Graco 3A6237A, ProMix® PD3K+ Electronic Proportioner Owner's Manual

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Graco 3A6237A, ProMix® PD3K+ Electronic Proportioner Owner's Manual | Manualzz

Operation

Electronic

Advanced

Important

Read all warnings and instructions in this manual and in your

Save

See page 3 for model part numbers and approvals information.

3A6237A

EN

PROVEN QUALITY. LEADING TECHNOLOGY.

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

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

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

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

Important Acid Catalyst Information ..................... 12

Acid Catalyst Conditions............................... 12

Moisture Sensitivity of Acid Catalysts ............ 12

Glossary of Terms .............................................. 13

Overview............................................................ 14

Usage ......................................................... 14

Component Identification and

Definition........................................ 14

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

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

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

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

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

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

Navigating the Screens ................................ 20

Screen Icons ............................................... 20

Booth Control ..................................................... 21

Booth Control Display................................... 21

Booth Control Keys and Indicators ................ 22

Pre-Operation Tasks........................................... 23

Pre-operation Checklist ................................ 23

Power On .................................................... 23

Initial System Setup ..................................... 23

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

Valve Settings.............................................. 24

Pressure Relief Procedure .................................. 25

Without Color Change .................................. 25

With Color Change....................................... 25

Operation ........................................................... 26

Prime and Fill the System ............................. 26

Pre-Fill the Pump ......................................... 26

Spraying...................................................... 27

Purging ....................................................... 28

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

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

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

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

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

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

Potlife Screen .............................................. 36

Usage Screen.............................................. 37

Jobs Screen ................................................ 38

Errors Screen .............................................. 38

Events Screen ............................................. 38

Setup Mode Screens .......................................... 39

Password Screen......................................... 39

System Screen 1 ......................................... 40

System Screen 2 ......................................... 42

System Screen 3 ......................................... 44

Information for Systems with Multiple

Guns.............................................. 46

System Screen 4 ......................................... 48

System Screen 5 ......................................... 49

Gateway Screen .......................................... 50

Recipe Screen 1 .......................................... 51

Recipe Screen 2 .......................................... 53

Recipe Screen 3 .......................................... 54

Differential Pressure and the Mix Pressure

Tolerance Set Point ........................ 55

Flush Screen ............................................... 56

Purge Screen .............................................. 57

Pump Screen 1 ............................................ 59

Pump Screen 2 ............................................ 60

Pump Screen 3 ............................................ 61

Pump Screen - Material Assignment ............. 61

Custom Valve Mapping ................................ 62

Calibrate Screen 1 ....................................... 65

Calibrate Screen 2 ....................................... 66

Calibrate Screen 3 ....................................... 67

Maintenance Screen 1 ................................. 68

Maintenance Screen 2 ................................. 68

Maintenance Screen 3 ................................. 68

Maintenance Screen 4 ................................. 69

Maintenance Screen 5 ................................. 69

Advanced Screen 1...................................... 70

Advanced Screen 2...................................... 71

Advanced Screen 3...................................... 71

Advanced Screen 4...................................... 72

Diagnostic Screens ...................................... 73

Calibration Checks.............................................. 74

Pump Pressure Check ................................. 74

Pump Volume Check.................................... 75

Solvent Meter Calibration ............................. 76

Color Change ..................................................... 77

Single Color Systems ................................... 77

Multiple Color Systems................................. 77

Color Change Failure ................................... 77

System Errors .................................................... 78

On-Screen Help ........................................... 78

Maintenance ...................................................... 98

Preventive Maintenance Schedule ................ 98

Flushing ...................................................... 98

Cleaning the ADM........................................ 98

Technical Specifications...................................... 99

Notes .............................................................. 101

2 3A6237A

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

MC0500 A 100 psi (0.7 MPa, 7.0 bar)

100 psi (0.7 MPa, 7.0 bar)

With lowpressure pumps:

300 psi (2.068 MPa,

20.68 bar)

With highpressure pumps:

1500 psi (10.34 MPa,

103.4 bar)

300 psi (2.068 MPa,

20.68 bar)

MC1000

MC3000

Acid-based

Material

MC2000

MC4000

Acid-based

Material

A

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

103.4 bar)

II 2 G

Electronic Proportioner

II 2 G

Ex ia IIA T3

FM13 ATEX 0026

IECEx FMG 13.0011

.7

ProMix

MAX AIR WPR

7

®

PD

FM16US0241

FM16CA0129

Intrinsically safe equipment for Class I,

Div 1, Group D, T3

Ta = 2°C to 50°C

100

MPa bar

MAX FLUID WPR

PSI

Intrinsically Safe (IS) System. Install per IS Control Drawing No. 16P577.

Control Box IS Associated

Apparatus for use in non hazardous location, with IS Connection to color change and booth control modules

Apparatus for use in:

Class I, Division 1, Group D T3

Hazardous Locations

Read Instruction Manual

Warning: Substitution of components may impair intrinsic safety.

PART NO.

SERIES SERIAL

2.068 20.68

300

MPa bar PSI

MAX TEMP 50°C (122°F)

MFG. YR.

GRACO INC.

P.O. Box 1441

Minneapolis, MN

55440 U.S.A.

Figure 1 Model MC1000 & MC3000 (Low Pressure)

Identification Label

Continued on the next page.

Models

3A6237A 3

Models

Figure 2 24M672 Control Box Identification Label

ProMix

®

II 2 G

Ex ia IIA T3

FM13 ATEX 0026

IECEx FMG 13.0011

PD

Electronic Proportioner

FM16US0241

FM16CA0129

Intrinsically safe equipment for Class I,

Div 1, Group D, T3

Ta = 2°C to 50°C

Intrinsically Safe (IS) System. Install per IS Control Drawing No. 16P577.

Control Box IS Associated

Apparatus for use in non hazardous location, with IS Connection to color change and booth control modules

Apparatus for use in:

Class I, Division 1, Group D T3

Hazardous Locations

MAX AIR WPR

Read Instruction Manual

Warning: Substitution of components may impair intrinsic safety.

.7

7 100

MPa bar

MAX FLUID WPR

PSI

PART NO.

SERIES SERIAL

10.34 103.4

1500

MPa bar PSI

MAX TEMP 50°C (122°F)

MFG. YR.

GRACO INC.

P.O. Box 1441

Minneapolis, MN

55440 U.S.A.

Figure 3 Model MC2000 & MC4000 (High Pressure)

Identification Label

Figure 4 Non-Intrinsically Safe Color Change Control

(Accessory) Identification Label

PART NO.

ProMix

®

PD

COLOR CHANGE CONTROL

SERIES SERIAL MFG. YR.

MAX AIR WPR

Intrinsically safe equipment for Class I, Div 1, Group D, T3

Ta = 2°C to 50°C

Install per 16P577

FM16US0241 FM16CA0129

Artwork No. 294055 Rev. D

Figure 5 Intrinsically Safe Color Change Control

(Accessory) Identification Label

.7

7

II 2 G

Ex ia IIA T3 Gb

FM13 ATEX 0026

IECEx FMG 13.0011

MPa

100 bar PSI

GRACO INC.

P.O. Box 1441

Minneapolis, MN

55440 U.S.A.

www.graco.com/patents

12 VDC FM16US0241

FM16CA0129

II 2 G

Ex ia IIA T3 Gb

FM13 ATEX 0026

IECEx FMG 13.0011

Figure 6 Booth Control Identification Label

Intrinsically safe equipment for

Class I, Div 1,

Group D, T3

Install per 16P577

Ta = 2°C to 50°C

4 3A6237A

Figure 7 Pump Expansion Kit (Accessory)

Identification Label

Models

3A6237A 5

Related Manuals

3A2800

332457

3A2801

332339

332454

332455

332456

333282

334512

PD2K Proportioner Repair-Parts Manual, Manual Systems

PD2K Proportioner Installation Manual, Manual Systems

Mix Manifold Instructions-Parts Manual

Pump Repair-Parts Manual

Color Change Valve Repair-Parts Manual

Color Change Kits Instructions-Parts Manual

3rd and 4th Pump Kits Instructions-Parts Manual

Color Change and Remote Mix Manifold Kits Instructions-Parts Manual

PD1K Pump Expansion Kits Instructions-Parts Manual

6 3A6237A

Warnings

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

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

or 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 arc).

• 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 antistatic or conductive.

equipment until 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.

3A6237A 7

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 gun, hose leaks, or ruptured components will pierce skin. This may

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

• Engage trigger lock when not spraying.

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

• Do not put your hand over the spray tip.

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

cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

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

8

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

3A6237A

3A6237A

Warnings

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

• Read Safety Data Sheet (SDS) for handling instructions and to know the specific hazards of the fluids you are using, including the effects of long-term exposure.

• When spraying, servicing equipment, or when in the work area, always keeps work area

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

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 reactions; 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

For complete information about your material, request Safety Data Sheets (SDSs) 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.

9

Important Isocyanate (ISO) Information

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

Some materials may become self-igniting if applied too thick. Read material manufacturer’s warnings and Safety Data Sheet (SDS).

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.

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.

10 3A6237A

Important Isocyanate (ISO) Information

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.

3A6237A 11

Important Acid Catalyst Information

The PD2K MC3000 and MC4000 Proportioner is designed for acid catalysts (“acid”) currently used in plural-component, wood-finishing materials. Current acids in use (with pH levels as low as 1) are more corrosive than earlier acids. More corrosion-resistant wetted materials of construction are required, and must be used without substitution, to withstand the increased corrosive properties of these acids.

Acid is flammable, and spraying or dispensing acid creates potentially harmful mists, vapors, and atomized particulates. To help prevent fire and explosion and serious injury:

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

• Use only genuine, manufacturer’s recommended acid-compatible parts in the catalyst system (hoses, fittings, etc). A reaction may occur between any substituted parts and the acid.

• To prevent inhalation of acid 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 acid manufacturer’s SDS.

• Avoid all skin contact with acid. Everyone in the work area must wear chemically impermeable gloves, protective clothing, foot coverings, aprons, and face shields as recommended by the acid manufacturer and local regulatory authority. Follow all acid manufacturer recommendations, including those regarding handling of contaminated clothing. Wash hands and face before eating or drinking.

• Regularly inspect equipment for potential leaks and remove spills promptly and completely to avoid direct contact or inhalation of the acid and its vapors.

• Keep acid away from heat, sparks, and open flames. Do not smoke in the work area. Eliminate all ignition sources.

• Store acid in the original container in a cool, dry, and well-ventilated area away from direct sunlight and away from other chemicals in accordance with acid manufacturer’s recommendations. To avoid corrosion of containers, do not store acid in substitute containers. Reseal the original container to prevent vapors from contaminating the storage space and surrounding facility.

Acid catalysts can be sensitive to atmospheric moisture and other contaminants. It is recommended the catalyst pump and valve seal areas exposed to atmosphere are flooded with ISO oil, TSL, or other compatible material to prevent acid build-up and premature seal damage and failure.

Acid build-up will damage the valve seals and reduce the performance and life of the catalyst pump. To prevent exposing acid to moisture:

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

Never store acids in an open container.

• Keep the catalyst pump and the valve seals filled with the appropriate lubricant. The lubricant creates a barrier between the acid and the atmosphere.

• Use only moisture-proof hoses compatible with acids.

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

12 3A6237A

Glossary of Terms

user interface for the system. See

Advanced Display Module, page 16

controller for the system.

value, the system enters Idle mode. Trigger the gun to resume operation.

.

the total amount of material dispensed through the system.

becomes unsprayable.

required to move through the mix manifold, hose, and applicator before the potlife timer is reset.

dispensed per revolution of the motor.

mix manifold, hose, and gun.

mixed material from the gun.

certain components in a hazardous location.

of material dispensed through the system for one job.

A job is complete when the user presses the Job

Complete key on the Booth Control or ADM.

depiction of system operation and current status.

See

Run Mode Screens, page 31

.

user to define the system, setup recipes, and establish system operating parameters. See

Setup Mode Screens, page 39 .

occurs.

3A6237A 13

Overview

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

• The system dispenses Material A, monitors fluid flow, and continually dispenses Materials B and

C at ratio.

• Can proportion at ratios from 0.1:1 to 100.0:1

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

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

Electrical Control Box

Fluid Components

Advanced Display Module

Booth Control

• Enhanced Fluid Control Module (EFCM)

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

• 48 V Power Supply for pump motors

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

• Air Flow Switch

• Relay

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

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

• CAN Isolation Board

• Intrinsically Safe Power Barrier Board

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

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

Materials A, B, and C, as well as solvent valves.

• Solvent Flow Switch

• Pumps

• Pressure transducers

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

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

Purge mode. Locate in the hazardous area.

14 3A6237A

Overview

Figure 8

H

J

K

L

A★

B★

D★

E★

F★

G★

Material A Pump

Material B Pump

Solvent Valve

Booth Control

Electrical Control Box

Advanced Display Module

N

Color Change Valves (accessory)

Color Change Module (accessory)

Catalyst Change Valves

(accessory)

Remote Mix Manifold

T

U

V

P

R

S

C

M

Material C Pump

Fluid/Air Hose Bundle (accessory)

— see PD2K Installation Manual

(332457) for acid-compatible hose bundles

Mix Manifold (accessory) — see

Mix Manifold Instruction-Parts

Manual (3A2801) for acid-compatible mix manifolds

Air Spray Gun (accessory)

Gun Air Hose (accessory)

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

Gun Fluid Hose (accessory)

Remote Color Change Valves

Remote Catalyst Change Valves

3A6237A 15

Advanced Display Module

The ADM display shows graphical and text information related to setup and spray operations.

For detail on the display and individual screens, see

Run Mode Screens, page 31

, or

Setup Mode Screens, page 39

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

.

2 3

4 5 6

7 8 9

0 .

Figure 9 Advanced Display Module

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

1.

Enable USB downloads.

See

Advanced Screen 3, page 71 .

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.

16 3A6237A

Advanced Display Module

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 this file from the UPLOAD folder on the USB flash drive. This will prevent inadvertently overwriting any future setup changes.

3A6237A 17

Advanced Display Module

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.

Numeric Keypad Use to input values. See

ADM Display, page 16 .

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.

18 3A6237A

Advanced Display Module

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.

Purge

Press to start a gun purge procedure.

Enter Screen

Press to enter screen for editing. Highlights editable data on a screen.

Use Up/Down arrows to move between data fields on the screen.

Press to exit screen after editing.

Exit Screen

Press to accept calibration value.

Accept

Press to cancel or reject calibration value.

Cancel

Press to start a pump priming procedure.

Prime Pump

Press to start a line fill procedure.

Line/Fill/Run

Pre-Fill Pump

Press to mark pump as filled.

(Only for applicable pumps.)

Press to start a spray procedure.

Mix

Standby Press to stop all pumps and put system in

Standby.

Stop

Press to start a pump pressure check.

Pressure Check

Press to start a pump volume check.

Volume Check

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

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

Backspace

Appears on the User ID

Keyboard screen. Use to erase one character at a time.

3A6237A 19

Advanced Display Module

Upper Case/Lower

Case

Appears on the User

ID Keyboard screen.

Use to change case

(upper/lower).

Press to get more information on active system error.

Info

Troubleshoot

Press to see troubleshooting information for system error.

Press to see QR Code for system error.

QR Code

Press to access additional information for that recipe.

Recipe Page Key

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

Job Number

Target Ratio

Flow Rate

Volume

Material B

Material C

Material D

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.

Material A+B+C

Calendar

Alarm/Advisory

Solvent

Time

Deviation

20 3A6237A

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

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

The booth control displays the recipe in the following formats:

• R-xx (active recipe)

• P-xx (recipe loaded in the pumps)

• G-xx (recipe loaded in the gun)

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

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

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

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

• For systems with multiple guns enabled, the active gun (AG-x) is identified.

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

for 2 seconds

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

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

.

Figure 10 Booth Control

Booth Control

3A6237A 21

Booth Control

22

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

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

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

• Starts Standby mode.

• Green LED remains lit while in Standby mode.

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

• Green LED blinks during pump maintenance checks.

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

• Starts Mix mode.

• Green LED remains lit while in Mix mode.

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

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

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

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

• Starts Pressure Change mode.

• Green LED blinks while in Pressure Change mode.

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

• Starts Purge mode.

• Green LED remains lit while in Purge mode.

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

• Scrolls recipe numbers up.

• Scrolls pressure value up in Pressure Change mode.

• Scrolls recipe numbers down.

• Scrolls pressure value down in Pressure Change mode.

• Enters selected recipe and starts color change sequence.

• Accepts pressure value change.

3A6237A

Pre-Operation Tasks

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

Verify all grounding connections

Installation manual.

1.

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

2.

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

3.

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

“Startup” to “Standby.”

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 24

, 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).

Figure 11 Power Switch

1.

Change optional setup selections to desired parameters, as described in

Setup Mode Screens, page 39

.

2.

Set recipe and flush information as described in

Recipe Screen 1, page 51

, and

Flush Screen, page 56

.

3A6237A 23

Pre-Operation Tasks

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.

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

Figure 12 Valve Adjustment

24 3A6237A

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.

valve on the supply line, set the mix manifold to

SPRAY and press . Cycle the A, B, C, and D dosing pumps a couple of times to drain the pumps. Repeat for each color.

2.

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

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.

1.

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

valve on the supply line, set the mix manifold to

SPRAY and press . Cycle the A, B, C, and D dosing pumps a couple of times to drain the pumps.

2.

Press Standby relieve pressure.

. Trigger the gun to

3.

Set the mix manifold to FLUSH.

Flush the mix manifold and gun. See

Flush Mixed Material, page 28 .

4.

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

between the solvent supply pump and the solvent valve, VERY SLOWLY loosen a fitting to relieve pressure gradually.

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

3.

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

4.

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

5.

Press Purge . Repeat for each color.

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

6.

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

7.

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

between the solvent supply pump and the solvent valve, VERY SLOWLY loosen a fitting to relieve pressure gradually.

3A6237A 25

Operation

NOTE:

Run Mode Screens, page 31

, for further screen information, if needed.

position.

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

7.

Select the desired color to load. Press the Prime

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

prime the pump out to the gun.

1.

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

2.

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

100 psi (0.7 MPa, 7.0 bar) as possible. Do not use less than 85 psi (0.6 MPa, 6.0 bar).

3.

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

Purging, page 28

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

4.

5.

Verify that the recipes and the flush sequences

6.

If the on the ADM. Make sure that the system is in

Standby mode.

are programmed correctly by checking the

Recipe Screen 1, page 51 , and the

Flush Screen, page 56

.

Go to the

Fill Screen, page 35 .

8.

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

9.

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

10. Repeat for all material lines.

.

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.

Go to the

Fill Screen, page 35 .

2.

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

26 3A6237A

Operation

To spray in a multiple color system, also see

Multiple Color Systems, page 77

NOTE: screen information, if needed.

.

Run Mode Screens, page 31

, for further

3.

Press Mix again. The Mix Mode LED will turn on solid to indicate the system is mixing.

Adjust the flow rate by changing the target pressure. The fluid flow rate shown on the Spray screen is the combined total of component A, B,

C, and D out of the gun.

1.

Set the desired mix manifold to the SPRAY position.

2.

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

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

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

System Screen 4, page 48

.

4.

spray pressure setting on the Spray screen or booth control.

spray pressure setting on the Spray screen or booth control.

or booth control while spraying, it is not saved in the recipe until the system is put in Standby. This changes the pressure in the desired recipe.

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

of material as it may not be thoroughly mixed due to errors while priming the system. The Spray LED must be on.

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.

3A6237A 27

Operation

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

Color Change, page 77

.

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

• end of potlife

• breaks in spraying that exceed the potlife

• overnight shutdown or end of shift

• before servicing the mix manifold(s), hose or gun.

1.

Press Standby .

2.

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

3.

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

4.

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

5.

Trigger the gun to relieve pressure.

6.

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

7.

Set the mix manifold to the FLUSH position.

8.

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

9.

If the system is not completely clean, repeat.

sequence times so only one cycle is required.

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

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

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

solvent after purging.

28 3A6237A

Operation

1.

Relieve the pressure.

See

Pressure Relief Procedure, page 25 .

2.

Attach regulated solvent supply lines as follows:

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 25 .

2.

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

3.

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

4.

Set the mix manifold to the SPRAY position.

5.

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

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

6.

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

7.

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

Material to Component B. Press . The system will pump solvent through pump B all the way to the gun.

8.

Repeat 6 and 7 for Component C and Component

D.

9.

Relieve the pressure.

See

Pressure Relief Procedure, page 25

4.

6.

7.

On pumps that have color change, do not disconnect the component supply line from the inlet manifold of the pump. Instead connect a regulated solvent supply line to the designated solvent valve on the component valve manifold. On pumps that do not have color change, disconnect the supply line from the inlet manifold of the pump, and connect a regulated solvent supply line.

regulated solvent supply lines to the designated solvent valves on each of the component valve manifolds. Do not connect solvent supply lines directly to the inlet manifolds of the pumps.

3.

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

Set the mix manifold to the SPRAY position.

5.

On the ADM, go to the Fill screen. Select

Component A. Enter the component number in the box to the right.

Select the Flush Line box.

If the solvent is not already loaded, press the

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

8.

Press the Fill softkey . The system will flush the selected Component A line with solvent until the user presses Stop .

9.

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

10. Repeat for each component line.

11. Relieve the pressure.

See

Pressure Relief Procedure, page 25 .

3A6237A 29

Operation

1.

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

Purging, page 28

.

2.

Follow the

Pressure Relief Procedure, page 25

.

3.

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

5.

Shut off system power (0 position).

flush acid from the system by completing a purge of the catalyst side of the proportioner to prevent unnecessary exposure to the acid catalyst.

4.

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

30 3A6237A

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 13 Splash Screen

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

To view pump flow rates and pressures

(as shown), select “Diagnostic Mode” on

System Screen 1, page 40

.

Figure 14 Home Screen, in Mix Mode with

Diagnostics On

3A6237A 31

Run Mode Screens

A

B

Date and Time

Menu Bar

C

D

Status Bar

Error Status

See

Advanced Screen 1, page 70 , to set.

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

• Home (shown in Diagnostic Mode)

• Spray (see

Spray Screen, page 34 )

• Fill (see

Fill Screen, page 35

)

• Potlife (see

Potlife Screen, page 36 )

• Usage (see

Usage Screen, page 37 )

• Jobs (see

Jobs Screen, page 38 )

• Errors (see

Errors Screen, page 38 )

• Events (see

Events Screen, page 38 )

System Status: Displays the current mode of operation:

• Pump Off

• Standby

• Startup

• Mix

• Fill

• Purge

• Shutdown

Displays any active error code.

• Change Recipe

• Idle

• Prime Pump

• Calibrate

• Stall Test

• Maintenance Test

32 3A6237A

Run Mode Screens

E

M

N

P

K

L

H

J

F

G

W

X

U

V

Y

Z

S

T

3A6237A

Pump Animation and

Diagnostic Information

Pump Number (1–4)

Material (A, B, C, or D)

Available Components

Pump Inlet Component

Pump Inlet Pressure

Pump Flow Rate

Pump Outlet Component

Pump Outlet Pressure

Pump Indicator Light

• Clear = power off

• Yellow = standby

• Green = active

Solvent Flow Rate

Gun Animation

Active Recipe ( )

Current Ratio ( )

Potlife Time Remaining ( )

Total Volume for the Current

Job ( )

Current Flow Rate ( )

Current Pressure ( )

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

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

(maximum of three) during Mix Fill, the stage numbers will be shown underneath the gun icon, and the current stage being filled will be highlighted.

Gun animation changes to show:

(Mix Fill) • (Gun Purge in GFB)

(Mix With Air Flow)

• (Purged Gun in

Standby, in GFB)

(Recipe Standby)

• (Solvent Standby)

(Purge)

• (Mix With No Air Flow)

33

Run Mode Screens

The Spray screen displays the following information:

• Active Recipe (can be changed on this screen)

• Target Ratio

• Actual Ratio

• Target Pressure (can be changed on this screen)

• Actual Pressure

• Actual Flow

• Potlife Remaining

• Gun Animation show the selected ratio format, and on the line below, each of the component ratio values. The ratio format is selectable for each recipe (See

Recipe Screen 1, page 51

).

Figure 16 Spray Screen, in Mix Mode

Figure 15 Spray Screen, in Standby Mode

Figure 17 Spray Screen, in Idle Mode

34 3A6237A

Run Mode Screens

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

• Material– Select Component A, B, C, D, or Solvent.

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

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

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

Prime and Fill the System, page 26 .

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

1.

Press the Edit softkey for editing.

to open the screen

2.

Select Component A.

3.

Enter the component number in the box to the right.

4.

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

5.

Press the Fill softkey . The system will attempt to fill the Component A lines until the user presses Stop waste container.

. Trigger the gun into a

6.

Repeat for all components.

Flush the System, page 29

.

Figure 18 Fill Screen, Component A Selected

Figure 19 Fill Screen, Solvent Selected

1.

Press the Edit softkey for editing.

to open the screen

2.

Select Solvent.

3.

Enter the pump number in the box to the right.

4.

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

The pump pre-fill option is available for pumps that have color change, but only a single material (A, B,

C, or D). The pre-fill option may be used for pumps that remain filled with material when the system was powered down.

Figure 20 Fill Screen, Pre-Fill Pump Option

3A6237A 35

Run Mode Screens

The Potlife screen displays the current remaining potlife time of any mixed materials in the system.

Each mixing stage (if more than one) will be shown with the recipe number that is currently loaded and the remaining potlife. If there is no potlife timer for a recipe or individual stage, the time field will be blank.

stages will be shown on the screen. The current active gun will be highlighted.

Figure 21 Potlife Screen

36 3A6237A

The first two Usage screens display the current job usage and grand total usage of component A, B,

C, D, A+B+C(+D), and solvent (S). The third Usage screen displays the total volume pumped for all available materials.

been enabled will be displayed.

1.

Press the Edit softkey for editing.

to open the screen

2.

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

3.

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

The Grand Totals cannot be cleared. See the

Jobs Screen, page 38

, to review past jobs.

4.

Press the Edit softkey to close the screen.

Figure 23 Usage Screen 2

Run Mode Screens

Figure 24 User ID Keyboard Screen

Figure 22 Usage Screen 1

Figure 25 Usage Log

3A6237A 37

Run Mode Screens

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

first press the Enter key to enter edit mode.

The first error will be highlighted. Using the Up and Down arrow keys, navigate to the desired error code, press the Enter key again. (See

System Errors, page 78

for more information on the troubleshooting information screens.)

Figure 26 Jobs Screen

Figure 28 Errors Screen

The Errors screen displays the 200 most recent Error

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

The Events screen displays the 200 most recent

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

Figure 27 Errors Screen

Additional information is available for system errors to assist with troubleshooting. To access this information for a system error that has occurred,

Figure 29 Events Screen

38 3A6237A

Setup Mode Screens

Press screens.

on any Run screen to enter the Setup grayed-out on the screens are not currently active.

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

Password Screen, page 39 .

Figure 30 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 70 .

3A6237A 39

Setup Mode Screens

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

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

Home Screen, page 31

.

Enter the number of Component A Pumps in your system.

Enter the number of Component B Pumps in your system.

Figure 31 System Screen 1, During Standby

Enter the number of Component C Pumps in your system.

Enter the number of Component D Pumps in your system.

connected. If there is not a Component D pump, then a second Component A, B, or C pump may be enabled.

Figure 32 System Screen 1, During Idle

40 3A6237A

Setup Mode Screens

Enter a lower pressure for use when not mixing and spraying (Example: during pump 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.

Select this box if your system uses a solvent meter.

The Solvent K-Factor field will then become active.

Enter the solvent meter K-Factor.

3A6237A 41

Setup Mode Screens

System screen 2 sets the following system operating parameters.

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

Recipe Screen 1, page 51

) for mixing.

The default value is 0. When set to 0, the system ignores the Mix Fill Set Point and instead uses the recipe’s target pressure setpoint (set on

Recipe Screen 1, page 51 ) while mix filling.

Figure 33 System Screen 2, in Standby Mode

The air flow switch (AFS) detects air flow to the gun and signals that the gun is triggered. If you are not using an air flow switch, the system does not know if the gun is spraying. If a pump failed you could spray pure resin or catalyst without knowing. This should be caught by the Mix No Flow Timeout; the default is 5 seconds. The Mix Idle Timeout will trigger Idle mode, which will run a pump stall test to check for leaks, then put the pumps in Standby (holding their current position) after the designated period of time.

Enter the desired Mix Idle Timeout in this field.

See

Air Flow Switch (AFS) Function, page 79

.

Figure 34 System Screen 2, in Mix Mode

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

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

Enter the desired shutdown time in this field.

See

Air Flow Switch (AFS) Function, page 79

.

Set a higher pressure for use while mix filling.

This higher pressure decreases the time needed

42 3A6237A

Setup Mode Screens

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.

Set the duration for the pump stall test. See

Calibrate Screen 1, page 65

.

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

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.

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.

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 65

.

3A6237A 43

Setup Mode Screens

System screen 3 sets the following system operating parameters.

enabled when the Number of Guns is set greater than 1.

entries the fields will indicate that by being highlighted red, and the system will prevent the user from loading recipes or mixing with that fluid stream.

Enter the number of mixing stages that are required for the fluid stream.

Figure 35 System Screen 3

Select the type of manifold used at each mixing point of the fluid stream. The options are Remote Mix,

Three Port, Mix at Belt, and None.

• Remote Mix is a two-inlet port manifold.

• Three Port is a three-inlet port manifold.

support three-in-one mixing before choosing this manifold.

• Mix-at-Belt is a two-inlet port manifold with handle manipulation for spraying/flushing.

Enter the number of separate fluid streams that will be used. The system supports a maximum of 3 guns.

selected as the manifold for the last stage of the fluid stream because it requires manual manipulation. If selected as any other stage, the manifold selections will be shown as invalid.

for use with 4K recipes.

• None may be chosen for a 1K fluid stream.

number of stages is 1.

Figure 36 System Screen 3, Multiple Guns

Select which fluid stream/gun to which the content of the page applies. Each gun must be set up individually.

Figure 37 System Screen 3, Invalid

44 3A6237A

Setup Mode Screens

Select the components that are mixed at each mixing stage of a fluid stream.

once in the fluid stream. If a component is used more than once, the component selections will be shown as invalid.

3A6237A 45

Setup Mode Screens

A ProMix PD3K+ with remote mix manifold normally operates with a single gun, but may be configured to use multiple (up to 3 maximum) fluidstreams and guns. Having multiple guns has the advantage of very fast color change, the system could have a recipe loaded in each gun and could then switch between them almost instantly. The PD3K+ will also track potlife time for multiple mixed recipes.

The Multiple Guns operation mode may be enabled on System Screen 3 by changing the number of

Guns to greater than 1.

Each component in the system must be assigned to a single gun. Assignment of the component to gun is done on Pump #, Screen 4 by entering the gun number next to the component number.

Components B, C, or D may be assigned to a single gun, shared among multiple guns (common), or a mix of both. Only one component per pump may be configured as Common, and because each assignment requires a remote valve, the total number

(including each common assignment) cannot exceed eight. To configure a component as common to multiple guns, check the Common box and then select all appropriate guns.

Figure 39 Pump Screen 2, Material Assignment without Common Component B

Figure 38 Pump Screen 1, Material Assignment

46

Figure 40 Pump Screen 2, Material Assignment with

Common Component B

Recipes can only be set up to use components that are assigned to the same gun. If the component gun assignments do not match, the recipe will be invalidated and disabled. See

Recipe Screen 1, page 51

for more info on invalid recipes.

3A6237A

Setup Mode Screens

The Spray Screen provides the same information and operating capabilities as with a single gun (see

Spray Screen, page 34 ), but has the added capability

of switching control among the guns (The active gun is, or was most recently, spraying or loading mixed material). If the system is in Standby, the user may select ‘Gun’ and enter the number to become the active gun. This provides the ability to purge a gun that is currently inactive but loaded with mixed material that has an expired potlife.

The Spray Screen will also indicate which recipe is loaded in each gun, with the active gun highlighted.

Color change valves may be manually overridden from Maintenance Screen the same as with a single gun (see

Maintenance Screen 5, page 69 ).

For a component configured as common, the user will have to identify which remote valve to cycle by selecting the appropriate gun.

Figure 41 Spray Screen

The Fill Screen operates the same as with a single gun (see

Fill Screen, page 35

).

trigger the appropriate gun to which the material is assigned to avoid over-pressurizing the system.

When filling a line with a component that is common, the user will also need to select one of the guns.

The system will open the appropriate valves and fill material to the selected gun.

Figure 43 Component View for Maintenance Screen

5

Because each gun has its own unique remote solvent valves, when overriding a remote solvent valve the user will similarly have to identify the appropriate gun.

Figure 44 Solvent View for Maintenance Screen 5

Figure 42 Fill Screen

3A6237A 47

Setup Mode Screens

System screen 4 sets the following system operating parameters.

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

The Autodump function will then become enabled.

manifold, the Gun Flush Box is disabled.

Select this box to activate the Autodump function. If a gun is loaded with a mixed recipe that has a potlife that has expired and is placed in the Gun Flush Box, after two minutes, the system will automatically purge the gun with solvent. If the gun is not in the Gun

Flush Box or the Autodump cannot complete, the system will generate an alarm.

Figure 45 System Screen 4

Enter the length and diameter of each mixing hose in the fluid stream. The system will automatically enable the appropriate number of stages and hoses based on the configuration entered on

System Screen 3, page 44

.

Select which fluid stream/gun to which the content of the page applies. Each gun must be set up individually.

enabled when the Number of Guns is set greater than 1 on

System Screen 3, page 44 .

48 3A6237A

Setup Mode Screens

System screen 5 sets the following system operating parameters.

Enter the length and diameter of the hose from the remote color stack to the mix manifold, for each component in the fluid stream.

stream component/manifold configuration settings entered on

System Screen 3, page 44 .

Select which fluid stream/gun to which the content of the page applies. Each gun must be set up individually.

enabled when the Number of Guns is set greater than 1 on

System Screen 3, page 44 .

Figure 46 System Screen 5

3A6237A 49

Setup Mode Screens

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

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.

Figure 47 Gateway Screen

Select the desired Gateway ID from the dropdown menu.

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

50 3A6237A

Setup Mode Screens

your system configuration, the field will be highlighted and the recipe becomes invalid. For example, if your configuration has 8 color valves and you enter 30, the field will appear as shown in the Invalid Recipe

Screen example.

Figure 48 Valid Recipe Screen 1

Enter the desired recipe number (1-40).

Figure 49 Invalid Recipe Screen 1

Use Recipe 0 to flush the system.

the previously active pumps and purge the gun.

flush all pumps and purge the gun.

Enter the desired component 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.

Selecting “Enabled” makes the selected recipe accessible from the booth control, in addition to the

ADM. The booth operator can then quickly select a desired recipe, without scrolling through all 40.

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

Select the component pump that will be driving to target pressure. Most often this will be the

Component A pump because it will have relatively high viscosity and volume compared to the other mixing components.

3A6237A 51

Setup Mode Screens

Enter the potlife time (0 to 999 minutes) for all or any of the individual mixing stages of the fluid stream.

Entering 0 disables this function for that particular mixing stage.

fluid stream is used based on component selection and will enable the appropriate potlife stage fields based on the fluid stream configuration settings entered on

System Screen 3, page 44 .

Values for the ratio fields can be set from 0.01- 100, and percent values from 0.1% - 100.0%. A value of 0 indicates that the component is not part of the recipe and it will be hidden from the recipe screens.

It is extremely important to consider hose sizing and fluid dynamics when implementing wide ratios

(50:1 – 100:1) and a relationship between any two components should never exceed 100:1.

component in a recipe is 1 cc/min.

Select the ratio format that most closely matches what is shown on the material data sheets. Multiple formats are available to simplify entering the ratio values. The ratio value fields will automatically update when the format is changed.

component percentages should always equal exactly

100%.

use ratio format A:B:C and set the ratio values of unused components to zero.

52 3A6237A

Setup Mode Screens

For each phase of the total purge cycle, select the component that will be flushed and the desired purge sequence (1-10). The purge sequence applies only to cleaning out the mixed material hoses and remote hoses feeding mix manifolds. (see

Purge Screen, page 57 )

Figure 50 Valid Recipe Screen 2

Enter the desired flush sequence (1-10). For hard to flush colors, select a longer sequence. The flush sequence applies only to cleaning of the pumps.

Each component pump used in the recipe that has color change may have a unique flush sequence assigned. (see

Flush Screen, page 56

)

Enter the order of filling of the remote hoses up to the mix manifold(s) with material. Setting the same number indicates filling in parallel. Unless there are materials that are incompatible and need to be filled in sequence, it is recommended to leave these values at 1 for each component.

Select the number of segments (0-6) for flushing of the mixed material out the gun. Each segment will flush out a particular component’s fluid hoses from the remote color change valves out the gun.

of purge phases to 0.

3A6237A 53

Setup Mode Screens

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

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

Figure 51 Valid Recipe Screen 3

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

The pressure of one component must be within a percentage of the pressure of the driving component during spray or mix. Set the desired Mix Pressure

Tolerance in these fields for the relationship between each component and the drive component. The component relationship labels are determined based on the components used with the recipe and the

Drive Pump set on

Recipe Screen 1, page 51 . The

labels indicate the reference (drive component) on the right of the colon. The default set point value is

25%. See

Differential Pressure and the Mix Pressure

Tolerance Set Point, page 55 .

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

54 3A6237A

Setup Mode Screens

A primary means of maintaining ratio assurance for the ProMix PD3K+ system is through monitoring of the differential pressure between the Drive pump outlet and the other component-pump outlet. Ideally these pressures would be identical, but factors such as line sizing, viscosity, and mix ratio will lead to some variation. Understanding where your system typically operates is imperative to setting up an effective differential pressure check that will notify the user when something has caused the accuracy of the mix ratio to come into question, but also not generate nuisance alarms.

It is recommended that once the system is fully installed and ready for use, that the user load a recipe and spray mixed material. While spraying, take note of the outlet pressures of all mixing pumps

(This can be seen on the main screen of the ADM), spray long enough that the pressures have stabilized to a nominal value. The difference between the outlet pressures of the Drive pump and other component pumps are 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 percent away from the A-side pump outlet (spray) pressure. As an example, if the spray pressure

(A-side pump outlet pressure) is 100 psi, and the Mix

Pressure Tolerance is set to 25%, then the B-side outlet pressure is allowed to float between 75 psi

(100 psi - 25%) and 125 psi (100 psi + 25%) before generating an alarm.

If, during operation the system has generated a lot of differential pressure alarms, or if it will mix a wide variety of materials and at different mix ratios, the

Mix Pressure Tolerance may have to be increased.

Otherwise it is recommended to maintain this set point as tight as is possible to alert the user that something might be affecting the mix ratio accuracy.

Pressure —

PSI (MPa)

* Acceptable Range

A: A pump nominal output pressure

B: B pump nominal output pressure

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

3A6237A 55

Setup Mode Screens

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.

Figure 52 Flush Screen

Enter the desired flush sequence (1-10). For hard to flush colors, select a longer sequence. 1 is the default, and should be designated for the longest, most thorough flush duration.

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

dictates the length of the chop cycle. Each stroke runs about 2 seconds long, so determine your total length of air/solvent chop time and divide by

2 seconds to determine an appropriate number of strokes.

Enable air/solvent chop for flushing of the pump.

An air/solvent chop may be utilized in place of the standard wash cycles to provide a more abrasive clean, especially effective for flushing metallic materials.

that have an air inlet valve enabled. See

Pump Screen - Advanced Configuration, page 62 .

Air/solvent chop requires additional hardware for the air purge valve. See manual 333282 for kit numbers and installation.

Figure 53 Flush Screen with Chop

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

Set the air chop duty cycle for the chop phase.

Set the solvent chop duty cycle for the chop phase.

56 3A6237A

Setup Mode Screens

Air/Solvent Chop replaces the standard Gun Purge

Time parameter on the Purge 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 54 Purge Screen

Enter the desired purge sequence (1-10). For hard to flush materials, select a longer sequence. The default is 1, and should be designated for the longest, most thorough flush duration.

Figure 55 Purge Screen with Air/Solvent Chop

Enter the gun purge time (0 to 999 seconds).

3A6237A 57

Setup Mode Screens

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 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.

Set the air chop duty cycle for the chop phase.

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.

Set the solvent chop duty cycle for the chop phase.

Figure 56 Air/Solvent Chop Timing Diagram

58 3A6237A

Setup Mode Screens

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

Select the tab for the desired pump. Each pump has four or more 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.

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.

Figure 57 Pump Screen 1

Enter the number of materials used in your system.

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 components available in your system. This field is not editable.

3A6237A 59

Setup Mode Screens

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

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

Figure 58 Pump Screen 2, Default Settings Enabled

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 59

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 59

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 59 Pump Screen 2, Default Settings Disabled

60 3A6237A

Setup Mode Screens

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

in

Pump Screen 1, page 59

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.

Figure 60 Pump Screen 3

For systems using Multiple Guns, see

Information for Systems with Multiple Guns, page 46 ,

for a description of use.

3A6237A 61

Setup Mode Screens

For the PD3K+, every color change solenoid may be assigned to any unique, valid control module location.

the pump out the dump valve. Select Disable if no air purge valve will be used for the pump. See

Air/Solvent Chop on

Flush Screen, page 56

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.

Figure 61 Pump Screen, Advanced Configuration

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 purge) for the pump.

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

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

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 selection for Outlet Color Change.

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

the user knows when a particular material is plumbed and filled to the inlet stack before performing a color change. The PD3K+ system does not know what material is connected up stream of the inlet valve stack.

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.

Select Enable to add an air purge valve to the pump inlet stack to allow for an air/solvent chop flush of

62 3A6237A

Setup Mode Screens

Figure 62 Pump Screen, Valve Assignment

This screen allows the user to assign each individual color change valve solenoid in the system to a unique 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 63 Solenoid Location Enumeration

3A6237A 63

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.

Figure 65 Recipe Screen with invalid component valve location

Figure 64 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 or purge procedure are considered invalid, the flush or purge sequence will be highlighted red.

Figure 66 Recipe Screen with invalid flush and purge valve location

64 3A6237A

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 a component—not a solvent—before doing the stall test. See

System Screen 2, page 42

to set test parameters. See

Pump Pressure Check, page 74

for complete test instructions.

To initiate the test, press the Pressure Check button for the desired pump. The system will first check the material supply pressure at the PD3K+ the Stall Test Pressure the system will generate an alarm and halt the stall test.) Next, 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.

Figure 67 Calibrate Screen 1 successfully completing the test.

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

Figure 68 Stall Test Screen

3A6237A 65

Setup Mode Screens

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 a component—not a solvent—before doing the Volume

Check. See

Pump Volume Check, page 75

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 70 Volume Check Screen

Figure 69 Calibrate Screen 2

66 3A6237A

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 76

for complete instructions.

To initiate the calibration, press the Volume Check button.

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

Volume field, or press to end the test.

After the Measured Volume is entered, the Accept

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

Figure 72 Enter Measured Volume of Solvent

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

for 1-2

Figure 73 Accept Calibration

Figure 71 Calibrate Screen 3

3A6237A 67

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 74 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 76 Maintenance Screen 3, Current Pump

Status

Figure 75 Maintenance Screen 2, Current Status

68 3A6237A

Setup Mode Screens

Maintenance screen 4 is used to manually relieve pump outlet pressure, or to configure automatic pressure relief.

for pumps that have a dump valve (color change outlet valves).

To manually relieve pump outlet pressure, change the number to the desired pump and press the Relief softkey .

To set the system to automatically relieve pump outlet pressure, check the Autodump box and set the Pressure Limit. All applicable pumps, while in

Standby, will briefly open the dump valves to relieve outlet pressure when the reading climbs above the set Pressure Limit. The system will attempt up to three times if the pressure does not drop below the set limit.

Maintenance screen 5 displays cycle counts for a selected component, 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 78 Maintenance Screen 5, Component Valve

Resets

Figure 77 Maintenance Screen 4, Manual Pump

Relief

Figure 79 Maintenance Screen 5, Solvent Valve

Resets field, the number to the right of “Solvent” is the pump number, not the material number.

3A6237A 69

Setup Mode Screens

Advanced screen 1 sets the following display parameters.

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.

Figure 80 Advanced Screen 1

Defines the language of the screen text. Select:

• English (default)

• Spanish

• French

• German

• Japanese

• Chinese

• Korean

• Dutch

• Italian

• Portuguese

• Swedish

• Russian

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.

70 3A6237A

Setup Mode Screens

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

Advanced screen 3 enables USB downloads and uploads.

Figure 81 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 82 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.

3A6237A 71

Setup Mode Screens

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

This is not an editable screen.

Figure 83 Advanced Screen 4

72 3A6237A

Setup Mode Screens

Use this screen to test and verify proper wiring for all inputs to the EFCM (see installation manual 332457 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.

Diagnostic screens 3–10 are only available for color change modules that are currently connected to the

PD3K+ 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.

This screen can be used to determine if 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.

3A6237A 73

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.

check.

1.

Set the mix manifold to the SPRAY position.

2.

The pump and lines must be primed with a component—not a solvent—before doing the Pressure Check. See

Prime and Fill the System, page 26

.

3.

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

4.

Scroll to Calibrate to display

Calibrate Screen 1, page 65 .

5.

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

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

6.

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

System Screen 2, page 42

. 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.

74 3A6237A

Calibration Checks

1.

Set the mix manifold to the SPRAY position.

2.

The pump and lines must be primed with a component—not a solvent—before doing the Volume Check. See

Prime and Fill the System, page 26

.

3.

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

4.

Scroll to Calibrate in the menu bar.

5.

Scroll to

Calibrate Screen 2, page 66 .

6.

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.

7.

Press the Reset key will reset to 0.

. The volume counter

8.

Trigger the gun into a graduated cylinder.

Dispense a minimum of 500cc of material.

9.

The volume that the unit measured displays on the screen.

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

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.

3A6237A 75

Calibration Checks

1.

3.

Set the mix manifold to the FLUSH position.

2.

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

Prime and Fill the System, page 26

.

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

4.

Scroll to Calibrate in the menu bar.

5.

Scroll to

Calibrate Screen 3, page 67 .

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 calibration process.

10. Enter the amount of solvent dispensed in the

Measured Volume field on the screen.

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

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

6.

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.

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

K-factor.

76 3A6237A

Color Change

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

1.

Follow the procedure under

Flush the System, page 29 .

2.

Load the new color.

See

Prime and Fill the System, page 26

.

3.

Press the Mix key to start spraying.

1.

Press Standby .

2.

Set the current mix manifold to FLUSH.

3.

Select the new recipe at the Booth Control or on the

Spray Screen, page 34 . This will change

colors in the pump and initiate a gun purge. The

Standby and Purge indicators should be blinking.

recipes. If an invalid recipe is entered, the display will show 4 dashes (— — — — ). See

Recipe Screen 1, page 51

to enable a recipe.

4.

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

5.

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

mix manifold, disconnect the gun from the purged mix manifold and connect it to the new color line.

6.

Wait for the color change to complete (the

Standby indicator is on solid).

7.

Set the mix manifold to SPRAY.

8.

Press the Mix key on the booth control.

The Mix indicator will be blinking.

9.

Trigger the gun to complete the Mix Fill.

before the system will fault.

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

3A6237A

When selecting a new recipe on the booth control or from the Spray Screen, if a color change sequence does not start, there are a number of things to check that prevent a color change from starting.

1.

Are there any active alarms? See

System Errors, page 78

.

2.

Is the recipe enabled?

See

Recipe Screen 1, page 51 .

3.

Are the recipe parameters valid? See

Recipe

Screen 1, page 51

;

Recipe Screen 2, page 53 ; and

Recipe Screen 3, page 54 .

4.

Is the fluid stream configuration valid? See

System Screen 3, page 44

.

77

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”.

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.

not shut down the equipment. The deviation must be acknowledged by the user. The four digit 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 80

).

• 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.

Figure 85 Error 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 38 ).

Figure 86 Error Troubleshooting Screen

Figure 84 Alarm Popup Screen

78 3A6237A

System Errors

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

Errors Screen, page 38 , to view the last 200 errors,

with date and time stamps.

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

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

on

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

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

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

If the unit detects through the AFS signal that the gun is triggered, yet one or both of the pumps are not running, a Flow Not Detected Alarm (F8D1) occurs after 10 seconds (default) and the system goes into

Standby.

3A6237A 79

System Errors

occurred, use the

Errors Screen, page 38

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

Code

ETD1 Devia-

ETE0

ET01

ETS1

F7P1

SGD1

Type tion

Record

Alarm

Deviation

Alarm

Alarm

Description Problem

Autodump

Color (A)

Passed

Purge Not

Complete

System has completed an auto dump of the contents from the pump all the way out to the gun.

The system was unable to complete a purge sequence.

Autodump

Failed

Autodump

Solvent

Passed

Air Flow

Switch On

Gun Flush

Box Open

Potlife time has expired and the system attempted to flush the mixed material contents out of the gun.

The solvent flow meter or solvent flow switch did not indicate any flow taking place during the attempted purge.

System has completed an auto dump of the gun contents only.

The air flow switch is indicating unexpected atomizing air flow.

GFB was left open when the system was trying to attempt a purge.

Potlife time has expired and the system was not purged, so the system refilled with color.

An indication that the system either could not complete or was interrupted before completing a gun purge.

Solvent flow switch not working.

Gun is not in gun flush box.

Potlife time has expired and the system was not purged, so the system performed an autodump with solvent.

Air flow switch is stuck in flow position.

Leak downstream in air line or fitting.

Air supply pressure fluctuation.

Gun is not in gun flush box.

GFB pressure switch not wired/working.

No action required.

No action required.

Replace the switch.

Ensure that the gun is replaced in the gun flush box and cover is closed when not in use.

No action required.

Clean or replace switch.

Check for leaks and tighten fittings.

Eliminate pressure fluctuations.

Ensure the gun is replaced in the gun flush box and cover is closed when not in use.

Double check that the pressure switch is wired properly to the EFCM.

80 3A6237A

System Errors

Code Type Description Problem

SPD1 Alarm Gun Purge

Incomplete

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

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.

3A6237A 81

System Errors

F7S1

F7S2

QP1#

Description Problem

Alarm Flow

Detected

Solvent

Gun

Alarm

Alarm then

Deviation

Flow

Detected

Solvent

Mix

Potlife

Expired

Stage 1 -

Gun #

The solvent flow switch is indicating unexpected solvent flow.

The solvent flow switches indicate that both are flowing solvent at the same time. *This only applies to systems with mix-at-wall.

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.

QP2#

QP3#

SND1

Alarm then

Deviation

Alarm then

Deviation

Alarm

Potlife

Expired

Stage 2 -

Gun #

Potlife

Expired

Stage 3 -

Gun #

Mix Fill

Incomplete

Potlife time has expired before the system has moved the required amount of material

(potlife volume) through the stage 1 mixed material line.

Potlife time has expired before the system has moved the required amount of material

(potlife volume) through the stage 2 mixed material line.

Potlife time has expired before the system has moved the required amount of material

(potlife volume) through the stage 3 mixed material line.

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

Purge process was not completed.

Solvent supply shut off or empty.

Purge process was not completed.

Solvent supply shut off or empty.

Mix manifold not set to spray position.

Spray gun was not triggered.

Restrictions in mixer, manifold, or spray gun.

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 allowed to complete.

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

Make sure purge process is allowed to complete.

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

Make sure purge process is allowed to complete.

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

Set manifold to spray.

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

Fix restrictions.

82 3A6237A

System Errors

applicable component number, which can vary. The unit’s display will show the applicable number as the last digit in the code. For example, the F1S# code listed in this table will be displayed as F1S1 if the affected component is pump 1, F1S2 for pump 2, and so on.

Type Description Problem

DA0# 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#

Alarm

Alarm

No Stall Up

Pump #

No Stall

Down Pump

#

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

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

Valve failure, seal failure, worn rod or cylinder.

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.

3A6237A 83

System Errors

Type Description Problem

DH0# Alarm No Stall

Pump #

DKD#

DKF#

EBH#

EF0#

Alarm

Alarm

Record

Alarm

Position

Failed Pump

#

Position

Overspeed

Pump #

Home

Complete

Pump #

Timeout

Startup

Pump #

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

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.

Valve failure, seal failure, worn rod or cylinder.

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.

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

Pump dose valves did not actuate.

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

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

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 not 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 1/2 – 1/3 greater than the target pressure.

No action required.

Verify air pressure to solenoid valves.

Verify the valves are actuating.

Verify motor is driving the pump.

Motor could not drive pumps and linear actuator.

Pump stroke length is shortened by mechanical system tolerance.

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

84 3A6237A

System Errors

EF1#

Type Description Problem

Alarm Timeout

Shutdown

Pump #

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

Pump dose valves did not actuate.

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

Pump outlet pressure exceeded relief threshold.

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.

No action required.

ETD#

F1F#

Record

Auto

Pressure

Relief Pump

#

Alarm Flow Low

Fill Pump #

F1S#

F7D#

F8D1

Record of pump completing an auto pressure relief.

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

Alarm Flow Low

Purge Pump

#

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

Alarm

Alarm

Flow

Detected

Pump #

Flow Not

Detected

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

No flow while mixing.

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

Thick viscosity paint requires more pressure to pump.

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

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

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.

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.

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.

3A6237A 85

System Errors

Type Description Problem

F9D# Alarm Flow

Unstable

Pump #

SAD1 Alarm Atomizing

Solvent

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

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

Potential leak in the system.

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

Check the system for leaks and run manual stall test.

Make sure atomizing air is shut off before purging or filling the spray gun. Use an

AA cutoff valve on the atomizing air supply.

86 3A6237A

System Errors

applicable component number, which can vary. The unit’s display will show the applicable number as the last digit in the code. For example, the P6F# code listed in this table will be displayed as P6F1 if the affected component is pump 1, P6F2 for pump 2, and so on.

P1F#

P2F#

P3D#

Type Description Problem

Alarm Pressure

Low Inlet

Pump #

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

Deviation

Deviation

Pressure

Low Inlet

Pump #

Pressure

High Outlet

Pump #

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

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

P3F# Deviation

Pressure

High Inlet

Pump #

P4D#

P4F#

P4P#

P6D#

Alarm

Alarm

Alarm

Alarm

Pressure

High Outlet

Pump #

Pressure

High Inlet

Pump #

Pressure

High Supply

Pump #

Press.

Sens.

Removed

Outlet #

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

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

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

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.

The supply pump pressure is too high.

Disconnected transducer.

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#

Alarm

Alarm

Press.

Sens.

Removed

Inlet #

Press.

Sens.

Failed

Outlet #

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

Outlet pressure transducer has failed.

Disconnected transducer.

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

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.

3A6237A 87

System Errors

P9F#

QAB1

QAC1

QAD1

QBA2

QCA2

QDA2

QBA1

QBC1

QBD1

QAB2

QCB2

QDB2

Type Description Problem

Alarm

Alarm

Alarm

Alarm

Alarm

Press.

Sens.

Failed Inlet

#

Differential

Pressure A

Over B

Differential

Pressure A

Over C

Differential

Pressure A

Over D

Differential

Pressure B

Over A

Differential

Pressure C

Over A

Differential

Pressure D

Over A

Differential

Pressure B

Over A

Differential

Pressure B

Over C

Differential

Pressure B

Over D

Differential

Pressure A

Over B

Differential

Pressure C

Over B

Differential

Pressure D

Over B

Inlet pressure transducer has failed.

Differential pressure is low between driving component and second component. This alarm is active only during Mix mode.

Differential pressure is high between driving component and second component. This alarm is active only during Mix mode.

Differential pressure is low between driving component and second component. This alarm is active only during Mix mode.

Differential pressure is high between driving component and second component. This alarm is active only during Mix mode.

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

There is a leak on the second component side.

The second component side pump is cavitating.

There is a leak on the driving component side.

The driving component side pump is cavitating.

There is a leak on the second component side.

The second component side pump is cavitating.

There is a leak on the driving component side.

The driving component side pump is cavitating.

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

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

Check paint supply on the second component side, increase paint supply pressure.

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

Check paint supply on the driving component side, increase paint supply pressure.

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

Check paint supply on the second component side, increase paint supply pressure.

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

Check paint supply on the driving component side, increase paint supply pressure.

88 3A6237A

System Errors

QCA1

QCB1

QCD1

QAC2

QBC2

QDC2

QDA1

QDB1

QDC1

QAD2

QBD2

QCD2

Type Description Problem

Alarm

Differential

Pressure C

Over A

Differential

Pressure C

Over B

Differential pressure is low between driving component and second component. This alarm is active only during Mix mode.

Alarm

Differential

Pressure C

Over D

Differential

Pressure A

Over C

Differential

Pressure B

Over C

Differential

Pressure D

Over C

Differential pressure is high between driving component and second component. This alarm is active only during Mix mode.

Alarm

Alarm

Differential

Pressure D

Over A

Differential

Pressure D

Over B

Differential

Pressure D

Over C

Differential

Pressure A

Over D

Differential

Pressure B

Over D

Differential

Pressure C

Over D

Differential pressure is low between driving component and second component. This alarm is active only during Mix mode.

Differential pressure is high between driving component and second component. This alarm is active only during Mix mode.

There is a leak on the second component side.

The second component side pump is cavitating.

There is a leak on the driving component side.

The driving component side pump is cavitating.

There is a leak on the second component side.

The second component side pump is cavitating.

There is a leak on the driving component side.

The driving component side pump is cavitating.

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

Check paint supply on the second component side, increase paint supply pressure.

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

Check paint supply on the driving component side, increase paint supply pressure.

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

Check paint supply on the second component side, increase paint supply pressure.

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

Check paint supply on the driving component side, increase paint supply pressure.

3A6237A 89

System Errors

EB00

EBIX

EC00

EL00

EM00

EMIX

Type Description Problem

Record

Record

Record

Record

Record

Advisory

EP0X Record

ES00 Advisory

Stop Button

Pressed

Power

Button

Pressed

Setup

Value(s)

Changed

System

Power On

System

Power Off

Pump Off

Auto Pump

Parked

Factory

Defaults

WSN0 Alarm Config Error

Valve Map

Record of a stop button press.

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.

Indicates system stop key on ADM was pressed.

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.

The auto park operation was completed.

n/a

No action required.

n/a n/a n/a

Start pumps by pressing pump start key on Advanced

Display module.

No action required.

Record of pumps being auto parked.

Record of defaults being loaded.

The system requires more color change valves than may be supplied (8x18 = 144)

The settings entered for the system requires too many color change valves.

n/a

Change the system settings to reduce the total number of valves to 144 or less.

90 3A6237A

System Errors

applicable component number, which can vary. The unit’s display will show the applicable number as the last digit in the code. For example, the CAC# code listed in this table will be displayed as CAC1 if the affected component is color change board 1, CAC2 for board 2, and so on.

CA0X

CAC#

CADX

CAGX

CAG#

CANX

CDC#

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Comm. Error

ADM

Comm. Error

Color Change

#

Comm. Error

Fluid Module

Comm. Error

Gateway

Comm. Error

Modbus

Gateway

Comm. Error

Booth Control

Duplicate

Color Change

#

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.

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.

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.

System does not detect the Booth

Control Module.

System detects two or more identical Color

Change Modules.

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

The Modbus CGM is not connected/failed.

This communication error indicates that the network has lost communication with the Booth Control.

More than one Color

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

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 CAN cable connecting the

Booth Control to the network.

Check the system and remove the extra color change module.

3A6237A 91

System Errors

CDDX Alarm

CDNX Alarm

Duplicate

Fluid Module

Duplicate

Booth Control

System sees two or more identical

Enhanced Fluid

Control Modules

EFCM).

System detects two or more identical Booth

Control Modules.

More than one EFCM is connected in the system.

More than one Booth

Control Module is connected in the system.

Check the system and remove the extra

EFCM.

Remove the extra

Booth Control

Module.

92 3A6237A

System Errors

Code Type

EAUX

EBUX

Advisory

Record

USB Busy

USB Drive

Removed

USB drive is inserted, download is in progress.

USB drive was removed while downloading or uploading.

EQU0

EQU1

EQU2

Advisory

Record

Record

USB Idle

USB Sys.

Settings

Downloaded

USB Sys.

Settings

Uploaded

USB download completed, drive may be removed.

Settings were downloaded to USB drive.

Settings were uploaded from USB drive.

EQU3

EQU4

Record

Record

USB Custom

Lang.

Downloaded

USB Custom

Lang.

Uploaded

USB Logs

Downloaded

Custom language was downloaded to USB drive.

Custom language was uploaded from USB drive.

EQU5 Record Data logs were downloaded to USB drive.

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

MMUX Advisory Maint. USB

Logs Full

USB memory is more than 90% full.

WSUX

WXUU

Advisory

Advisory

USB Config.

Err.

WXUD Advisory USB Download

Err.

USB Upload

Err.

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

An error occurred while downloading to the USB drive.

An error occurred while uploading from the USB drive.

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.

Wait for USB Idle.

Replace the USB device and begin process again.

Remove USB device from ADM.

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

Change configuration to enable USB download function.

Complete download to ensure no data is lost.

Reinstall software.

User installed incompatible USB device in ADM USB port.

User installed incompatible USB device in ADM USB port.

Repeat process with compatible USB device.

Repeat process with compatible USB device.

3A6237A 93

System Errors

B9A0

B9AX

B9B0

B9BX

B9C0

B9CX

B9D0

B9DX

B9P#

B9S0

B9SX

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

WX00 Alarm

Volume

Rollover A

Current

Volume

Rollover A

Lifetime

Volume

Rollover B

Current

Volume

Rollover D

Lifetime

Volume

Rollover

Pump #

Volume

Rollover

Solvent

Current

Volume

Rollover

Solvent

Lifetime

Software

Errors

Volume

Rollover B

Lifetime

Volume

Rollover C

Current

Volume

Rollover C

Lifetime

Volume

Rollover D

Current applicable component number, which can vary. The unit’s display will show the applicable number as the last digit in the code. For example, the B9D# code listed in this table will be displayed as B9D1 if the affected component is pump 1, B9D2 for pump 2, and so on.

Batch counter for material A rolled over.

Grand total counter for material A rolled over.

Batch counter for material B rolled over.

Grand total counter for material B rolled over.

Batch counter for material C rolled over.

Grand total counter for material C rolled over.

Batch counter for material D rolled over.

Grand total counter for material D rolled over.

Grand total counter for pump # rolled over.

Batch counter for solvent rolled over.

Grand total counter for solvent rolled over.

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.

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.

An unexpected software error has occurred.

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

Call Graco technical support.

94 3A6237A

System Errors

applicable component number, which can vary. The unit’s display will show the applicable number as the last digit in the code. For example, the ENT# code listed in this table will be displayed as ENT1 if the affected component is pump 1, ENT2 for pump 2, and so on.

END#

ENS0

ENT#

Record

Record

Record

Calibration Pump #

Calibration Solvent Meter

Calibration Stall Test Pump #

A calibration test was run on the pump.

A calibration test was run on the solvent meter.

A stall test was completed successfully on pump #.

3A6237A 95

System Errors

applicable component number, which can vary. For example, the MAD# code listed in this table will be displayed as MAD1 if the affected component is pump 1, MAD2 for pump 2, and so on.

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

For example, code MEDZ represents outlet valve 30.

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

ME#6

ME#7

ME#8

ME#9

ME#A

ME#B

ME#C

ME#2

ME#3

ME#4

ME#5

MAD#

MAT#

MFS0

MGH0

MGP0

ME#1

ME#D

ME#E

ME#F

ME#G

Maint. Outlet Pump #

Maint. Stall Test Pump #

Maint. Meter Solvent

Maint. Filter Fluid

Maint. Filter Air

Maint. Valve CC Module #, Valve

1

Maint. Valve CC Module #, Valve

2

Maint. Valve CC Module #, Valve

3

Maint. Valve CC Module #, Valve

4

Maint. Valve CC Module #, Valve

5

Maint. Valve CC Module #, Valve

6

Maint. Valve CC Module #, Valve

7

Maint. Valve CC Module #, Valve

8

Maint. Valve CC Module #, Valve

9

Maint. Valve CC Module #, Valve

10

Maint. Valve CC Module #, Valve

11

Maint. Valve CC Module #, Valve

12

Maint. Valve CC Module #, Valve

13

Maint. Valve CC Module #, Valve

14

Maint. Valve CC Module #, Valve

15

Maint. Valve CC Module #, Valve

16

Maintenance is due on pump.

Maintenance stall test is due on pump.

Maintenance stall test is due on solvent meter.

Maintenance is due on fluid filter.

Maintenance is due on air filter.

Maintenance is due on color change valve 1 of color change module #.

Maintenance is due on color change valve 2 of color change module #.

Maintenance is due on color change valve 3 of color change module #.

Maintenance is due on color change valve 4 of color change module #.

Maintenance is due on color change valve 5 of color change module #.

Maintenance is due on color change valve 6 of color change module #.

Maintenance is due on color change valve 7 of color change module #.

Maintenance is due on color change valve 8 of color change module #.

Maintenance is due on color change valve 9 of color change module #.

Maintenance is due on color change valve 10 of color change module #.

Maintenance is due on color change valve 11 of color change module #.

Maintenance is due on color change valve 12 of color change module #.

Maintenance is due on color change valve 13 of color change module #.

Maintenance is due on color change valve 14 of color change module #.

Maintenance is due on color change valve 15 of color change module #.

Maintenance is due on color change valve 16 of color change module #.

96 3A6237A

A

B

C

D

E

F

8

9

6

7

3

4

5

1

2

System Errors

ME#H

ME#J

Advisory

Advisory

Maint. Valve CC Module #, Valve

17

Maint. Valve CC Module #, Valve

18

Maintenance is due on color change valve 17 of color change module #.

Maintenance is due on color change valve 18 of color change module #.

10

11

12

13

8

9

6

7

14

15

3

4

5

1

2

N

P

R

L

M

J

K

G

H

W

Y

Z

T

U

V

20

21

22

23

24

16

17

18

19

28

29

30

25

26

27

3A6237A 97

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.

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

• 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.

98 3A6237A

Technical Specifications

Maximum fluid working pressure:

MC0500 Systems with

Low-Pressure Pumps

MC0500 Systems with

High-Pressure Pumps

MC1000 and MC3000 Air

Spray Systems

MC2000 and MC4000

Air-Assisted Spray Systems

Maximum working air pressure:

Air supply:

Air filter inlet size:

Air filtration for air logic

(user-supplied):

Air filtration for atomizing air

(user-supplied):

Mixing ratio range:

Fluids handled:

Viscosity range of fluid:

Fluid filtration (user-supplied):

Maximum fluid flow:

Fluid outlet size:

External power supply requirements:

Operating temperature range:

Storage temperature range:

Weight (approximate):

Sound data:

Wetted parts:

MC0500

300 psi

1500 psi

300 psi

1500 psi

100 psi

85–100 psi

3/8 npt(f)

2.1 MPa, 21 bar

10.5 MPa, 105 bar

2.1 MPa, 21 bar

10.5 MPa, 105 bar

0.7 MPa, 7.0 bar

0.6–0.7 MPa, 6.0–7.0 bar)

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

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

0.1:1 — 100:1, ±1% one or two component:

• solvent and waterborne paints

• polyurethanes

• epoxies

• acid catalyzed varnishes

• moisture sensitive isocyanates

20–5000 centipoise

100 mesh minimum

1600 cc/minute (depending on material viscosity)

1/4 npt(m)

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

15 amp maximum circuit breaker required

8 to 14 AWG power supply wire gauge

36 to 122°F 2 to 50°C

–4 to 158°F

195 lb

–20 to 70°C

88 kg

Less than 75 dB(A)

Pumps sold separately; see selected pump manual for wetted parts information.

3A6237A 99

Technical Specifications

MC1000 and MC2000

MC3000 and MC4000

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

316 SST, 17–4PH SST, PEEK, perfluoroelastomer; PTFE, PPS, UHMWPE

100 3A6237A

Notes

3A6237A 101

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

INCLUDING

FOR

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 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 332562 www.graco.com

Revision A, September 2018

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