trigger input). The flow control system continually monitors the desired outlet pressure compared to the actual outlet pressure. If the actual pressure remains

50% or 50 psi higher than the desired pressure, whichever is larger, for longer than 10 msec, then the system predicts that the gun trigger has been released. If the actual pressure drops below the desired pressure longer than 10 msec, then the system predicts that the gun has been triggered.

The gun on/off prediction is used in the flow control algorithm to prevent the fluid pressure from becoming too high or too low due to a system disturbance. For example, if a gun off prediction occurs while the gun trigger input is high, the system will begin to control to the pressure value last stored in the pressure table for the current flow set point.

The pressure table is reset for every mix cycle, or after a power cycle of the ProMix PD2K controller.

This issue is not significant because the system generally is able to recalculate new pressure table values within a few seconds (depending on the stability of the fluid system).

3A4486E 59

Run Mode Screens

grayed-out on the screens are not currently active.

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

Figure 17 Opening Screen

The Home screen displays the current status of the system. The following table details the information shown. Only one of the two Mix Units is shown as active on the Home screen (regardless of the

Mix Unit’s status). The active Mix Unit’s pumps will appear highlighted. The other Mix Unit’s pumps will be muted with an arrow icon indicating the user must toggle mix units by pressing the Up/Down Arrow key.

To view pump flow rates and pressures

(as shown), select “Diagnostic Mode” on

System Screen 1, page 67

. The Status Bar (C), Error

Status (D), Solvent Gun (S), Gun Animation (T), and

Recipe Information (U) apply to the active Mix Unit.

Figure 18 Home Screen, in Mix Mode with

Diagnostics On

60 3A4486E

Run Mode Screens

A

B

C

Date and Time

Menu Bar

Status Bar*

H

J

F

G

L

M

N

P

D

E

S

Error Status*

Pump Animation and

Diagnostic Information

Pump Number (1–4)

Material (A or B)

Available Colors

Pump Inlet Color

Pump Flow Rate

Pump Outlet Color

Pump Outlet Pressure

Pump Indicator Light

• Clear = power off

• Yellow = standby

• Green = active

Solvent Flow Rate*

See

Advanced Screen 1, page 91

, 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 63 )

• Fill (see

Fill Screen, page 64

), available only if Manual Override is enabled on

System Screen 1, page 67 .

• Usage (see

Usage Screen, page 65 )

• Jobs (see

Jobs Screen, page 66 )

• Errors (see

Errors Screen, page 66 )

• Events (see

Events Screen, page 66 )

System Status: Displays the current mode of operation:

• Pump Off

• Standby

• Startup

• Mix (Dispense in 1K Mode)

• Mix Fill

• Purge

• Shutdown

Displays any active error code.

• Change Recipe

• Idle

• Prime Pump

• Calibrate

• Stall Test

• Maintenance Test

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

3A4486E 61

Run Mode Screens

T Spray Device Animation* Shows mixed material in the spray device and displays active recipe at the spray device. Gun animation changes to show:

• •

(Mix Fill)

(Purge)

(Mix With Gun Triggered)

• (Solvent Standby)

Y

Z

W

X

U

V

Gun Not Triggered)

(Mix With

(Recipe Standby)

Active Recipe ( )*

Current Ratio ( ) (Not shown in 1K Mode.)*

Potlife Time Remaining ( )*

Total Volume for the Current

Job ( )*

Current Flow Rate ( )*

Current Pressure ( )*

* Applies specifically to the active Mix Unit on the display. To toggle between Mix Units, use the Up/Down arrows on the Navigation keypad ( ).

62 3A4486E

Run Mode Screens

PLC, the Spray Screen is display only. No changes can be made. This section provides information about the Spray Screen if Manual Override is enabled on

System Screen 1, page 67

. The screens show a system in Manual Override mode.

The Spray screen includes the following information for the selected Mix Unit:

• Active Recipe (can be changed on this screen)

• Target Ratio (not shown in 1K Mode)

• Actual Ratio (not shown in 1K Mode)

• Target Pressure (if Pressure Mode is selected on

System Screen 4) or Target Flow (if Flow Mode is selected). Target pressure or flow can be changed on this screen).

• Actual Pressure

• Actual Flow

• Potlife Remaining

• Gun Animation

In addition, the Spray screen includes four soft keys:

Press to put the system in

Standby.

Press to spray mixed material.

Press to purge the gun.

Press to switch between Mix

Units.

When the system is configured for solvent push, the purge soft key changes to the solvent push soft key while in Mix mode.

Press to initiate solvent push.

Figure 20 Spray Screen, in Mix Mode

Figure 21 Spray Screen, in Idle Mode

Figure 22 Spray Screen, in Mix Mode, Solvent Push

Enabled

Figure 19 Spray Screen, in Standby Mode

3A4486E 63

Run Mode Screens

is enabled on

System Screen 1, page 67 .

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

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

The pump animation at the top of the screen will show the selected material.

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

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

Units.

To prime the pumps and fill the lines, first read

Prime and Fill the System, page 19 .

1.

Press the Edit softkey for editing.

2.

Select Color (A).

to open the screen

3.

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

4.

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

. Trigger the gun into a waste

5.

Repeat for Catalyst (B).

Figure 24 Fill Screen, Solvent Selected

The pump pre-fill option is available for pumps that have color change, but only a single material (color or catalyst). The pre-fill option may be used for pumps that remain filled with material when the system was powered down.

Press the Pre-Fill softkey to “prime” the pump without flushing or expelling any material unnecessarily.

Figure 25 Fill Screen, Pre-Fill Option

Figure 23 Fill Screen, Color (A) Selected

64 3A4486E

Run Mode Screens

The first Usage screen displays the current job usage of component A, B, A+B, and solvent (S). The second Usage screen displays grand total usage of component A, B, A+B, and solvent (S). Edits may be made only if Manual Override is enabled on

System Screen 1, page 67

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

not shown.

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 for the appropriate Mix Unit, press the corresponding Job Complete softkey, or . 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 66

, to review past jobs.

4.

Press the Edit softkey to close the screen.

Figure 28 User ID Keyboard Screen

Figure 29 Usage Grand Total

Figure 26 Usage Screen

Figure 30 Usage Log

Figure 27 Usage Screen, 1K Mode

3A4486E 65

Run Mode Screens

The Jobs screen displays the 200 most recent job numbers, recipes, Mix Unit, and A+B volumes in a log, with date, time, and User ID.

Figure 33 Errors Screen, Edit Mode

Figure 31 Jobs Screen

The Events screen displays the 200 most recent

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

The Errors screen displays the 200 most recent Error

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

Additional information is available for system errors to assist with troubleshooting. To access this information for a system error that has occurred, first press to enter edit mode; the first error will be highlighted. Using the Up and Down arrow keys, navigate to the desired error code, press again

(see

System Errors, page 98

, for more information on the troubleshooting information screens).

Figure 34 Events Screen

Figure 32 Errors Screen

66 3A4486E

Setup Mode Screens

Press screens.

on any Run screen to enter the Setup

Most parameters on the Setup screens may be configured individually for each Mix Unit, while some are global. Those that may be set individually appear in two columns.

grayed-out on the screens are not currently active.

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

Password Screen, page 67 .

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

Figure 35 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 91 .

Figure 36 System Screen 1, During Standby

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

Home Screen, page 60

.

Select this box to enable recipe linking on the

Recipe Screen, page 75

.

Check this box to give users system control at the

ADM. Leave the box unchecked if all system settings are controlled through a PC, PLC, or other networked device.

Select this box if your system uses a solvent meter.

The Solvent K-Factor field will then become active.

3A4486E 67

Setup Mode Screens

System screen 2 sets the following system operating parameters.

Figure 37 System Screen 2, in Standby Mode

Enter the number of color pumps in your system.

Enter the number of catalyst pumps in your system.

will put the mix unit into 1K Mode.

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

(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.

Set a higher flow rate or pressure for use while mix filling to decrease the time needed to fill the hose and spray device. Once the spray device is filled, the system will use the target set point as set by the PLC.

The default value is ‘0’. When set to ‘0’, the system ignores the Mix Fill Set Point and instead uses the target set point as set by the PLC.

The value will be a flow rate if Fluid Control is set to ‘Flow’, or a pressure if Fluid control is set to

‘Pressure’.

The Gun Trigger Input signals that the device is triggered. If you are not using a gun trigger signal, the system does not know if the spray device is spraying. If a pump failed you could spray pure resin or catalyst without knowing. This should be caught by the Mix No Flow Timeout; the default is 5 seconds.

The Mix Idle Timeout will trigger Idle mode, which will run a pump stall test to check for leaks, then put the pumps in Standby (holding their current position) after the designated period of time. Enter the desired

Mix Idle Timeout in this field.

See

Digital Inputs, page 23 .

The Gun Trigger Input signals that the gun is triggered. If the Gun Trigger Input indicates that the gun is triggered, but there is no fluid flow through a pump, you could spray pure resin or catalyst without knowing. The Mix No Flow Timeout will cause the system to shutdown after the designated period of time. The default is 5 seconds. Enter the desired shutdown time in this field.

See

Digital Inputs, page 23 .

The Max Flow Rate setting allows you to limit the total flow rate of the Mix Unit while in Mix mode. Normally, while controlling to the target pressure set point, flow rates may fluctuate slightly due to a number of variations, including ambient conditions or user adjustment of the applicator tip. The Max Flow Rate may be used to ensure a more consistent application of material, and could result in material savings.

The default setting is 0. When set to 0, the system does not limit the flow rate beyond what the pumps are capable of delivering.

applies to all recipes in the same way.

68 3A4486E

Setup Mode Screens

System screen 3 sets the following system operating parameters.

Figure 38 System Screen 3

Enter the length of the hose from the remote mix manifold to the spray device.

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

Deselect this box only if your system is not using a remote mix manifold.

Enter the length and diameter of the hose from the remote color stack to the remote mix manifold, for both A and B hoses.

This option is for systems that have fluid circulation and use mix-at-belt manifolds. This should not be used with Automatic systems.

3A4486E 69

Setup Mode Screens

System screen 4 sets the following system operating parameters.

Figure 39 System Screen 4

Select the desired operating mode (pressure or flow), using the pull-down menu.

speed to maintain the fluid pressure set by an external control device.

speed to maintain the target flow rate set by an external control device.

Select the format of the signal indicating whether the spray device is triggered.

• Discrete — the signal is sent via a direct, hard-wired connection

• Network — the signal is sent via a PC, PLC, or other networked device.

Select the format of the signal that indicates system flow rate or pressure.

• Discrete — the signal is sent via a direct, hard-wired connection. This selection will make the Max Set Point field active.

• Network — the signal is sent via a PC, PLC, or other networked device.

• Recipe — flow rate or pressure is set according to user-entered value on each recipe screen.

Set the scaling factor for the 4–20 mA discrete Flow

Control Signal (see

Analog Inputs, page 23

).

This field is active if Fluid Control is set to ‘Flow’.

The system will detect if the flow rate falls below a designated percentage of the target flow rate. Set that percentage in this field. For example, you might want the system to time out if it detects a flow rate that is 10 percent of the target, rather than waiting until a no flow timeout occurs.

The low flow timeout causes the system to shut down after the designated period of time if the flow rate continues to be at or below the low flow tolerance set in the previous section. The default is 5 seconds.

Enter the desired shutdown time in this field.

Enable the Solvent Push option for the end of a mix/spray cycle. When enabled, the system may be commanded to end a mix/spray cycle with solvent push using the soft key on the ADM Spray Screen or using a PLC command. For more details, see

Solvent Push, page 71

.

for Flow Mode fluid control systems with single outlet color change valve configurations (see

Custom Valve Mapping, page 81

). The checkbox is only visible if the mix unit is configured in this way.

70 3A4486E

Setup Mode Screens

Certain fluid stream configurations can benefit from switching from resin to solvent before concluding a mixing/spray cycle. The solvent is dispensed directly behind the resin material and is used to push the resin material (and, as a result, the mixed material) down the fluid path and to the spray device. The dispensed solvent comes at a cost savings over the resin material and also provides a head start on the flushing of the pump and fluid lines before the next color change.

The solvent push feature is available as an option for certain system configurations. See

Custom Valve Mapping, page 81 .

Flow Mode

System Screen 4, page 70

).

The following figure shows a typical MISO (multiple color in, single color out) configuration.

Figure 40 MISO Fluid Stream Configuration (for Solvent Push)

3A4486E 71

Setup Mode Screens

When the Solvent Push feature has been enabled on System Screen 4, a new configuration screen becomes visible for setting the solvent push dispense volume.

Solvent may be pushed past the mix manifold and into the mix hose, if needed. To prevent atomizing solvent, it may only be dispensed to a percent of the mix hose volume. The default value is 0%, which will not dispense solvent beyond the mix manifold. The mix hose volume is set by the Gun Hose Length and

Gun Hose Diameter (see

System Screen 3, page 69

).

Figure 41 Solvent Push Configuration Screen

The displayed volume shows the total amount of solvent to be dispensed during the solvent push sequence. This volume includes, at minimum, the total fluid stream volume from the inlet color stack to the mix manifold. Additionally, if set to greater than

0%, this volume includes a percentage of the mix hose volume.

If using an electrostatic gun, to reduce the risk of fire and explosion, confirm the mix hose parameters are accurately represented in the settings.

The solvent push sequence is initiated using a soft key on the Spray Screen (see

Spray Screen, page 63

) or a PLC command (see

INPUT REGISTER 00 and

10: System Mode Command, page 34 ).

Timing is critical to avoid having the solvent push sequence end before the last part has been finished.

The mix unit will go into Standby and must complete a recipe change before it can mix again.

72 3A4486E

System screen 5 sets the following operating parameters.

Figure 42 System Screen 5

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.

NOTE: If the material supply pressure at the pump inlet is greater than 90% of the Stall Test Pressure, the system will generate an alarm and will not complete the stall test. See

Calibrate Screen 1, page 87 .

Set the duration for the pump stall test. See

Calibrate Screen 1, page 87

.

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

Setup Mode Screens

Parking the pumps will help prevent material from hardening on the pump rods. The Auto Park Pumps timer will automatically park all pumps and turn off pump power. The default value of 0 minutes turns off this feature.

Standby and all guns are purged to prevent volumes from going off ratio.

When transitioning from Standby mode to Mix Mode, fluid viscosities and high ratios may affect how quickly fluid dynamics balance, which may result in nuisance Exceed Max Flow or Differential Pressure mixing alarms.

The Mix Balance Interval set point may be used to enable a brief period at the start of a mix cycle for fluids to balance before generating any mixing alarms.

while the gun is triggered. Setting this time to zero turns the timer off.

Select this box if you wish to prevent a mix unit from being powered up and to suppress all related alarms.

3A4486E 73

Setup Mode Screens

The Gateway screen sets the following system operating parameters for the CGM protocol installed.

Figure 43 Gateway Screen

Select the desired Gateway ID from the dropdown menu.

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.

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.

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

74 3A4486E

Setup Mode Screens

Each Mix Unit has its own chapter of Recipe screens for Mix Unit #2. These recipes can be set up entirely unique, or for systems that will be mixing two equivalent recipes at the same time, recipes can be linked between two Mix Units.

Figure 44 Valid Recipe Screen

Pressing the Link softkey on a Recipe screen will copy data from the equivalent recipe number of the other Mix Unit to the screen currently displayed.

The softkey will then change states to indicate the two recipes are linked. Once linked, changing a recipe parameter will affect both Mix Unit recipes concurrently. Recipes may be un-linked by simply pressing the Link softkey again.

Recipe linking must be enabled on

System Screen 1, page 67 . If recipe linking

is not enabled, the Link softkey will not be shown on the Recipe screen.

numbers will appear different, but are equivalent relative to each Mix Unit (i.e., Color 1 = Color 17,

Catalyst 1 = Catalyst 5).

neither Mix Unit is configured for mix-at-wall.

Figure 46 Linked #2 Recipes Screen

Enter the desired recipe number (1-30).

Use Recipe 0 to flush the system.

the previously active pumps and purge the gun.

flush all pumps and purge the gun.

Selecting “Enabled” makes the selected recipe accessible from the Spray screen on the ADM or to the PLC.

Figure 45 Linked #1 Recipes Screen

3A4486E

Enter the desired color valve number (1-32).

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 14, the field will appear as shown below.

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

(A) valve and the catalyst (B) valve. The gun purge time for each material depends on the flush sequence assigned to each. See

Flush Screen, page 78

. If materials A and B require different purge times, assign separate flush sequences. Set the necessary gun purge time for each. For hard to flush colors, select a longer sequence. 1 is the default, and should be designated for the longest, most thorough flush duration.

75

Setup Mode Screens

Enter the desired catalyst valve number (1-8).

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.

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

0 disables this function.

Enter the desired target spray pressure or flow rate, depending on whether the Mix Unit is configured for

Pressure Control or Flow Control (see Fluid Control on System Screen 4). This is the pressure or flow rate the pumps will maintain while mixing. This field is only available when the Flow Control is set to

‘Recipe’ (see Flow Control on System Screen 4).

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 25%.

Figure 47 Invalid Recipe Screen

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

76 3A4486E

A primary means of maintaining ratio assurance for the ProMix PD2K system is through monitoring of the differential pressure between the A-pump and

B-pump outlets. Ideally, these two pressures would be identical, but factors such as line sizing, viscosity, and mix ratio lead to some variation. Understanding where your system typically operates is imperative when setting up an effective differential pressure check that notifies the user of potential mix ratio inaccuracies while avoiding nuisance alarms.

It is recommended that, once the system is fully installed and ready to use, the user load a recipe and then spray the mixed material. While spraying, note the outlet pressures of both the A and B pumps (per the ADM’s main screen or the PLC) and spray long enough to ensure the pressures have stabilized to a nominal value. The difference between the outlet pressures of the A and B pumps is an established baseline for the Mix Pressure Tolerance set point.

The Mix Pressure Tolerance set point allows the

B-side pump outlet pressure to vary a specified percentage away from the A-side pump outlet (spray) pressure. For example: In the following figure, if the spray pressure (A-side pump outlet pressure) is 100 psi, and the Mix Pressure Tolerance is set to 25%, the B-side outlet pressure is allowed to float between

Setup Mode Screens

75 and 125 psi (100 psi ± 25%) without generating an alarm.

140

120

100 A

80

60

40

B

20

0

Figure 48 The acceptable B-side pump outlet pressure range for a system with a target spray pressure (A) of 100 psi and a Mix Pressure Tolerance of 25%.

It is recommended that you keep the Mix Pressure

Tolerance set point as low as possible to alert the user of anything affecting the mix ratio accuracy.

However, if your system is generating several differential pressure alarms, or will be mixing a wide variety of materials at different mix ratios, you may need to increase the Mix Pressure Tolerance.

Select the sequence for purging the mixed material from the mix hose and spray device. Each stage of the sequence can be set to either ‘A’ or ‘B’.

The solvent corresponding to each material will be dispensed out the spray device for the Gun Purge

Time of the Flush sequence assigned to that material for each stage. See Table 6 for a progression of the successive stages of the purge sequence.

Select the sequence for dispensing material into the mix hose and spray device. The choices are: ‘A then B’, ‘B then A’, and ‘Parallel’, if no fill sequencing is necessary. The fill sequence is typically dictated by the last material used in the purge sequence.

See Table 6 for a progression of the fill sequence following the last stage of the purge sequence.

Figure 49 Dual Solvent Recipe Screen

If Mix-at-Wall is enabled on System Screen 3, Dual

Solvent becomes an option on the Recipe screen.

Selecting ‘Dual Solvent’ enables the sequencing of flushing mixed material for a system using two types of solvent (i.e., water and solvent based) that should not be mixed together.

Mixed

Material

2nd Fill

Material

(if applicable)

1st Fill Material (If applicable)

Purge 3

Solvent

Purge 2

Solvent

Purge 1

Solvent

Mixed

Material

3A4486E 77

Setup Mode Screens

Figure 50 Flush Screen

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.

This option is available if Mix At Wall is enabled on

System Screen 3, page 69 . Enable an air and solvent

chop for flushing the gun rather than just a solvent purge. See

Air/Solvent Chop, page 79

.

Air and solvent chop may also be enabled for flushing out a pump. See

Custom Valve Mapping, page 81

, for more information.

for the air purge valve. See manual 333282 for kit numbers and installation details.

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

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.

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

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

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

78 3A4486E

Setup Mode Screens

Air/Solvent Chop replaces the standard Gun Purge

Time parameter on the Flush screen. Instead the purge is split into three phases: First Purge, Chop, and Final Purge. The Chop Phase will always start with Air and each phase has multiple configuration parameters.

Figure 51 Flush Screen with Air/Solvent Chop

Select the material to be either Air or Solvent and the length of time for the first purge phase, which dispenses only the material selected.

Set the air chop duty cycle for the chop phase.

Set the solvent chop duty cycle for the chop phase.

Set the length of time for the chop phase. The system will switch between air and solvent pulses according to the duty cycles set for the length of the

Total Chop time.

Select the material to be either Air or Solvent and the length of time for the final purge phase, which dispenses only the material selected.

Figure 52 Air/Solvent Chop Timing Diagram

3A4486E 79

Setup Mode Screens

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 53 Pump Screen 1

Select 35cc or 70cc, as appropriate.

Select one of the following:

• Disabled

• Monitor, to track inlet pressure

Select this box if your system uses color change.

Enter the number of materials used in your system.

Each color change module controls 8 colors.

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.

Enter the diameter of the supply and output hoses.

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

Select whether to use Standard, static valve mapping, or fully configurable Custom valve mapping. The color change valve mapping is the assignment of the location of the solenoids in the color change control modules. A static, pre-determined map layout makes for an easily predictable and hands-free option. However, an application and user may benefit from laying out the valve mapping on their own for consolidation of equipment, reduced hardware complexity, or simply to lay out valves according to what makes most sense.

See

Custom Valve Mapping, page 81

for more detailed information.

80 3A4486E

For a PD2K system that has color change, the user has an option for how the control solenoids are mapped on the control modules. Selecting Standard

(default) will use the traditional, static valve mapping.

The static maps are laid out logically and established for retro-fitting. If Standard is selected no additional set up for the color change valves is required at the

ADM. For more information or to see the static map layouts, refer to manuals 332455 and 333282.

By selecting Custom, every color change solenoid may be assigned to any unique, valid control module location. This option offers the ultimate customization as well as the benefit of consolidation of equipment.

Additionally, custom valve mapping enables some advanced color change valve features.

it for one will change it for all.

the PD2K will automatically pull in the static map assignments for all valves as a starting point. When going from Custom to Standard, the PD2K will clear all custom valve assignments and revert to the static mappings.

Figure 54 Pump Screen, Advanced Configuration

Select Multiple if each individual material has its own valve on the inlet color stack for a particular pump.

Setup Mode Screens

Select Single if there is more than one material using a single valve on the inlet color stack (i.e., a piggable system). This option is only available for pumps that have more than one color change material.

the user knows when a particular material is plumbed and filled to the inlet stack before performing a color change. The PD2K system does not know what material is connected up stream of the inlet valve stack.

Select Enable to add an air purge valve to the pump inlet stack to allow for an air/solvent chop flush of the pump out the dump valve. Select Disable if no air purge valve will be used for the pump. This option is only available for color pumps. See Pump Air/Solvent

Chop on

Pump Screen - Valve Assignment, page 83 ,

for further detail.

Select Multiple if each individual material has its own valve on the outlet color stack for a particular pump.

Select Single if there is more than one material using a single hose connected to the outlet color stack.

This option is only available for pumps that have more than one color change material.

to the outlet stack will need to be purged before completing a color change.

Select Multiple if each individual material has its own valve on the remote color stack for a particular pump.

Select Single if there is more than one material using a single hose connected to the remote color stack. Select Disable if there are no remote color change valves (only solvent and air) for the pump.

The Disable option is only available if Mix-at-Wall is enabled, and Single is only available for pumps that have more than one color change material.

the selection for Outlet Color Change unless.

between the outlet stack and remote stack will need to be purged before completing a color change.

3A4486E 81

Setup Mode Screens

Select Enable to add an auxiliary valve downstream of the remote valve stack for the pump. The Auxiliary valve is only opened when that particular pump is dispensing (either mixing or purging). This option is only available if Mix-at-Wall is enabled.

The following figure illustrates an example application of the auxiliary valve. Pumps 1 and 3 both dispense color, but one is solvent based and one is water based. (Pump 2 dispenses a catalyst.) With the auxiliary valves in place for both pumps, only one will flow through the A-side of the remote mix manifold, and the other is completely isolated by the auxiliary valve.

Figure 55 Example Application of the Auxiliary Valve

Check this box to clear all valve assignments. The user will be prompted to confirm the choice. This will erase any valve assignments permanently, including any that were automatically set based on the static mapping.

82 3A4486E

Figure 56 Pump Screen, Valve Assignment

This screen allows the user to assign each individual color change valve solenoid in the system to a unique

Setup Mode Screens

location. The list of valves will automatically populate based on the settings that apply to the pump. A description of the valve includes what stack it belongs to, the material identification, and a specific gun or pump designator, if that applies.

more than one pump. They will show up on the valve list for all pumps to which they apply.

All color change valves require a valid location be assigned for the system to be able to operate properly. There are two columns that determine the solenoid location. The left column is the color change module number. This number must be between 1 and 8 and should reflect the dip switch settings on one of the color change boards (see manual 332455 for more details on dip switch settings). The second column is the solenoid location, and this number must be between 1 and 18. The following figure shows the solenoid location enumeration.

Figure 57 Solenoid Location Enumeration

3A4486E 83

Setup Mode Screens

If more than one valve is assigned a valid solenoid location, all instances of that location will be highlighted in red, and are considered invalid.

for the air purge valve. See manual 333282 for kit numbers and installation details.

Figure 58 Pump Screen, Valve Assignment with duplicates

A value of 0 for the control module, or 00 for the solenoid, indicates no previous location assignment and both are also invalid assignments.

If a valve location is considered invalid, any operation that uses that valve will be prevented from running.

This is easily identified on the Recipe screens. If any of the material’s valves are considered invalid, that material will be highlighted red. If any of the valves used in the flush procedure are considered invalid, the flush sequence will be highlighted red.

Figure 60 Flush Screen with pump air/solvent chop

Figure 59 Recipe Screen with invalid valve location

Enabling an air purge valve on the inlet stack of a color pump allows for an air/solvent chop during the pump flush process. The air/solvent chop will replace the wash cycles in a pump flush. Instead, the pump will run at a steady speed for the set number of strokes (full length travel in one direction) while alternating between air and solvent for the desired duty cycles. One pump stroke takes approximately 2 seconds during this phase.

Figure 61 Flush Screen with both air/solvent chops

To enable air/solvent chop for a pump flush, check the Air/Solvent Chop box on the Flush screen.

Because air/solvent chop may also be used for purging the gun, if Mix-at-Wall is enabled, the

Air/Solvent Chop option becomes a pull-down selection where the user may choose None, Pump,

Gun, or Both. If air/solvent chop is enabled for the gun purge, all gun purge parameters will appear on the right side, and pump flush parameters are on the left side. The following parameters apply to the pump flush. For details on air/solvent chop for the gun, see

Flush Screen, page 78

.

Set the air chop duty cycle for the chop phase of the pump flush.

Set the solvent chop duty cycle for the chop phase of the pump flush.

84 3A4486E

Setup Mode Screens

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

Figure 62 Pump Screen 2, Default Settings Enabled

When the “Use Default Settings” box is selected, default settings are used for the calibration values, and the fields are grayed out.

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.

Pressure

Pump Screen 1, page 80

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

Pump Screen 1, page 80

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 63 Pump Screen 2, Default Settings Disabled

3A4486E 85

Setup Mode Screens

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

Inlet Pressure

Pump Screen 1, page 80

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 86 .

in

Pump Screen 1, page 80

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

• Alarms and Deviations will display when the inlet or outlet pressure drops below the low limit or exceeds the high limit.

using Flow Control.

Figure 64 Pump Screen 3, Pressure Monitoring

Disabled

Inlet Pressure

Pump Screen 1, page 80

is set to Monitor, all fields are active. See

Pressure Alarm and Deviation Limits, page 86 .

Figure 65 Pump Screen 3, Pressure Monitoring

Enabled

86 3A4486E

Setup Mode Screens

Calibrate Screen 1 initiates a pump pressure check

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

Stall Test screen will appear.

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

System Screen 2, page 68

, to set test parameters.

See

Pump Pressure Check, page 95

for complete test instructions.

To initiate the test, press the Pressure Check button for the desired pump. The system will first check the inlet pressure due to the material supply pressure. If this pressure is greater than 90% of the Stall Test Pressure, the system will generate an alarm and halt the stall test. 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.

successfully completing the test.

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

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 96

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 68 Calibrate Screen 2

Figure 66 Calibrate Screen 1

Figure 69 Volume Check Screen

Figure 67 Stall Test Screen

3A4486E 87

Setup Mode Screens

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 96

for complete instructions.

To initiate the calibration, press the Volume Check button.

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

Volume field, or press to end the test.

After the Measured Volume is entered, the Accept

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

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

for 1-2

Figure 71 Enter Measured Volume of Solvent

Figure 72 Accept Calibration

Figure 70 Calibrate Screen 3

88 3A4486E

Setup Mode Screens

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

must enter a value other than 0.

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.

successfully completing the test.

Figure 73 Maintenance Screen 1, Interval Settings

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 75 Maintenance Screen 3, Current Pump

Status

Figure 74 Maintenance Screen 2, Current Status

If two solvent meters are used, enter the desired solvent meter number.

3A4486E 89

Setup Mode Screens

Maintenance Screen 4 provides the ability to relieve pump outlet pressure. This feature is only functional for pumps that have color change valves (fluid pressure is relieved via the dump valve).

kitchen is in a controlled environment, but the PD2K

Dual Panel unit is not and is subject to warm, or even hot, conditions.

Maintenance screen 5 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. Leaving this screen will close all manually-driven valves.

Figure 76 Maintenance Screen 4, Pump Pressure

Relief

Enter the number of the pump for which you wish to relieve outlet pressure (pump must have a dump valve) and press the Pressure Relief softkey. The system will briefly open the pump’s dump valve, which will allow trapped fluid pressure to evacuate.

Select the Autodump checkbox to enable the automated pressure relief functionality. The automatic pressure relief will perform the same function as the manual pressure relief, but will trigger on its own once the pump’s outlet pressure rises above the set Pressure Limit. The system will only perform a pressure dump when the pump is in

Standby or Off.

NOTE: It is recommended to set the Pressure Limit significantly above the spray pressure to avoid unnecessarily dumping fluid.

Figure 77 Maintenance Screen 5, Color Valve Resets

Figure 78 Maintenance Screen 5, Solvent Valve

Resets is the pump number, not the material number.

90 3A4486E

Advanced screen 1 sets the following display parameters.

Figure 79 Advanced Screen 1

Defines the language of the screen text. Select:

• English (default)

• Spanish

• French

• German

• Japanese

• Chinese

• Korean

• Dutch

• Italian

• Portuguese

• Swedish

• Russian

Setup Mode Screens

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

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

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

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.

it in a secure location.

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

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

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

3A4486E 91

Setup Mode Screens

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

Advanced screen 3 enables USB downloads and uploads.

Figure 80 Advanced Screen 2

Select the desired display units:

• Grand Total Volume (US gallon or liter)

• Pressure (psi, bar, or MPa)

• Length (ft or m)

Figure 81 Advanced Screen 3

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

Depth field.

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

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.

92 3A4486E

Setup Mode Screens

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

This is not an editable screen.

Figure 82 Advanced Screen 4

3A4486E 93

Setup Mode Screens

Figure 83 Diagnostic Screen 1

Use this screen to test and verify proper wiring for all inputs to the EFCM. (See installation manual for details.) The screen shows all available inputs to the

EFCM, but only highlights those that are relevant to the system configuration. All inputs are normally open. When the input sees a switch closure the status indicator on the screen will turn green.

Figure 84 Diagnostic Screen 2

This screen can be used to determine whether any of the EFCM outputs are currently on or off. The screen shows all available outputs from the EFCM, but only highlights those that are relevant to the system configuration. The status indicator next to each output indicates the output is ON when it is green.

94

Figure 85 Diagnostic Screen 1

Diagnostic screens 3–10 are only available for color change modules that are currently connected to the PD2K system. These screens provide real time status of the color change valve outputs by changing the status indicator from white to green when the system energizes that solenoid. The user may scroll through the boards with the up and down arrows, or jump directly to a specific color change module by selecting it from the drop-down box.

3A4486E

Calibration Checks

doing 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.

pressure check.

1.

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

Prime and Fill the System, page 19 .

2.

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

3.

Scroll to Calibrate to display

Calibrate Screen 1, page 87

.

4.

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

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

5.

The pressure and flow that the unit measured are displayed on the screen. Compare with the maximum leak rate entered on

System Screen 5, page 73

. If the values are substantially different, repeat the test.

minimum. The system may stall at a higher pressure depending on hose lengths and fluid composition.

3A4486E 95

Calibration Checks

1.

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

Prime and Fill the System, page 19

.

2.

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

3.

Scroll to Calibrate in the menu bar.

4.

Scroll to

Calibrate Screen 2, page 87 .

5.

Press the soft key to check.

for the pump you want

(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.

6.

Press the Reset key will reset to 0.

. The volume counter

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.

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.

to cancel the test.

1.

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

Prime and Fill the System, page 19

.

2.

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

3.

Scroll to Calibrate in the menu bar.

4.

Scroll to

Calibrate Screen 3, page 88 .

5.

Press the soft key to initiate the calibration.

(mass) method to determine the actual volumes dispensed.

proper pressure before calibrating. Air in the line or pressure that is too high may cause incorrect calibration values.

6.

Trigger the gun into a graduated cylinder.

Dispense a minimum of 500cc of material.

7.

The volume that the unit measured displays on the screen.

8.

Compare the amount on the screen to the amount in the graduated cylinder.

repeat the calibration process.

9.

Enter the amount of solvent dispensed in the

Measured Volume field on the screen.

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

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

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

K-factor.

by Mix Unit. Solvent Meter 1 applies to Mix Unit #1 only, Solvent Meter 2 applies to Mix Unit #2 only.

96 3A4486E

Color Change Module Kits are available as an accessory. See manual 333282 for complete information.

1.

Command the system to Standby.

2.

Enable manual override on

System Screen 1, page 67

.

Color Change

3.

Select the new recipe on the

Spray Screen, page 63

. This will change colors in the pump and initiate a gun purge.

4.

The system will purge material B then material

A out of the gun. Each material will purge for the amount of time designated by the Flush

Sequence selected for each material on the

Recipe Screen, page 75

.

5.

Wait for the color change to complete. The system automatically goes from Color Change to

Mix Fill and the remote mix manifold automatically selects the correct color.

6.

Trigger the gun to complete the Mix Fill.

before the system will fault.

7.

Wait for the system to complete the Mix Fill operation. Command the system to Mix and begin spraying..

3A4486E 97

System Errors

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

Advisory, Deviation, and Alarm.

clear itself after 60 seconds. The four-digit error code will be followed by ‘-V’.

not shut down the equipment. The deviation must be acknowledged by the user. The four-digit error code will be followed by ‘-D’.

error code will be followed by ‘-A’.

If any of the system error types occur:

• Alarm buzzer sounds (unless in silent mode).

• Alarm popup screen shows the active alarm code

(see

Error Codes, page 100

).

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

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

background. These are informational only and can be reviewed on the Events screen, which displays the 200 most recent events, with date, time, and description.

Unit and therefore only show up on the appropriate menu bar and Event Flag PLC register when that Mix

Unit is active. All alarms will generate a pop-up on the ADM regardless of the active Mix Unit.

All alarms have a QR code screen. A mobile device with internet access and a QR reader may use the QR code to access additional information on a webpage hosted by help.graco.com.

Figure 87 QR Code Screen

A number of the alarms that are most likely to be encountered during typical operation have detailed troubleshooting information screens. The troubleshooting screens will replace the QR code screen, though the QR code may still be accessed by pressing .

When a system alarm occurs, a help screen is available to provide timely and relevant troubleshooting information for the user. On the alarm popup screen, press to access the help screens. The help screens may also be accessed at any time by going to the Errors Screen and selecting an alarm in the log (see

Errors Screen, page 66 ).

Figure 88 Troubleshooting Screen

Figure 86 Alarm Popup

98 3A4486E

sure to determine the error code before resetting it. If you forget which code occurred, go to the

Errors Screen, page 66 , to view the last 200 errors,

with date and time stamps.

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

To acknowledge a deviation or clear an alarm, press on the Advanced Display Module. Users also may acknowledge and clear errors via a network device (see

INPUT REGISTER 01 and 11: Clear

Active Alarm/Deviation, page 34

).

System Errors

The Gun Trigger Input signals the controller when the gun is triggered. The gun icon on the Advanced

Display Module shows spray when the Gun Trigger

Input is activated.

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

If the unit detects through the Gun Trigger Input signal that the gun is triggered, yet one or both of the pumps are not running, a Flow Not Detected Alarm

(F8D1) occurs after 10 seconds (default) and the system goes into Standby.

3A4486E 99

System Errors

the

Errors Screen, page 66

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

EJS#

SPD#

Description Problem

Record Purge Not

Complete

The Mix Unit was unable to complete a purge sequence.

Alarm Gun Purge

Incomplete

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

An indication that Mix

Unit # either could not complete or was interrupted before completing a gun purge.

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.

No action required.

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.

F7S1

F7S2

F7S3

F7S4

QPD# Alarm, then

Deviation

SND#

Alarm

Alarm

Alarm

Description Problem

Flow

Detected

Solvent Gun

Flow

Detected

Solvent Mix

Potlife

Expired

Mix Fill

Incomplete

The solvent flow switch is indicating unexpected solvent flow for Mix Unit

(1) or Mix Unit (2).

The solvent flow switches indicate that both are flowing solvent at the same time for Mix Unit

#1 (3) or Mix Unit #2 (4).

Potlife time has expired before the Mix Unit has moved the required amount of material

(potlife volume) through the mixed material line.

Mix Unit # timed out before the mix fill cycle loaded the gun with mixed material.

Solvent flow switch is stuck in flow position.

There is a leak through the solvent cutoff valve.

One or both solvent flow switches are stuck in flow position.

There is a leak through one or both of the solvent cutoff valves.

Purge process was not completed.

Solvent supply shut off or empty.

Clean or replace switch.

Check for leaks and repair valve.

Clean or replace the switch(es).

Check for leaks and repair valve(s).

Make sure purge process is completed.

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

Mix manifold not set to spray position.

Spray gun was not triggered.

Restrictions in mixer, manifold, or spray gun.

Set manifold to spray.

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

Fix restrictions.

100 3A4486E

System Errors

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.

DA0#

Type Description

Alarm Exceeded

Maximum

Flow Pump

#

Pump was driven to its maximum allowed speed.

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.

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.

DE0# Alarm Leak

Detected

Pump #

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

Pressure.” Will fault after

30 seconds.

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.

DF0#

DG0#

DH0#

Alarm

Alarm

Alarm

No Stall Up

Pump #

No Stall

Down Pump

#

No Stall

Pump #

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

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

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

Valve failure, seal failure, worn rod or cylinder.

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.

Replace inlet and outlet valve and seal for up and down strokes. Replace piston and throat seals.

Replace rod and cylinder as necessary.

3A4486E 101

System Errors

DKD#

DKF#

EBH#

EF0#

EF1#

ETD#

EP0#

F1A#

F1D#

102

Alarm

Alarm

Record

Alarm

Alarm

Position

Failed Pump

#

Position

Overspeed

Pump #

Home

Complete

Pump #

Timeout

Startup

Pump #

Timeout

Shutdown

Pump #

Pump was unable to reach its drive position.

Pump moved beyond its drive position.

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.

Motor could not drive pumps and linear actuator.

Pump stroke length is shortened by mechanical system tolerance.

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

Not enough air is supplied to the dosing valves.

The pressure at the pump outlet is too high.

The pump was knocked out of position.

Pump dose valves did not actuate.

Ensure that at least 85 psi is being supplied to the dosing valves.

Check for an obstruction downstream of the pump that would increase pressure. Ensure the feed pressure is within

1/2 – 1/3 of the target pressure

There is no fluid pressure at the outlet of the pump; run the pump at a lower pressure to fill the lines.

Check that the feed pressure is not more than the target pressure.

No action required.

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.

Record

Record

Auto

Pressure

Relief Pump

#

Auto Pump

Parked Mix

Unit #

Alarm Flow Low

Dispense

Pump #

Record of pump completing an auto pressure relief.

Record of pumps being auto parked.

The pump was unable to maintain its target flow rate.

Alarm Flow Low Mix

Unit #

The Mix Unit was unable to maintain it's target flow rate.

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

Motor or drive is worn or damaged.

Pump outlet pressure exceeded relief threshold.

The auto pump park operation was completed.

There is a restriction in the hose or gun that is preventing the pump from dispensing at its target rate.

There is a restriction in the hose or gun that is preventing the pump from dispensing at it's target rate.

No action required.

No action required.

Check that the gun is triggered and for restrictions in the hose.

Check that the gun is triggered and for restrictions in the hose.

3A4486E

F1F#

F1S#

F7D#

F8D#

F9D#

System Errors

Type Description

Alarm Flow Low Fill

Pump #

Alarm

Alarm

Flow Low

Purge Pump

#

Flow

Detected

Pump #

Alarm Flow Not

Detected Mix

Unit #

Alarm Flow

Unstable

Pump #

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

Thick viscosity paint requires more pressure to 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.

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.

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

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.

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.

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.

3A4486E 103

System Errors

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.

P1D#

P1F#

P2F#

P3D#

P3F#

P4D#

P4F#

P4P#

P6D#

Type Description Problem

Alarm Presure Low

Oultet Pump

#

Alarm Pressure

Low Inlet

Deviation

Pump #

Pressure

Low Inlet

Pump #

The outlet pressure on pump # is less than the user-entered alarm limit. *This alarm is only enabled with Flow

Control.

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.

Deviation

Deviation

Pressure

High Outlet

Pump #

Pressure

High Inlet

Pump #

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.

Alarm Pressure

High Outlet

Pump #

Alarm

Alarm

Alarm

Pressure

High Inlet

Pump #

Pressure

High Supply

Pump #

Press. Sens.

Removed

Outlet #

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.

The supply pump fluid pressure for pump # is greater than 90% of the user-entered Stall Test

Pressure.

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

There is no fluid pressure or pump is cavitating.

The supply pump pressure is too high.

Disconnected transducer.

Check supply for pump

#, increase supply pressure.

Increase inlet pressure.

Increase inlet pressure.

Relieve system pressure.

Decrease inlet pressure.

Relieve system pressure.

Decrease inlet pressure.

Check supply for pump

#, decrease supply pressure.

P6F#

P9D#

P9F#

Alarm

Alarm

Alarm

Press. Sens.

Removed

Inlet #

Press. Sens.

Failed Outlet

#

Press. Sens.

Failed Inlet #

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

Outlet pressure transducer has failed.

Inlet pressure transducer has failed.

Disconnected transducer.

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

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

Verify transducer is connected properly.

Replace if reconnecting does not eliminate the alarm.

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.

Relieve system pressure.

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

104 3A4486E

System Errors

QAD# Alarm Differential

Pressure A

Over B

QBD#

Type Description Problem

Alarm Differential

Pressure B

Over A

Mix Unit # low differential pressure. This alarm is active only during Mix mode.

There is a leak on the B side.

The B side pump is cavitating.

Mix Unit # high differential pressure. This alarm is active only during Mix mode.

There is a leak on the A side.

The A side pump is cavitating.

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.

EB00

EBC#

EBI#

EC00

EL00

EM00

EMI#

ES00

Type Description

Record

Record

Record

Record

Record

Record

Advisory

Advisory

Stop Button

Pressed

PLC Power

Command for Mix Unit #

Power Button

Pressed Mix

Unit #

Setup

Value(s)

Changed

System

Power On

System

Power Off

Pump Off Mix

Unit #

Factory

Defaults

Record of a stop button press.

Record of pumps powered off by PLC command.

Record of pumps powered off by button press.

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 for Mix Unit #.

Record of defaults being loaded.

Indicates system stop key on ADM was pressed.

The PLC command was used to shut down pump power.

The power button on the

ADM was used to shut down pump power.

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.

n/a

No action required.

No action required.

n/a n/a n/a

Start pumps by pressing pump start key on

Advanced Display module.

n/a

3A4486E 105

System Errors

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.

CA0X

CAC#

Alarm

Alarm

CADX Alarm

CAGX

CAG#

CDC#

CDDX

Alarm

Alarm

Alarm

Alarm

Comm. Error

ADM

Comm. Error

Color Change

#

Comm. Error

Fluid Module

Comm. Error

Gateway

Comm. Error

Modbus

Gateway

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).

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.

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

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

The Modbus CGM address dial was changed while the system was powered up.

The Modbus CGM is not connected/failed.

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.

Unplug the Modbus

CGM from the CAN network and re-plug it back in so that it re-registers with the new address.

Check that the Modbus

CGM is properly connected to the CAN network and it's LEDs indicate it is powered.

Check the system and remove the extra color change module.

Duplicate Color

Change #

System detects two or more identical Color

Change Modules.

Duplicate Fluid

Module

System sees two or more identical

Enhanced Fluid

Control Modules

EFCM).

More than one Color

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

More than one EFCM is connected in the system.

Check the system and remove the extra

EFCM.

106 3A4486E

System Errors

EAUX

EBUX

EQU0

EQU1

EQU2

EQU3

EQU4

EQU5

EVUX

MMUX

WSUX

WXUD

WXUU

Advisory

Record

Advisory

USB Busy

USB Drive

Removed

USB Idle

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.

Record

Record

Record

Record

USB Sys.

Settings

Downloaded

USB Sys.

Settings

Uploaded

USB Custom

Lang.

Downloaded

USB Custom

Lang.

Uploaded

Settings were uploaded from USB drive.

Custom language was downloaded to USB drive.

Custom language was uploaded from USB drive.

Record USB Logs

Downloaded

Data logs were downloaded to USB drive.

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

Advisory Maint. USB

Logs Full

USB memory is more than 90% full.

Advisory

Advisory

Advisory

USB Config.

Err.

USB Download

Err.

USB Upload

Err.

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.

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.

User installed incompatible USB device in ADM USB port.

User installed incompatible USB device in ADM USB port.

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.

Repeat process with compatible USB device.

Repeat process with compatible USB device.

3A4486E 107

System Errors

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.

B9A#

B9AX

B9B#

B9BX

B9D#

B9S1

B9S2

B9S3

B9S4

WX00

Advisory

Advisory

Advisory

Volume

Rollover A

Current Mix

Unit #

Volume

Rollover A

Lifetime

Volume

Rollover B

Current Mix

Unit #

Advisory Volume

Rollover B

Lifetime

Advisory Volume

Rollover Pump

#

Advisory Volume

Rollover

Solvent

Current Mix

Unit #

Advisory Volume

Rollover

Solvent

Lifetime

Alarm Software

Errors

Batch counter for material A rolled over for Mix Unit #.

Grand total counter for material A rolled over.

Batch counter for material B rolled over for Mix Unit #.

Grand total counter for material B rolled over.

Grand total counter for pump # rolled over.

Batch counter for solvent rolled over for

Mix Unit 1 (1) or Mix

Unit 2 (2).

Grand total counter for solvent rolled over for

Mix Unit 1 (3) or Mix

Unit 2 (4).

An unexpected software error has occurred.

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.

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

Call Graco technical support.

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.

END#

ENS#

ENT#

Record

Record

Record

Calibration Pump #

Calibration Solvent Meter #

A calibration test was run on the pump.

A calibration test was run on the solvent meter.

Calibration Stall Test Pump # A stall test was completed successfully on pump #.

108 3A4486E

B

C

9

A

6

7

8

D

E

F

3

4

5

1

2

System Errors

MAD#

MAT#

MEB#

MED#

MEF#

MEG#

MEN#

MES#

MFF#

MFS#

MGH0

MGP0

MJP# 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.

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Maint. Outlet Pump # Maintenance is due on pump.

Maint. Stall Test Pump

#

Maintenance stall test is due on pump.

Maint. Valve Catalyst

(B) #

Maint. Valve Outlet #

Maintenance is due on catalyst valve.

Maint. Valve Inlet #

Maint. Valve Gun #

Maintenance is due on outlet valve.

Maintenance is due on inlet valve.

Maintenance is due on gun valve.

Maint. Valve Auxiliary Maintenance is due on auxiliary valve.

Maint. Valve Solvent # 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

Maint. Valve Air

Maintenance is due on fluid filter.

Maintenance is due on air filter.

Maintenance is due on air valve.

9

10

11

12

6

7

8

13

14

15

3

4

5

1

2

N

P

R

L

M

J

K

G

H

T

U

Y

Z

V

W

20

21

22

23

24

16

17

18

19

25

26

27

28

29

30

3A4486E 109

Maintenance

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.

• 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.

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

110 3A4486E

Appendix A: Integration with Allen Bradley PLC

This appendix outlines how to integrate a ProMix PD2K with an Allen Bradley Studio 5000 Programmable Logic

Controller (PLC).

To integrate, the ProMix PD2K must have the Ethernet/IP protocol for PLC CGM (Graco Part number CGMEPO) installed prior to performing this procedure.

In the PLC software, perform the following steps:

1.

Add the new Ethernet module.

2.

Select Module a.

In the search field, type “generic” .

b.

Select ETHERNET-MODULE Generic Ethernet Module.

c.

Click the Create button.

3A4486E 111

Appendix A: Integration with Allen Bradley PLC

3.

The New

Configure the module by defining the fields as follows: after completing this screen.

a.

Name (required): Enter a name for the module (select a name that will have meaning for you when viewed on the Ethernet directory shown by the figure in step 1).

b.

Description (optional): Use any description desired.

c.

IP Address (required): Enter the static IP address of the Graco EtherNet/IP CGM installed in the ProMix PD2K.

d.

Input: Assembly Instance (required): Enter “100”, which is a device-specific parameter for the Graco

EtherNet/IP CGM.

e.

Input: Size (required): Enter “62”, which is the number of 32–bit registers that are allocated for input variables in the Graco EtheNet/IP CGM.

f.

Output: Assembly Instance (required): Enter “150”, which is the device-specific parameter for the Graco

EtherNet/IP CGM.

g.

Output: Size (required): Enter “30”, which is the number of 32–bit registers that are allocated for output variables in the Graco EtheNet/IP CGM.

h.

Configuration: Assembly Instance (required): Enter “1”.

i.

Configuration: Size (required): Enter “0”.

j.

Module Properties

112 3A4486E

4.

On the Connection tab:

Appendix A: Integration with Allen Bradley PLC

save changes without exiting this screen.

a.

Enter a Requested Packet Interval (RPI) value.

b.

If desired, select the available checkboxes.

c.

Click the OK button to save all changes and exit this screen.

Connection Request Error — Invalid Input

Application Path

Connection Request Error — Invalid Input

Size

This error, which also triggers an I/O Fault on the PLC, is caused by

Connection Request Error — Invalid Output

Application Path parameter. The correct value for this parameter is “100”.

This error, which also triggers an I/O Fault on the PLC, is caused by parameter. The correct value for this parameter is “150”.

This error, which also triggers an I/O Fault on the PLC, is caused by

Connection Request Error — Invalid Output

Size correct value for this parameter is “62”.

This error, which also triggers an I/O Fault on the PLC, is caused by

Module Configuration Rejected — Format

Error correct value for this parameter is “30”.

This error, which also triggers an I/O Fault on the PLC, is caused parameter. Because there are no configuration registers associated with the module, the correct value for this parameter is “0”.

3A4486E 113

Technical Data

Maximum fluid working pressure:

AC1002 Air Spray Systems

AC2002 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:

300 psi

1500 psi

100 psi

85–100 psi

3/8 npt(f)

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

• moisture sensitive isocyanates

20–5000 centipoise

100 mesh minimum

Viscosity range of fluid:

Fluid filtration

(user-supplied):

Maximum fluid flow:

Fluid outlet size:

External power supply requirements:

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 Operating temperature range:

Storage temperature range:

Weight (approximate):

Sound data:

Wetted parts:

AC1002 and AC2002

—4 to 158°F

195 lb

Less than 75 dB(A)

—20 to 70°C

88 kg

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

114 3A4486E

California Proposition 65

3A4486E 115

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by

Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall

Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS

IMPLIED,

OF

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO

AND

MATERIALS not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from

Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

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

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 3A4486 www.graco.com

Revision E, June 2020

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