Graco 3A4486B, ProMix® PD2K Dual Fluid PanelElectric Proportioner for Automatic Spray Applications Owner's Manual

Operation
ProMix® PD2K Dual Fluid Panel
Electric Proportioner for Automatic
Spray Applications
3A4486B
two--component materials. Automatic system with
Electronic positive displacement proportioner for two
Advanced Display Module. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual and in your PD2K
installation, repair, and associated component manuals. Save these
instructions.
See page 4for model part numbers and
approvals information.
PROVEN QUALITY. LEADING TECHNOLOGY.
EN
Contents
Related Manuals .................................................. 3
Models................................................................. 4
Warnings ............................................................. 6
Important Isocyanate (ISO) Information .................. 9
Important Acid Catalyst Information ..................... 10
General Information ............................................ 11
Advanced Display Module (ADM) ........................ 12
ADM Display................................................ 12
USB Download Procedure ............................ 12
USB Upload Procedure ................................ 13
ADM Keys and Indicators ............................. 14
Soft Key Icons ............................................. 15
Navigating the Screens ................................ 16
Screen Icons ............................................... 16
Pre-Operation Tasks........................................... 17
Pre-operation Checklist ................................ 17
Power On .................................................... 17
Initial System Setup ..................................... 18
Flush Before Using Equipment...................... 18
Valve Settings.............................................. 18
Pressure Relief Procedure .................................. 19
Without Color Change .................................. 19
With Color Change....................................... 19
Operation Using Advanced Display Module
(ADM)................................................... 20
Prime and Fill the System ............................. 20
Pre-Fill the Pump ......................................... 20
Spraying...................................................... 20
Purging ....................................................... 21
Shutdown .................................................... 22
Operation Using a Programmable Logic
Controller (PLC) .................................... 23
Network Communications and Discrete
I/O ................................................. 23
Discrete I/O ................................................. 23
Communication Gateway Module (CGM)
Details ........................................... 26
Network Communication I/O Data Map ........... 27
Operation Flow Charts ................................. 42
Network Communication - Dynamic
Command Structure (DCS) ............. 50
PLC Diagnostic Screens............................... 59
Flow Control System .................................... 60
Run Mode Screens ............................................. 61
Opening Screen........................................... 61
Home Screen .............................................. 61
2
Spray Screen............................................... 64
Fill Screen ................................................... 65
Usage Screen.............................................. 66
Jobs Screen ................................................ 67
Errors Screen .............................................. 67
Events Screen ............................................. 67
Setup Mode Screens .......................................... 68
Password Screen......................................... 68
System Screen 1 ......................................... 68
System Screen 2 ......................................... 69
System Screen 3 ......................................... 70
System Screen 4 ......................................... 71
System Screen 5 ......................................... 72
Gateway Screen .......................................... 73
Recipe Screen ............................................. 74
Flush Screen ............................................... 77
Air/Solvent Chop.......................................... 78
Pump Screen 1 ............................................ 79
Custom Valve Mapping ................................ 80
Pump Screen 2 ............................................ 84
Pump Screen 3 ............................................ 85
Calibration Screens...................................... 86
Maintenance Screens................................... 88
Advanced Screen 1...................................... 90
Advanced Screen 2...................................... 91
Advanced Screen 3...................................... 91
Advanced Screen 4...................................... 92
Diagnostic Screens ...................................... 93
Calibration Checks.............................................. 94
Pump Pressure Check ................................. 94
Pump Volume Check.................................... 95
Solvent Meter Calibration ............................. 95
Color Change ..................................................... 96
Multiple Color Systems................................. 96
System Errors .................................................... 97
On-Screen Help ........................................... 97
To Clear Error and Restart............................ 98
Gun Trigger Input Function ........................... 98
Error Codes ................................................. 99
Maintenance .................................................... 109
Preventive Maintenance Schedule .............. 109
Flushing .................................................... 109
Cleaning the ADM...................................... 109
Appendix A: Integration with Allen Bradley
PLC.................................................... 110
Technical Data ................................................. 113
3A4486B
Related Manuals
Related Manuals
Current manuals are available at www.graco.com.
Manual No.
Description
Manual No.
Description
332709
ProMix PD2K Proportioner for
Automatic Spray Applications,
Repair — Parts
333282
Color Change and Remote Mix
Manifold Kits, Instructions — Parts
332456
332458
ProMix PD2K Proportioner for
Automatic Spray Applications,
Installation
Pump Expansion Kits, Instructions
— Parts
334183
Modbus TCP Gateway Module,
Instructions — Parts
332339
Dosing Pumps, Instructions —
Parts
334494
ProMix PD2K CGM Installation
Kits, Instructions — Parts
332454
Color/Catalyst Dispense Valves,
Instructions — Parts
3A4486B
3
Models
Models
See Figs. 1–6 for component identification labels, including approval information and certification.
Part No.
Series
Maximum Air Working
Pressure
Maximum Fluid Working
Pressure
AC1002
A
100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa,
20.68 bar)
A
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa,
103.4 bar)
AC3002
Acid-based
Material
AC2002
AC4002
Acid-based
Material
0359
Location of PD2K and
Electrical Control Box
(ECB) Labels
II 2 G
®
ProMix PD2K / PD1K
Electronic Proportioner
II 2 G
Ex ia IIA T3
FM13 ATEX 0026
IECEx FMG 13.0011
FM16US0241
FM16CA0129
Intrinsically safe
equipment for Class I,
Div 1, Group D, T3
Ta = 2°C to 50°C
.7
7
100
MPa
bar
PSI
MAX FLUID WPR
2.068 20.68
MPa
bar
300
PSI
MAX TEMP 50°C (122°F)
Artwork No. 294021 Rev. F
MAX AIR WPR
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
MFG. YR.
SERIAL
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
®
ProMix PD2K / PD1K
PART NO. SERIES NO. MFG. YR.
POWER REQUIREMENTS
90-250 ~
AMPS 7 AMPS MAX
Intrinsically safe connections
for Class I, Div 1, Group D
50/60 Hz
Ta = 2°C to 50°C
GRACO INC.
P.O. Box 1441
Install per 16P577
Minneapolis, MN FM16US0241
55440 U.S.A.
FM16CA0129 Um: 250 V
Figure 2 26A188 Control Box Identification Label
4
VOLTS
II (2) G
[Ex ia] IIA Gb
FM13 ATEX 0026
IECEx FMG 13.0011
Artwork No. 294024 Rev. D
Figure 1 Model AC1002 & AC3002 (Low Pressure)
Identification Label
Continued on the next page.
3A4486B
Models
®
ProMix PD2K / PD1K
Electronic Proportioner
II 2 G
Ex ia IIA T3
FM13 ATEX 0026
IECEx FMG 13.0011
FM16US0241
FM16CA0129
Intrinsically safe
equipment for Class I,
Div 1, Group D, T3
Ta = 2°C to 50°C
.7
7
100
MPa
bar
PSI
MAX FLUID WPR
10.34 103.4 1500
MPa
bar
PSI
MAX TEMP 50°C (122°F)
Artwork No. 294022 Rev. F
MAX AIR WPR
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
MFG. YR.
SERIAL
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
Figure 3 Model AC2002 & AC4002 (High Pressure)
Identification Label
Figure 4 Non-Intrinsically Safe Color Change Control (Accessory) Identification Label
ProMix® PD2K / PD1K COLOR CHANGE CONTROL
PART NO.
SERIES
MAX AIR WPR
SERIAL MFG. YR.
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. C
II 2 G
Ex ia IIA T3 Gb
FM13 ATEX 0026
IECEx FMG 13.0011
.7
7
MPa
bar
100
PSI
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
Figure 5 Intrinsically Safe Color Change Control
(Accessory) Identification Label
Figure 6 Pump Expansion Kit (Accessory) Identification Label
PART NO.
DATE / SERIES
RECOGNIZED
COMPONENT
SERIAL NO.
4003764
Conforms to
UL STD 508
Certified to CAN/CSA
STD C22.2 No. 14
Artwork No.
Pending 293656 Rev. D
12-30 VDC
4 AMP MAX
Type 1 ENCL
U.S. Patent
Figure 7 CGM Identification Label
3A4486B
5
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation
point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these
symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard
symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint 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 sparking).
• Ground all equipment in the work area. See Grounding instructions.
• Never spray or flush solvent at high pressure.
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable
fumes are present.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are anti-static or conductive.
• Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment until
you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause
electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
6
3A4486B
Warnings
WARNING
INTRINSIC SAFETY
Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe
equipment will create a hazardous condition and can cause fire, explosion, or electric shock. Follow
local regulations and the following safety requirements.
• Be sure your installation complies with national, state, and local codes for the installation of
electrical apparatus in a Class I, Group D, Division 1 (North America) or Class I, Zones 1 and 2
(Europe) Hazardous Location, including all of the local safety fire codes (for example, NFPA 33,
NEC 500 and 516, OSHA 1910.107, etc.).
• To help prevent fire and explosion:
• Do not install equipment approved only for a non-hazardous location in a hazardous location.
See model ID label for the intrinsic safety rating of your model.
• Do not substitute system components as this may impair intrinsic safety.
• Equipment that comes in contact with the intrinsically safe terminals must be rated for Intrinsic
Safety. This includes DC voltage meters, ohmmeters, cables, and connections. Remove the unit
from the hazardous area when troubleshooting.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin.
This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate
surgical treatment.
•
•
•
•
Do not point dispensing device at anyone or at any part of the body.
Do not put your hand over the fluid outlet.
Do not stop or deflect leaks with your hand, body, glove, or rag.
Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure and disconnect all power sources.
TOXIC FLUID OR FUMES
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.
3A4486B
7
Warnings
WARNING
PERSONAL PROTECTIVE EQUIPMENT
Always wear appropriate personal protective equipment and cover all skin when spraying, servicing
equipment, or when in the work area. Protective equipment helps prevent serious injury, including
long-term exposure; inhalation of toxic fumes, mists or vapors; allergic reaction; burns; eye injury and
hearing loss. This protective equipment includes but is not limited to:
• A properly fitting respirator, which may include a supplied-air respirator, chemically impermeable
gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local
regulatory authority.
• Protective eyewear and hearing protection.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and
create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
8
3A4486B
Important Isocyanate (ISO) Information
Important Isocyanate (ISO) Information
Isocyanates (ISO) are catalysts used in two
component materials.
Isocyanate Conditions
Moisture Sensitivity of Isocyanates
Exposure to moisture (such as humidity) will cause
ISO to partially cure; forming small, hard, abrasive
crystals, which become suspended in the fluid.
Eventually a film will form on the surface and the ISO
will begin to gel, increasing in viscosity.
NOTICE
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.
Keep Components A and B Separate
Partially cured ISO will reduce performance and
the life of all wetted parts.
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere.
Never store ISO in an open container.
• Keep the ISO pump wet cup or reservoir (if
installed) filled with appropriate lubricant. The
lubricant creates a barrier between the ISO and
the atmosphere.
• Use only moisture-proof hoses compatible with
ISO.
• Never use reclaimed solvents, which may
contain moisture. Always keep solvent
containers closed when not in use.
• Always lubricate threaded parts with an
appropriate lubricant when reassembling.
NOTE: The amount of film formation and rate of
crystallization varies depending on the blend of ISO,
the humidity, and the temperature.
Changing Materials
NOTICE
Changing the material types used in your
equipment requires special attention to avoid
equipment damage and downtime.
• When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.
• Always clean the fluid inlet strainers after
flushing.
• Check with your material manufacturer for
chemical compatibility.
• When changing between epoxies and urethanes
or polyureas, disassemble and clean all fluid
components and change hoses. Epoxies often
have amines on the B (hardener) side. Polyureas
often have amines on the A (resin) side.
Cross-contamination can result in cured
material in fluid lines which could cause serious
injury or damage equipment. To prevent
cross-contamination:
• Never interchange component A and component
B wetted parts.
• Never use solvent on one side if it has been
contaminated from the other side.
3A4486B
9
Important Acid Catalyst Information
Important Acid Catalyst Information
The PD2K AC4002 Proportioner is designed for acid catalysts (“acid”) currently used in two-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 Catalyst Conditions
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.
Moisture Sensitivity of Acid Catalysts
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.
NOTICE
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.
10
3A4486B
General Information
General Information
• Reference numbers and letters in parentheses
in the text refer to numbers and letters in the
illustrations.
• Be sure all accessories are adequately sized and
pressure-rated to meet system requirements.
3A4486B
• To protect the screens from paints and solvents,
clear-plastic protective shields (10 per pack) are
available. Order Part No. 197902 for the Advanced
Display Module. Clean the screens with a dry cloth
if necessary.
11
Advanced Display Module (ADM)
Advanced Display Module (ADM)
ADM Display
USB Download Procedure
The ADM display shows graphical and text
information related to setup and spray operations.
Use the USB port on the ADM to download or upload
data.
For detail on the display and individual
screens, see Run Mode Screens, page 61, or
Setup Mode Screens, page 68.
1. Enable USB downloads. See
Advanced Screen 3, page 91.
Keys are used to input numerical data, enter setup
screens, navigate within a screen, scroll through
screens, and select setup values.
NOTICE
To prevent damage to the softkey buttons, do not
press the buttons with sharp objects such as pens,
plastic cards, or fingernails.
2. Remove the cover from the USB port on the
bottom of the ADM. Insert the USB drive.
3. During the download, USB BUSY appears on the
screen.
4. When the download is complete, USB IDLE
appears on the screen. The USB drive may then
be removed.
NOTE: If the download operation takes longer
than 60 seconds, the message disappears. To
determine if the USB is busy or idle, check the
Error Status bar on the screen. If idle, remove
the USB.
5. Insert the USB flash drive into the USB port of
the computer.
6. The USB flash drive window automatically opens.
If it does not, open the USB flash drive from
within Windows® Explorer.
7. Open Graco folder.
1
2
3
4
5
6
7
8
9
0
.
Figure 8 Advanced Display Module
8. Open system folder. If downloading data from
more than one system, there will be more than
one folder. Each folder is labeled with the
corresponding serial number of the ADM. (The
serial number is on the back of the ADM.)
9. Open DOWNLOAD folder.
10. Open LOG FILES folder labeled with the highest
number. The highest number indicates the most
recent data download.
11. Open log file. Log files open in Microsoft®
Excel® by default if the program is installed.
They also can be opened in any text editor of
Microsoft® Word.
NOTE: All USB logs are saved in Unicode
(UTF-16) format. If opening the log file in
Microsoft Word, select Unicode encoding.
12. Always reinstall the USB cover after removing
the USB, to keep the drive free of dirt and dust.
12
3A4486B
Advanced Display Module (ADM)
USB Upload Procedure
Use this procedure to install a system configuration
file and/or a custom language file.
7. If installing the custom language file, place
DISPTEXT.TXT file into UPLOAD folder.
1. If necessary, follow the USB Download
Procedure, to automatically generate the proper
folder structure on the USB flash drive.
8. Remove the USB flash drive from the computer.
2. Insert the USB flash drive into the USB port of
the computer.
10. During the upload, USB BUSY displays on the
screen.
3. The USB flash drive window automatically opens.
If it does not, open the USB flash drive from
within Windows Explorer.
11. Remove the USB flash drive from the USB port.
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.)
9. Install the USB flash drive into the USB port of
the ProMix PD2K system USB port.
NOTE: If the custom language file was installed,
users can now select the new language from the
Language drop-down menu in the Advanced Setup
Screen 1.
NOTE: If the system configuration settings file was
installed, it is recommended to remove the file from
the UPLOAD folder on the USB flash drive. This will
prevent inadvertently overwriting any future setup
changes.
6. If installing the system configuration settings file,
place SETTINGS.TXT file into UPLOAD folder.
3A4486B
13
Advanced Display Module (ADM)
ADM Keys and Indicators
NOTICE
To prevent damage to the softkey buttons, do not
press the buttons with sharp objects such as pens,
plastic cards, or fingernails.
Table 1 : ADM Keys and Indicators
Key
Function
Press to startup or shutdown the pump/motor.
• Solid green indicates that power is applied to the motor.
Startup/Shutdown
Key and Indicator
• Solid yellow indicates that power to the motor is off.
• Blinking green or yellow indicates that the system is in Setup mode.
Press to immediately stop the system and remove motor power.
Stop
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.
Soft Keys
• Left/Right Arrows: Use to move from screen to screen.
• Up/Down Arrows: Use to move among fields on a screen, items on a dropdown menu, or
multiple screens within a function. Also used to toggle between Mix Units on Home Screen.
Navigation Keys
Numeric Keypad
Use to input values. See ADM Display, page 12.
Use to cancel a data entry field.
Cancel
Press to enter or exit Setup mode.
Setup
Press to choose a field to update, to make a selection, to save a selection or value, to
enter a screen, or to acknowledge an event.
Enter
14
3A4486B
Advanced Display Module (ADM)
Soft Key Icons
The following icons appear in the ADM display,
directly to the left or right of the soft key which
activates that operation.
Key
Function
NOTICE
To prevent damage to the softkey buttons, do not
press the buttons with sharp objects such as pens,
plastic cards, or fingernails.
Table 2 : Soft Key Functions
Key
Standby
Stop
Press to link recipe data
for a specific recipe on
both Mix Units.
Function
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 stop all pumps
and put system in
Standby.
Recipe Link
Press to start a pump
pressure check.
Pressure Check
Press to start a pump
volume check.
Press to exit screen
after editing.
Volume Check
Exit Screen
Press to accept
calibration value.
Pressure Relief
Accept
Press to cancel or reject
calibration value.
Press to log the material
usage and increment
the job number, for Mix
Unit #1 or Mix Unit #2.
Cancel
Press to switch between
Mix Units on the Spray
and Fill screens.
Appears on the
Maintenance screen to
relieve pump pressure
out the color change
dump valve.
Job Complete
Toggle
Press to reset the
current usage counter.
Press to start a pump
priming procedure.
Counter Reset
Prime Pump
Press to mark pump
as filled. (Only for
applicable pumps.)
Move Cursor to Left
Appears on the User ID
Keyboard screen. Use
to move cursor to the
left.
Move Cursor to Right
Appears on the User ID
Keyboard screen. Use
to move cursor to the
right.
Pre-Fill Pump
Press to start a line fill
procedure.
Line/Fill/Run
Appears on the User ID
Keyboard screen. Use
to erase all characters.
Press to start a spray
procedure.
Erase All
Mix
Press to start a purge
procedure.
Backspace
Appears on the User ID
Keyboard screen. Use
to erase one character
at a time.
Purge
3A4486B
15
Advanced Display Module (ADM)
Key
Function
Screen Icons
Appears on the User
ID Keyboard screen.
Use to change case
(upper/lower).
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.
Upper Case/Lower
Case
Screen Icons
Press to get more
information on active
system error.
User ID
Job Number
Info
Press to see
troubleshooting
information for system
error.
Potlife
Target Ratio
Recipe Number
Flow Rate
Pressure
Volume
Troubleshooting
Press to see QR Code
for system error.
Material B
QR Code
Material A
Navigating the Screens
Material A+B
Solvent
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.
on any Run screen to enter the Setup
Press
screens. If the system has a password lock, the
Password screen displays. If the system is not locked
(password is set to 0000), System Screen 1 displays.
Calendar
Time
Alarm/Advisory
Deviation
Mix Unit
Press
on any Setup screen to return to the
Home screen.
Press the Enter soft key
function on any screen.
Press the Exit soft key
to activate the editing
to exit any screen.
Use the other softkeys to select the function adjacent
to them.
16
3A4486B
Pre-Operation Tasks
Pre--Operation Tasks
Pre
Pre--operation Checklist
Pre
Power On
Go through the Pre-Operation Checklist daily, before
each use.
1. Turn the AC Power Switch (P) ON (I = ON,
0 = OFF).
✔
Checklist
2. The Graco logo will display while the system
initializes, followed by the Home screen.
System grounded
Verify all grounding connections
were made. See Grounding in the
Installation manual.
3. Press the Start key
Power pop-up screen.
to display the Pump
All connections tight and correct
Verify all electrical, fluid, air, and
system connections are tight and
installed according to the Installation
manual.
Fluid supply containers filled
Check component A and B and
solvent supply containers.
Dose valves set
Check that dose valves are set
1–1/4 turns open. Start with
the settings recommended in
Valve Settings, page 18, then adjust
as needed.
Fluid supply valves open and
pressure set
The recommended component A and
B fluid supply pressures are 1/2 to 2/3
of the target spray pressure.
The softkey options allow for powering a specific
Mix Unit, or both at the same time. The system
status will change from “System Off” to “Startup.”
Once the pumps are powered and are in the
Home position, the system status will change
from “Startup” to “Standby.”
NOTE: Low pressure systems may
be set within a range of ± 100 psi (0.7
MPa, 7 bar); high pressure systems
may be set within a range of ± 300 psi
(2.1 MPa, 21 bar). If the inlet pressure
is higher than the outlet pressure,
ratio accuracy may be affected.
Solenoid pressure set
85-100 psi inlet air supply (0.6-0.7
MPa, 6-7 bar).
Figure 9 Power Switch
3A4486B
17
Pre-Operation Tasks
Initial System Setup
Valve Settings
1. Change optional setup selections to
desired parameters, as described in
Setup Mode Screens, page 68.
Dose valves and purge valves are factory set with the
hex nut (E) 1-1/4 turns out from fully closed.
2. Set recipe and flush information as
described in Recipe Screen, page 74,
and Flush Screen, page 77.
Flush Before Using Equipment
The pump fluid section was tested with lightweight
oil, which is left in the fluid passages to protect parts.
To avoid contaminating your fluid with oil, flush the
equipment with a compatible solvent before using
the equipment.
18
Figure 10 Valve Adjustment
3A4486B
Pressure Relief Procedure
Pressure Relief Procedure
With Color Change
Follow the Pressure Relief Procedure
whenever you see this symbol.
NOTE: The following procedure relieves all fluid and
air pressure in the system.
1. Turn off the supply pumps. Open the drain valve
on the supply line fluid filter to relieve pressure in
the supply lines. Do this for each color.
2.
This equipment stays pressurized until pressure
is manually relieved. To help prevent serious
injury from pressurized fluid, such as skin injection,
splashing fluid and moving parts, follow the
Pressure Relief Procedure when you stop spraying
and before cleaning, checking, or servicing the
equipment.
Without Color Change
NOTE: The following procedure relieves all fluid and
air pressure in the system. Use your control interface
to issue the necessary commands to your system.
1. Turn off the supply pumps. Open the drain valve
on the supply line fluid filter to relieve pressure
in the supply line.
2. Command Mix Unit #1 to Standby. From
Maintenance Screen 4 on the ADM, check the
box in the field labeled Gun for the color or
catalyst in the pump. Trigger the spray device to
relieve pressure. Repeat for each pump.
3. Flush the remote mix manifold and spray device.
See Flush Mixed Material, page 21.
4. Shut off the solvent supply pump. To relieve
pressure, command Mix Unit #1 to Purge and
trigger the spray device. When the pressure is
relieved, command Mix Unit #1 to Standby to
avoid getting a Purge Incomplete alarm.
To help prevent fire and explosion, shut off
electrostatics before flushing.
If using an electrostatic gun, shut off the
electrostatics before flushing the gun.
3. Trigger the gun to relieve pressure. From
Maintenance Screen 5on the ADM, check the box
in the field labeled Gun for each color used with
Mix Unit #1, to manually open each color valve.
4. Set the system to Recipe 0 to flush the pumps
and to purge to the spray device. Hold the gun
trigger open after the solvent valve shuts off to
relieve all pressure. When flushing is complete
Mix Unit #1 will go to Standby.
5. Shut off the solvent supply pump. Set Mix Unit
#1 to Recipe 0 to flush solvent from the pumps
and to purge to the spray device. Command Mix
Unit #1 to Standby after just a couple of seconds,
to avoid getting a Purge Incomplete alarm.
6. If pressure remains in the solvent line between
the solvent supply pump and the solvent valve:
• VERY SLOWLY loosen a fitting to relieve
pressure gradually.
• Loosen the fitting completely.
7. Verify on the ADM Home Screen that neither
pump 1 nor 2 is showing any pressure.
8. Repeat for Mix Unit #2 and pumps 3 and 4.
5. If pressure remains in the solvent line between
the solvent supply pump and the solvent valve:
• VERY SLOWLY loosen a fitting to relieve
pressure gradually.
• Loosen the fitting completely.
6. Repeat for Mix Unit #2
3A4486B
19
Operation Using Advanced Display Module (ADM)
Operation Using Advanced Display Module (ADM)
Prime and Fill the System
Pre--Fill the Pump
Pre
NOTE: See Run Mode Screens, page 61, for further
screen information, if needed.
NOTE: This option is only available for pumps that
have color change valves and only a single material.
NOTE: You must prime the input lines to the pumps
or the inputs to the color change valves before
priming the pump and filling the entire system.
If a pump is filled with a material when the system
is powered down, this will allow the user to change
the pump’s contents, without flushing the pump, the
next time power is restored.
1. Enable the manual override on
System Screen 1, page 68.
2. Go to the Fill Screen, page 65.
1. If using an electrostatic gun, shut off the
electrostatics before filling the lines.
2. Adjust the main air pressure. To ensure proper
operation, set the main air pressure as close to
100 psi (0.7 MPa, 7.0 bar) as possible. Do not
use less than 85 psi (0.6 MPa, 6.0 bar).
3. If this is the first time starting up the system, or if
lines may contain air, purge as instructed under
Flush the System, page 21. The equipment
was tested with lightweight oil, which should be
flushed out to avoid contaminating your material.
4. If the system is powered down, press
on the ADM to bring up the Pump Power pop-up
screen and, using the softkeys, turn on power to
a specific Mix Unit or both. Make sure that the
system is in Standby mode.
5. Verify that the recipes and the flush sequences
are programmed correctly by checking
the Recipe Screen, page 74, and the
Flush Screen, page 77.
6. Enable the manual override on System Screen 1.
7. Go to the Fill Screen, page 65.
8. Select the desired color to load. Press the Prime
Pump key
. The color will load the pump
through the color stack and out the outlet stack
dump valve.
NOTE: In a single color system, step 8 can be
skipped..
to run color out to
9. Press the Fill Line key
the remote mix manifold. The pump will run until
you press the Stop key
to stop the pump.
10. Trigger the gun into a grounded reservoir or
purge receptacle until the line is full, then press
the Stop key
.
11. Repeat for all material lines.
20
. The pump
3. Press the Pre-Fill Pump key
will change from material 61 to the proper color
or catalyst.
Spraying
To spray in a multiple color system, also see
Multiple Color Systems, page 96.
NOTE: See Run Mode Screens, page 61, for further
screen information, if needed.
1. Command a Mix Unit to Mix. The system will
load the correct mixed material volume.
NOTE: The Mix Unit will automatically run a Mix
Fill if the recipe is not currently loaded into the
system. The Mix Fill volume calculation includes
the remote mix manifold volume and the mixed
material hose volume. The mixed material hose
volume is determined by the gun hose length and
diameter entered in System Screen 3, page 70,
and the remote-to-mix hose length and diameter
also entered in System Screen 3, page 70.
2. Adjust the flow rate by changing the target
pressure (in Pressure Mode) or the target flow
rate (in Flow Mode) on the Spray Screen or
through the PLC. The fluid flow rate shown on the
Spray screen is the combined total of component
A and B out of the spray device.
3. Turn on atomizing air to the spray device. Check
the spray pattern as instructed in your spray
device manual.
NOTICE
Do not allow a fluid supply tank to run empty.
This can damage the pumps and lead to the
proportioning of fluid and air that meets the ratio
and tolerance settings of the equipment. This can
further result in spraying uncatalyzed or poorly
catalyzed material.
3A4486B
Operation Using Advanced Display Module (ADM)
Purging
To purge one color and fill with a new color, see
Color Change, page 96.
Flush the System
Flush Mixed Material
To avoid fire and explosion, always ground
equipment and waste container. To avoid static
sparking and injury from splashing, always flush at
the lowest possible pressure.
There are times when you only want to purge the
remote mix manifold and the spray device, such as:
•
•
•
•
end of potlife
breaks in spraying that exceed the potlife
overnight shutdown or end of shift
before servicing the remote mix manifold, hose or
gun.
1. Command the Mix Unit to Standby.
2. If you are using a high pressure spray device or
an electrostatic gun, shut off the atomizing air.
3.
To reduce the risk fire and explosion, shut off
electrostatics before flushing the gun.
If using an electrostatic gun, shut off the
electrostatics before flushing the gun.
4. Command the Mix Unit to Purge A,
Purge B, or Recipe Purge. (See
Purge Mode Sequence, page 42.) Trigger the
spray device into a grounded metal pail until
the purge sequence is complete. When done
purging, the Mix Unit automatically switches to
Standby mode, signalling the spray device to
stop spraying.
5. If the Mix Unit is not completely clean, repeat
Step 5.
NOTE: For optimal efficiency, adjust purge
sequence times so only one cycle is required.
NOTE: The remote mix manifold and gun remain full
of solvent after purging.
3A4486B
To avoid fire and explosion, always ground
equipment and waste container. To avoid static
sparking and injury from splashing, always flush at
the lowest possible pressure.
Follow this procedure before:
• the first time material is loaded into the equipment
• servicing
• shutting down equipment for an extended period
of time
• putting equipment into storage
Single Color System
1. Relieve the pressure. See
Pressure Relief Procedure, page 19.
2. Disconnect the color and catalyst supply lines
from the pump inlet manifolds, and connect
regulated solvent supply lines.
3. Set the solvent supply pressure regulator at the
lowest pressure possible. Generally a setting
of 25–50 psi (0.18–0.35 MPa, 1.8–3.5 bar) is
sufficient.
4. Enable manual override on
System Screen 1, page 68.
5. On the ADM, go to the Fill screen for Mix Unit
#1. Set the Material to Color (A). Press
.
The system will pump solvent through pump A
all the way to the gun.
6. Hold a metal part of the spray device firmly to a
grounded metal pail. Trigger the spray device
until clean solvent dispenses.
7. On the ADM, go to the Fill screen for Mix Unit
#1. Set the Material to Catalyst (B). Press
.
The system will pump solvent through pump B
all the way to the gun.
8. Relieve the pressure. See
Pressure Relief Procedure, page 19
9. Repeat for Mix Unit #2.
21
Operation Using Advanced Display Module (ADM)
Color Change System
1. Relieve the pressure. See
Pressure Relief Procedure, page 19.
2. Attach regulated solvent supply lines as follows:
• Multiple color/single catalyst system: On the
color side, do not disconnect the color supply
line from the inlet manifold of Pump A. Instead,
connect a regulated solvent supply line to the
designated solvent valve on the color valve
manifold. On the catalyst side, disconnect
the catalyst supply line from the inlet manifold
of Pump B, and connect a regulated solvent
supply line.
• Multiple color/multiple catalyst system:
Connect regulated solvent supply lines to
the designated solvent valves on the color
and catalyst valve manifolds. Do not connect
solvent supply lines directly to the inlet
manifolds of the pumps.
3. Set the solvent supply pressure regulator at the
lowest pressure possible. Generally a setting
of 25–50 psi (0.18–0.35 MPa, 1.8–3.5 bar) is
sufficient.
8. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger the gun until clean solvent
dispenses.
9. Repeat for each color line.
10. Relieve the pressure. See
Pressure Relief Procedure, page 19
11. Repeat for Mix Unit #2.
Shutdown
1. Flush out the mixed material to avoid potlife errors
and fluid setup in the lines. See Purging, page 21.
2. Follow the Pressure Relief Procedure, page 19.
3. Close the main air shutoff valve on the air supply
line and on the control box.
on the Display Module to turn off
4. Press
power to the pumps to display the following
pop-up screen. Make sure that the system is in
Standby mode.
4. On the ADM, go to the Fill screen for Mix Unit
#1. Select Color (A). Enter the color number in
the box to the right.
5. Select the Flush Line box.
6. If the solvent is not already loaded, press the
. The Mix Unit will prime
Prime softkey
solvent into the selected pump and out the outlet
dump valve.
. The Mix Unit will
7. Press the Fill softkey
flush the selected Color (A) line with the solvent
until the user presses Stop
22
.
5. Select either Mix Unit, or both, to power off.
6. Shut off system power (0 position).
3A4486B
Operation Using a Programmable Logic Controller (PLC)
Operation Using a Programmable Logic Controller (PLC)
Network Communications and
Discrete I/O
The ProMix PD2K Automatic system does not use
a Booth Control module. Instead, it uses Network
Communications and has optional Discrete I/O
features to drive the system remotely.
Some automation control elements of the
ProMix PD2K can be driven by a discrete
input or network communications. These
options need to be configured at the ADM (see
Gateway Screen, page 73). The following features
can be set to ‘Discrete’ or ‘Network’:
• Flow Control – Means of adjusting the control set
point (see Flow Control Set Point below).
• Gun Trigger – Means of signaling the ProMix PD2K
when the spray device is triggered.
NOTE: The Manual Override check box on System
Screen 1 enables a user to operate the system
before the automation (PLC) is available. Manual
Override can be used to run all functions of the
system if a proper gun trigger signal is provided. It is
not intended to be the main mode of control. Graco
recommends that Manual Override be disabled
during normal operation to avoid driving the system
in a way that conflicts with the automation sequence.
3A4486B
Discrete I/O
The ProMix PD2K does not supply power for
Discrete I/O. A clear understanding of these inputs
is necessary to properly integrate the ProMix PD2K
with the PLC or networking device. Input and output
connections are made at the Discrete I/O terminal
strips on the Enhanced Fluid Control Module (EFCM)
inside the control box.
Table 3 and Figure 12 show where discrete I/O
connections are made on the ProMix PD2K.
Table 3 PD2K Discrete I/O Connections
I/O
Description
EFCM
Connector
Pins
Type
Gun Trigger
#1 Input
6
1,2
Normally Open
Contact
Gun Trigger
#2 Input
6
3.4
Normally Open
Contact
Control Set
Point #1
7
1,2
4-20 mA Input
Control Set
Point #2
7
3.4
4-20 mA Input
Safety
Interlock
Input
5
10,11
Normally Open
Contact
23
Operation Using a Programmable Logic Controller (PLC)
Digital Inputs
Analog Inputs
Interlock: This normally open contact works
• Safety Interlock
like a soft emergency stop button. If the ProMix
PD2K reads the input as CLOSED it interrupts
system operation and removes power from the
pumps regardless of the current operating mode.
If the input is read as OPEN, the system operates
normally
#2: When enabled,
Flow Control Set Point #1 and #2
these 4-20 mA signal inputs are used to set and
adjust the operating flow control set point for each
Mix Unit. The ProMix PD2K scales the set point
linearly from 0 to the Max Set Point setting (see
System Screen 4, page 71). Examples,
NOTE: This digital input is always enabled.
Do not toggle this input to put the system into
Standby mode.
#2: These normally open
• Gun Trigger #1 and #2
(maintained) contacts provide a signal to the Mix
Units to indicate whether or not a spray device is
triggered. These inputs provide timing for alarm
functions and also drives the flow control algorithm.
If an input is OPEN the Mix Unit operates as
though the spray device is off. The input must
be maintained CLOSED to signal that the spray
device is triggered.
• In Flow Control Mode: If the Max Set Point is 500
cc/min, a 4mA signal is 0 cc/min and a 20mA signal
is 500 cc/min.
• In Pressure Control Mode: If the Max Set Point is
500 psi, a 4mA signal is 0 psi and a 20mA signal
is 500 psi.
NOTE: The Flow Control discrete inputs must be
enabled individually via System Screen 4, page 71,
on the ADM. If set to ‘Network’ the discrete input is
ignored and set point adjustment is handled via the
network communications.
NOTE: The Gun Trigger discrete inputs must be
enabled individually via System Screen 4, page 71,
on the ADM. If it is set to ‘Network’ the discrete
input is ignored and the spray device trigger signal
is handled via the network communications.
If enabled, it is imperative that this signal be sent
any time the spray device is triggered. Without the
signal, the flow control features will not work.
4–20 mA Flow Control Set Point Input
Figure 11
PLC (4–20 mA Signal) Mix Unit #2
PLC (4–20 mA Signal) Mix Unit #1
PD2K Discrete Input
24
O = Output
R = Return
3A4486B
Operation Using a Programmable Logic Controller (PLC)
Discrete I/O Connections on EFCM
Figure 12
KEY
A1
Gun Trigger Input #1
A2
Gun Trigger Input #2
B1
Analog Set Point Input #1
B2
Analog Set Point Input #2
C1
Safety Interlock Input
3A4486B
25
Operation Using a Programmable Logic Controller (PLC)
Communication Gateway Module (CGM) Details
CGM Overview
CGM
Installation Kit
Part No.
Field Bus
Manual
24W829
DeviceNet
EtherNet/IP
Modbus TCP
334494
25D997
PROFINET
334494
312864
The PD2K system does not come with a CGM; it
must be purchased separately. The available CGM
field bus protocols are listed in the tables.
CGM Part No.
Fieldbus
Manual
CGMDN0
DeviceNet
312864
NOTE: The CGM Installation kit is also required for
DeviceNet, EtherNet/IP, and Modbus TCP protocols.
PROFINET protocol calls for two CGM modules with
the PD2K Dual Panel application. The PROFINET kit
consolidates all installation hardware as well as the
two CGM modules into a single part number.
CGMEP0
EtherNet/IP
312864
24W462
Modbus TCP
334183
The CGM provides a control link between the PD2K
system and a selected fieldbus. This linkage provides
the means for remote monitoring and control by
external automation systems.
CGM Kits
26
3A4486B
Operation Using a Programmable Logic Controller (PLC)
Network Communication I/O Data Map
The PD2K has PLC Diagnostic Screens built into the software that assist in the system integration process. See
Setup Mode Screens, page 68.
NOTE: The PD2K Dual Panel system has identical network register blocks for the two Mix Units. All registers are
shown with indices for Mix Unit #1 and Mix Unit #2, respectively.
ProMix PD2K Network Outputs
The ProMix PD2K Network Outputs are Read-Only and should be treated as inputs to a PLC or other networking
device. These registers provide various system and component status, measurement, and set point values. See
Network Output Data Map (Read Only), page 31.
OUTPUT REGISTER 00 and 26: Current System Mode
The Current System Mode register contains a number that indicates the current operation mode of the PD2K system.
Number
Operation Mode
Description
1
Pump Off
The pumps are currently powered down
and the Mix Unit is not in operation.
2
Recipe Change
The Mix Unit is in the process of a color
change sequence.
3
Recipe Change: Purge A
The Mix Unit is purging material A as part
of a recipe change.
4
Recipe Change: Purge B
The Mix Unit is purging material B as part
of a recipe change.
5
Recipe Change: Fill
The Mix Unit is filling the hose from the
remote valves to the mix manifold with
material as part of a recipe change.
6
Mix Fill
The Mix Unit is mixing material at ratio
through the mix manifold and out the gun.
7
Mix
The Mix Unit is currently mixing/spraying
material.
8
Mix Idle
The Mix Unit has paused mix operation
due to the absence of a gun trigger signal.
9
Purge A
The Mix Unit is purging material A while
in Standby.
10
Purge B
The Mix Unit is purging material B while
in Standby.
11
Standby: Mix Ready
The Mix Unit has a valid recipe loaded
out to the gun.
12
Standby: Fill Ready
The Mix Unit has a valid recipe loaded in
the pumps, but not in the gun.
13
Standby: Mix Not Ready
The Mix Unit requires that a recipe
change operation be completed.
14
Standby: Alarm
The Mix Unit has an active alarm.
15
Line Filling/Flushing
The Mix Unit is filling/flushing a color
change hose between the outlet valves
and remote valves.
16
Pump Prime/Flush
The Mix Unit is priming/flushing one of
the pumps.
17
Maintenance/Calibration
The Mix Unit is currently performing a
calibration or maintenance procedure.
3A4486B
27
Operation Using a Programmable Logic Controller (PLC)
OUTPUT REGISTER 01 and 27: Event Flag
The Event Flag register provides indication when an
event (Alarm or Deviation) has occurred that requires
user acknowledgement.
• The value will be 0 if there are no events requiring
acknowledgement.
• The value will be 1 if there is at least one event
needing acknowledgement.
OUTPUT REGISTER 02 and 28: Actual Mix
Flow/Pressure
The Actual Mix Flow/Pressure register reports back
the instantaneous mixing flow rate in cc/min or mixing
pressure in PSI. This register is primarily used to
reflect that the Mix Unit is on it’s target fluid control
set point. See INPUT REGISTER 03 and 13: Mix
Control Set Point, page 36 .
This data register is valid only for systems configured
to use the discrete inputs for the Gun Triggers. See
Gun Trigger Signal, page 71.
OUTPUT REGISTERS 06:
OUTPUT REGISTERS 07:
OUTPUT REGISTERS 32:
OUTPUT REGISTERS 33:
Pump 1 Status
Pump 2 Status
Pump 3 Status
Pump 4 Status
The Pump Status registers contain a number that
indicates the state of Pumps 1 – 4. This status can be
used for general monitoring of the pump state, or as
an indicator for driving independent pump operations.
See INPUT REGISTER 06 and 16: Flush/Prime
Pump Command, page 37.
Table 4 Pump States for Output Registers 06, 07,
32, and 33
Number
Pump State
Description
0
Off
The pump is powered
down or not enabled.
OUTPUT REGISTER 03 and 29: Actual Mix
Ratio
1
Standby
The pump is powered
but not currently
active.
The Actual Mix Ratio register contains the
instantaneous calculated mix ratio.
2
Busy
The pump is currently
in a recipe change or
mixing operation.
3
Flushing
The pump is currently
flushing with solvent
4
Priming
The pump is currently
priming with material.
NOTE: This register is valid only during a mix
operation.
• The value reported is the ratio antecedent
multiplied by 100. The ratio consequent is
always 1.
Example: Value = 250 >> A mix ratio of 2.5:1
(Material A to Material B)
• If the current recipe ratio is 0:1 (1K recipe) this
value will be 0.
This register is valid only during a mix operation.
OUTPUT REGISTER 04 and 30: Actual Mix
Potlife Remaining
The Actual Potlife Remaining register contains
the current amount of time remaining in the active
recipe’s potlife in seconds.
NOTE: If potlife is disabled for the active recipe or at
initial startup this value will be 0xFFFFFFFF.
OUTPUT REGISTER 05: Gun 1 Trigger
Input Status
OUTPUT REGISTER 31: Gun 2 Trigger
Input Status
OUTPUT REGISTER 08:
OUTPUT REGISTER 09:
OUTPUT REGISTER 34:
OUTPUT REGISTER 35:
Pump 1 Material
Pump 2 Material
Pump 3 Material
Pump 4 Material
The Pump Material register values indicate what
material is currently loaded in each pump.
• Colors are numbered 1 – 32.
• Catalysts are numbered 33 – 40.
• The value is 0 if the pump is filled with solvent.
• The value is 61 if the material is unknown, such as
initial startup.
The Gun Trigger Input Status registers contain the
status of the Gun Trigger Discrete Inputs.
• The value is 0 if the input is OPEN (gun not
triggered).
• The value is 1 if the input is CLOSED (gun
triggered).
28
3A4486B
Operation Using a Programmable Logic Controller (PLC)
OUTPUT REGISTER 10:
Flow Rate
OUTPUT REGISTER 11:
Flow Rate
OUTPUT REGISTER 36:
Flow Rate
OUTPUT REGISTER 37:
Flow Rate
Actual Pump 1
Actual Pump 2
Actual Pump 3
Actual Pump 4
These registers contain the instantaneous flow rate
of Pumps 1–4 in cc/min.
This is NOT the mix flow rate. For mix flow rate see
Actual Mix Flow.
OUTPUT REGISTER 12:
Fluid Pressure
OUTPUT REGISTER 13:
Fluid Pressure
OUTPUT REGISTER 38:
Fluid Pressure
OUTPUT REGISTER 39:
Fluid Pressure
Actual Pump 1
Actual Pump 2
Actual Pump 3
Actual Pump 4
These registers contain the instantaneous fluid
pressure on the outlet of pumps 1–4 in PSI.
OUTPUT REGISTER 14 and 40: Active
Recipe Number
OUTPUT REGISTER 16 and 42: Active
Recipe Material B
The Active Recipe Material B data register contains
the number of the Catalyst (33 – 40) that is associated
with the current recipe.
• This value is 0 if the Mix Unit was flushed.
• This value is 61 if the current recipe is invalid or at
initial startup.
• This value is 0 if the current recipe ratio is 0:1 (1K
recipe).
OUTPUT REGISTER 17 and 43: Active
Recipe Material A Flush Sequence
The Active Recipe Material A Flush Sequence
register contains the number of the Flush Sequence
(1 – 5) that is associated with the Color pump of the
current recipe.
If the current recipe is invalid this value reflects the
Flush Sequence associated with Material A pump
of recipe 0.
OUTPUT REGISTER 18 and 44: Active
Recipe Material B Flush Sequence
The Active Recipe Material B Flush Sequence
register contains the number of the Flush Sequence
(1 – 5) that is associated with the Catalyst pump of
the current recipe.
• This value is 0 if the Mix Unit was flushed.
• If the current recipe is invalid this value reflects the
Flush Sequence associated with Material B pump
of recipe 0.
• This value is 0 if the current recipe ratio is 0:1 (1K
recipe).
• This value is 61 if the Mix Unit does not know the
current loaded recipe, if the recipe is invalid, or at
initial startup.
OUTPUT REGISTER 19 and 45: Active
Recipe Ratio Set Point
OUTPUT REGISTER 15 and 41: Active
Recipe Material A
The Active Recipe Ratio Set Point data register
contains the ratio set point associated with the
current recipe.
The Active Recipe Number register contains the
number of the active recipe (1 – 30).
The Active Recipe Material A register contains the
number of the Color (1 – 32) that is associated with
the current recipe.
• The value reported is the ratio antecedent
multiplied by 100. The ratio consequent is
always 1.
Example: Value = 250 >> A mix ratio of 2.5:1
• This value is 0 if the Mix Unit was flushed.
(Material A to Material B)
• This value is 61 if the current recipe is invalid or at
initial startup.
• This value is 0 if the current recipe ratio is 0:1 (1K
recipe).
3A4486B
29
Operation Using a Programmable Logic Controller (PLC)
OUTPUT REGISTER 20 and 46: Active
Recipe Potlife Timeout Set Point
OUTPUT REGISTER 24 and 50: Job
Solvent Volume
The Active Recipe Potlife Timeout Set Point register
contains the set point for the potlife time associated
with the current recipe in minutes.
The Job Solvent Volume register provides a real time
volume of solvent dispensed during the current job
in cc.
• This value is 0 if the potlife time is disabled for the
current recipe.
OUTPUT REGISTER 21 and 47: Job
Number
OUTPUT REGISTER 25 and 51: Safety
Interlock Input Status
The Safety Interlock Input Status register contains
the status of the Safety Interlock Discrete Input.
The Job Number register contains the number of the
job currently running on the Mix Unit.
• The value will be 0 if the input is OPEN (Normal).
OUTPUT REGISTER 22 and 48: Job A
Sprayed Volume
See Safety Interlock in Digital Inputs, page 24.
The Job A Sprayed Volume register provides a real
time volume of color sprayed during the current job
in cc.
OUTPUT REGISTERS 52 – 61: DCS
Command Structure
• The value will be 1 if the input is CLOSED (Safety
Stop).
See Dynamic Command Description, page 50.
OUTPUT REGISTER 23 and 49: Job B
Sprayed Volume
The Job B Sprayed Volume register provides a real
time volume of color sprayed during the current job
in cc.
30
3A4486B
Operation Using a Programmable Logic Controller (PLC)
Network Output Data Map (Read Only)
Network
Output ID
Modbus
Register
Parameter Name
Data Type
Units
Range
0000
41000
Current System Mode
uint32
NONE
1 = Pump Off
2 = Color Change
3 = Color Change: Purge A
4 = Color Change: Purge B
5 = Color Change: Fill
6 = Mix Fill
7 = Mix
8 = Mix Idle
9 = Purge A
10 = Purge B
11 = Standby: Mix Ready
12 = Standby: Fill Ready
13 = Standby: Mix Not Ready
14 = Standby: Alarm
15 = Line Filling/Flushing
16 = Pump Prime/Flush
17 = Maintenance/Calibration
0001
41002
Event Flag
uint32
NONE
0 = No Events
1 = New Event
0002
41004
Actual Mix
Flow/Pressure
uint32
cc/min
PSI
1 – 1600
0003
41006
Actual Mix Ratio
uint32
NONE
0 – 5000
0004
41008
Actual Mix Potlife
Remaining
uint32
sec
0 – 59940
0005
41010
Gun 1 Trigger Status
uint32
NONE
0 = Gun not triggered
1 = Gun triggered
0006
41012
Pump 1 Status
uint32
NONE
0 = Off
1 = Standby
2 = Busy
3 = Flushing
4 = Priming
0007
41014
Pump 2 Status
uint32
NONE
0 = Off
1 = Standby
2 = Busy
3 = Flushing
4 = Priming
0008
41016
Pump 1 Material
uint32
NONE
0 – 40, 61
0009
41018
Pump 2 Material
uint32
NONE
0 – 40, 61
0010
41020
Actual Pump 1 Flow
Rate
uint32
cc/min
0 – 800
3A4486B
31
Operation Using a Programmable Logic Controller (PLC)
Network
Output ID
Modbus
Register
Parameter Name
Data Type
Units
Range
0011
41022
Actual Pump 2 Flow
Rate
uint32
cc/min
0 – 800
0012
41024
Actual Pump 1 Fluid
Pressure
uint32
PSI
0 – 1500
0013
41026
Actual Pump 2 Fluid
Pressure
uint32
PSI
0 – 1500
0014
41028
Active Recipe Number
uint32
NONE
0 – 30, 61
0015
41030
Active Recipe Material
A
uint32
NONE
1 – 32, 61
0016
41032
Active Recipe Material
B
uint32
NONE
33 – 40, 61
0017
41034
Active Recipe Material
A Flush Sequence
uint32
NONE
1–5
0018
41036
Active Recipe Material
B Flush Sequence
uint32
NONE
1–5
0019
41038
Active Recipe Ratio
Set Point
uint32
NONE
0 – 5000
0020
41040
Active Recipe Potlife
Time Set Point
uint32
min
0 – 999
0021
41042
Job Number
uint32
NONE
0 – 9999
0022
41044
Job A Sprayed Volume
unit32
cc
0 – 999999999
0023
41046
Job B Sprayed Volume
unit32
cc
0 – 999999999
0024
41048
Job Solvent Volume
unit32
cc
0 – 999999999
0025
41050
Safety Interlock Input
Status
unit32
NONE
0 = Open
Current System Mode
uint32
0026
42000
1 = Closed
NONE
1 = Pump Off
2 = Color Change
3 = Color Change: Purge A
4 = Color Change: Purge B
5 = Color Change: Fill
6 = Mix Fill
7 = Mix
8 = Mix Idle
9 = Purge A
10 = Purge B
11 = Standby: Mix Ready
12 = Standby: Fill Ready
13 = Standby: Mix Not Ready
14 = Standby: Alarm
15 = Line Filling/Flushing
16 = Pump Prime/Flush
17 = Maintenance/Calibration
0027
42002
Event Flag
uint32
NONE
0 = No Events
1 = New Event
32
3A4486B
Operation Using a Programmable Logic Controller (PLC)
Network
Output ID
Modbus
Register
Parameter Name
Data Type
Units
Range
0028
42004
Actual Mix
Flow/Pressure
uint32
cc/min
or PSI
1 – 1600
0029
42006
Actual Mix Ratio
uint32
NONE
0 – 5000
0 – 59940
0 = Gun not triggered
0030
42008
Actual Mix Potlife
Remaining
uint32
sec
0031
42010
Gun 2 Trigger Status
uint32
NONE
1 = Gun triggered
0032
42012
Pump 3 Status
uint32
NONE
0 = Off
1 = Standby
2 = Busy
3 = Flushing
4 = Priming
0033
42014
Pump 4 Status
uint32
NONE
0 = Off
1 = Standby
2 = Busy
3 = Flushing
4 = Priming
0034
42016
Pump 3 Material
uint32
NONE
0 – 40, 61
0035
42018
Pump 4 Material
uint32
NONE
0 – 40, 61
0036
42020
Actual Pump 3 Flow
Rate
uint32
cc/min
0 – 800
0037
42022
Actual Pump 4 Flow
Rate
uint32
cc/min
0 – 800
0038
42024
Actual Pump 3Fluid
Pressure
uint32
PSI
0 – 1500
0039
42026
Actual Pump 4 Fluid
Pressure
uint32
PSI
0 – 1500
0040
42028
Active Recipe Number
uint32
NONE
0 – 30, 61
0041
42030
Active Recipe Material
A
uint32
NONE
1 – 32, 61
0042
42032
Active Recipe Material
B
uint32
NONE
33 – 40, 61
0043
42034
Active Recipe Material
A Flush Sequence
uint32
NONE
1–5
0044
42036
Active Recipe Material
B Flush Sequence
uint32
NONE
1–5
0045
42038
Active Recipe Ratio
Set Point
uint32
NONE
0 – 5000
0046
42040
Active Recipe Potlife
Time Set Point
uint32
min
0 – 999
0047
42042
Job Number
uint32
NONE
0 – 9999
0048
42044
Job A Sprayed Volumn
unit32
cc
0 – 999999999
0 – 999999999
0 – 999999999
0049
42046
Job B Sprayed Volume
unit32
cc
0050
42048
Job Solvent Volume
unit32
cc
3A4486B
33
Operation Using a Programmable Logic Controller (PLC)
Network
Output ID
Modbus
Register
Parameter Name
Data Type
Units
Range
0051
42050
Safety Interlock Input
Status
unit32
NONE
0 = Open
1 = Closed
0052
43000
Command Return 1
unit32
NONE
N/A
0053
43002
Command Return 2
unit32
NONE
N/A
0054
43004
Command Return 3
unit32
NONE
N/A
0055
43006
Command Return 4
unit32
NONE
N/A
0056
43008
Command Return 5
unit32
NONE
N/A
0057
43010
Command Return 6
unit32
NONE
N/A
0058
43012
Command Return 7
unit32
NONE
N/A
0059
43014
Command Return 8
unit32
NONE
N/A
0060
43016
Command Return 9
unit32
NONE
N/A
0061
43018
Command
Acknowledgment
unit32
NONE
0 = NOP
1 = BUSY
2 = ACK
3 = NAK
4 = ERR
DCS Registers
34
3A4486B
Operation Using a Programmable Logic Controller (PLC)
ProMix PD2K Network Inputs
The ProMix PD2K Network Inputs are Write-Read capable, but should be treated as outputs from a PLC or other
networking device. These registers allow the user to control system operation and configure system settings remotely.
Invalid values (i.e. out of bounds or not consistent with system configuration) will be ignored by the ProMix PD2K. All
values must be written as integers. Floating point numbers are not supported.
Do not rely on these registers for Read status, other than to confirm data that has been written and accepted.
NOTE: The PD2K system does not refresh the values for these registers. At power up all input registers initialize
to invalid values.
INPUT REGISTER 00 and 10: System
Mode Command
The System Mode Command register accepts a number that represents a command to the PD2K system to
initiate a particular operation. Some operation modes may be initiated only under certain conditions (see Figures
5 – 9 for details).
Input Value
Operation Mode
Description
0
No OP
The Mix Unit takes no action.
1
Power Pumps
The Mix Unit powers on or powers off the pumps.
2
Remote Stop
The Mix Unit stops all current operations and turns off power to the
pumps.
3
Recipe Change
The Mix Unit initiates a recipe change. (See also Input Register 02
and 12..)
4
Mix Fill
The Mix Unit fills the mix manifold and gun with material at ratio for
a valid recipe.
5
Mix
The Mix Unit initiates a mix/spray cycle.
6
Purge A
The Mix Unit purges only Material A out through the gun.
7
Purge B
The Mix Unit purges only Material B out through the gun.
8
Standby
The Mix Unit puts both active pumps into Standby mode.
9
Recipe Purge
The Mix Unit automatically determines the purge sequence required
based on the loaded recipe.
INPUT REGISTER 01 and 11: Clear Active
Alarm/Deviation
The Clear Active Alarm/Deviation register is used to
remotely acknowledge a system error. The Event
Flag register indicates whether a system error
requiring acknowledgement exists (see OUTPUT
REGISTER 01 and 27: Event Flag, page 28). In
the case of an alarm condition, the alarm must be
acknowledged and resolved before the Mix Unit
is allowed to resume operation. Write a ‘1’ to this
register to acknowledge the latest active system
error. If more than one system error is currently
active, only the most recent will be acknowledged.
3A4486B
A repeated write should be performed to clear any
remaining active system errors.
(See System Errors, page 97 for more information on
alarms and deviations.)
NOTE: This register is not polledd by the ProMix
PD2K. A system error is cleared only when a value
of ‘1’ is written to this register. It is recommended
that the automation reset this register by writing a ‘0’
to it at all other times to avoid inadvertently clearing
an alarm.*
* It is recommended to wait at least 500 msec for the
PD2K to process before resetting to ‘0’.
35
Operation Using a Programmable Logic Controller (PLC)
INPUT REGISTER 02 and 12: Go To
Recipe Number
INPUT REGISTER 04 and 14: Mix Fill Set
Point
The Go to Recipe Number register is used as a
queue for the next recipe to be loaded when a recipe
change is initiated. A number between 0 and 30 can
be written to this register. However, a recipe must be
enabled via the ADM before it can be loaded. See
Recipe Screen, page 74.
The Mix Fill Set Point register is used to set an
alternate control set point during the mix fill process
(see Mix Fill Set Point on System Screen 2, page 69).
NOTE: Writing to this register does not trigger a recipe
change. See Color Change Sequence, page 46.
INPUT REGISTER 03 and 13: Mix Control
Set Point
The Mix Control Set Point register is used to set and
adjust the mixing fluid control set point. It can be
changed at any time, and the system will immediately
adjust to the new set point.
• If the Mix Unit is configured for Flow Control this
value can be set between 5 and 1600 cc/min for a
2K recipe, and between 5 and 800 for a 1K recipe.
See Fluid Control on System Screen 4, page 71.
• If the Mix Unit is configured for Pressure Control
this value can be set between 0 and the maximum
pump pressure in PSI. See Fluid Control on
System Screen 4, page 71.
NOTE: The Flow Control must be configured to
‘Network’ via System Screen 4 on the ADM. If set
to ‘Discrete’ this register is ignored and set point
adjustment is handled via the discrete input. See
Analog Inputs, page 24.
• If the Mix Unit is configured for Flow Control this
value can be set between 5 and 1600 cc/min for a
2K recipe, and between 5 and 800 for a 1K recipe.
See Fluid Control on System Screen 4, page 71.
• If the Mix Unit is configured for Pressure Control
this value can be set between 1 and the maximum
pump pressure in PSI. See Fluid Control on
System Screen 4, page 71.
NOTE: The Flow Control must be configured
to ‘Network’ via System Screen 4 on the ADM.
If set to ‘Discrete’ this register is ignored and
set point is handled via the discrete input. See
Analog Inputs, page 24.
INPUT REGISTER 05 and 15: Pump Flush
Sequence/Prime Material Selection
The Pump Flush Sequence/Prime Material Selection
register is used in conjunction with the Flush/Prime
Pump Command register (see INPUT REGISTER 06
and 16: Flush/Prime Pump Command, page 37 ) to
independently prime or flush an inactive pump.
• Write a value between 1 and 5 if flushing a pump.
• Write a value between 1 and 32 if priming a Color
pump.
• Write a value between 33 and 40 if priming a
Catalyst pump.
NOTE: It is important that the user know which
material is assigned to each pump. An invalid
selection will be ignored by the ProMix PD2K.
36
3A4486B
Operation Using a Programmable Logic Controller (PLC)
INPUT REGISTER 06 and 16: Flush/Prime Pump Command
The Flush/Prime Pump Command register is used in
conjunction with the Pump Flush Sequence/Prime
Material Selection register (see INPUT REGISTER
05 and 15) to independently prime or flush an inactive
pump. The desired pump MUST be in Standby
mode. Confirm by reading the corresponding Pump
Status output register (see OUTPUT REGISTERS
06, 07, 32, and 33).
Material Selection register then the Flush/Prime
command will be ignored. The user must know
what material is assigned to each pump. (See
Color Change Kits Instruction Manual 332455 for
color/catalyst pump mapping.)
This register can also be used to fill or flush a specific
material hose.
If an invalid Flush Sequence or invalid material
number is written to the Pump Flush Sequence/Prime
Input Value
Operation Mode
Description
0
No OP
The system takes no action.
1
Flush Pump 1
Flush Pump 1 using selected sequence.
2
Prime Pump 1
Prime Pump 1 using selected material.
3
Flush Pump 2
Flush Pump 2 using selected sequence.
4
Prime Pump 2
Prime Pump 2 using selected material.
5
Flush Pump 3
Flush Pump 3 using selected sequence.
6
Prime Pump 3
Prime Pump 3 using selected material.
7
Flush Pump 4
Flush Pump 4 using selected sequence.
8
Prime Pump 4
Prime Pump 4 using selected material.
9
Fill Line
Run selected material from the pump and out the gun.
10
Flush Line
Run solvent through hoses for selected material from the pump and
out the gun.
11
Stop Line Fill/Flush
Stop Line Fill/Flush command.
INPUT REGISTER 07 and 17: Job Complete
The Job Complete register is used to log the current
job remotely. Write a ‘1’ to the register to command
the ProMix PD2K to flag a job complete.
is written to this register. It is recommended the
automation reset this register by writing a ‘0’ to it at
all other times to avoid inadvertently logging a job.*
(See Usage Screen, page 66 for more information on
Job Logs and Job Complete.)
* It is recommended to wait at least 500 msec for the
PD2K to process before resetting to ‘0’.
NOTE: This register is not polled by the ProMix
PD2K. A job is logged only when a value of ‘1’
3A4486B
37
Operation Using a Programmable Logic Controller (PLC)
INPUT REGISTER 08: Gun 1 Trigger
INPUT REGISTER 18: Gun 2 Trigger
INPUT REGISTER 09 and 19: Fluid Control
Mode
The Gun Trigger register is used to signal the ProMix
PD2K when the automatic spray device is triggered.
This signal should be sent any time the spray device
is triggered. The state of this register provides timing
for alarm functions and also drives the flow control
algorithm.
The Fluid Control Mode register is used to
toggle system control between Flow Control
and Pressure Control (see Fluid Control on
System Screen 4, page 71).
NOTE: If enabled, it is imperative that this signal be
sent any time the spray device is triggered. Without it
the flow control features will not work.
• A value of ‘1’ sets the Mix Unit to Pressure Control.
• Write a value of ‘1’ to signal that the gun is
triggered.
• Write a value of ‘0’ to signal that the gun is NOT
triggered.
NOTE: This register is used only if the Gun Trigger
is set to ‘Network’ via System Screen 4 on the ADM.
If it is set to ‘Discrete’ this register is ignored and
gun trigger is handled via the discrete input. See
Digital Inputs, page 24.
• A value of ‘0’ sets the Mix Unit to Flow Control.
NOTE: This setting is available remotely for flexibility,
but typical applications will not change it.
INPUT REGISTERS 20 – 29: DCS
Command Structure
See Dynamic Command Description, page 50.
NOTE: Because timing is so critical for flow control
Graco recommends that users provide a discrete
input to minimize latency effects.
Input Register 08
1
0
1
0
Gun Trigge r
Discrete Signal
ProMix PD2K:
Mix Unit #1
Gun Trigge r S ta te
Figure 13 Gun 1 Trigger Timing (Network and
Discrete Signals Shown
38
3A4486B
Operation Using a Programmable Logic Controller (PLC)
Network Input Data Map (Write/Read)
Network
Input ID
Modbus
Register
Parameter Name
Data
Type
Units
Range
0000
41100
System Mode Command
uint32
NONE
0 = No OP
1 = Power Pumps
2 = Remote Stop
3 = Color Change
4 = Mix Fill
5 = Mix
6 = Purge A
7 = Purge B
8 = Standby
9 = Recipe Purge
0001
41102
Clear Active Alarm/Deviation
uint32
NONE
1 = Clear Active Alm/Dev
0002
41104
Goto Recipe Number
uint32
NONE
0, 1 – 30
0003
41106
Mix Control Set Point
uint32
cc/min
PSI
1 - 1600
0004
41108
Mix Fill Set Point
unit32
cc/min or
PSI
1 – 1600
0005
41110
Pump Flush Sequence #/Prime
Material #
unit32
NONE
1 –5, 1 – 40
0006
41112
Flush/Prime Pump Command
unit32
NONE
0 = No OP
1 = Flush Pump 1
2 = Prime Pump 1
3 = Flush Pump 2
4 = Prime Pump 2
5 = Flush Pump 3
6 = Prime Pump 3
7 = Flush Pump 4
8 = Prime Pump 4
9 = Fill Line
10 = Flush Line
11 = Stop Line Fill/Flush
0007
41114
Job Complete
unit32
NONE
1 = Trigger job complete
0008
41116
Gun 1 Trigger
unit32
NONE
0 = Gun not triggered
1 = Gun triggered
0009
41118
Fluid Control Mode
unit32
NONE
0 = Flow Control
1 = Pressure Control
3A4486B
39
Operation Using a Programmable Logic Controller (PLC)
Network
Input ID
Modbus
Register
Parameter Name
Data
Type
Units
Range
0010
42100
System Mode Command
uint32
NONE
0 = No OP
1 = Power Pumps
2 = Remote Stop
3 = Color Change
4 = Mix Fill
5 = Mix
6 = Purge A
7 = Purge B
8 = Standby
9 = Recipe Purge
0011
42102
Clear Active Alarm/Deviation
uint32
NONE
1 = Clear Active Alm/Dev
0012
42104
Goto Recipe Number
uint32
NONE
0, 1 – 30
0013
42106
Mix Control Set Point
uint32
cc/min or
PSI
1 - 1600
0014
42108
Mix Fill Set Point
unit32
cc/min or
PSI
1 – 1600
0015
42110
Pump Flush Sequence #/Prime
Material #
unit32
NONE
1 –5, 1 – 40
0016
42112
Flush/Prime Pump Command
unit32
NONE
0 = No OP
1 = Flush Pump 1
2 = Prime Pump 1
3 = Flush Pump 2
4 = Prime Pump 2
5 = Flush Pump 3
6 = Prime Pump 3
7 = Flush Pump 4
8 = Prime Pump 4
9 = Fill Line
10 = Flush Line
11 = Stop Line Fill/Flush
0017
42114
Job Complete
unit32
NONE
1 = Trigger job complete
0018
42116
Gun 2 Trigger
unit32
NONE
0 = Gun not triggered
1 = Gun triggered
0019
42118
Fluid Control Mode
unit32
NONE
0 = Flow Control
1 = Pressure Control
0020
43100
Command Argument 1
unit32
NONE
N/A
0021
43102
Command Argument 2
unit32
NONE
N/A
0022
43104
Command Argument 3
unit32
NONE
N/A
0023
43106
Command Argument 4
unit32
NONE
N/A
0024
43108
Command Argument 5
unit32
NONE
N/A
0025
43110
Command Argument 6
unit32
NONE
N/A
40
3A4486B
Operation Using a Programmable Logic Controller (PLC)
Network
Input ID
Modbus
Register
Parameter Name
Data
Type
Units
Range
0026
43112
Command Argument 7
unit32
NONE
N/A
0027
43114
Command Argument 8
unit32
NONE
N/A
0028
43116
Command Argument 9
unit32
NONE
N/A
0029
43118
Command ID
unit32
NONE
See Command Table
DCS Registers
3A4486B
41
Operation Using a Programmable Logic Controller (PLC)
Operation Flow Charts
NOTE: All flow charts reference registers for Mix Unit
#1. For Mix Unit #2, reference the Network Maps for
corresponding register indices.
Purge Mode Sequence
Purge A System Command
Write ‘6’ to Input Re gis te r 00
Is Mix Unit #1 in Standby or
Pumps Of f?
NOTE: Purge B command works
similarly with the catalyst lines and
solvent flow switch 2.
NO
No action taken.
Either pumps are currently
running or an alarm condition
exists.
YES
System Mode = Purge A
(Output Register 00 = ‘9’)
System opens color solvent valve at remote stack to allow
solvent flow through mix manifold and out gun.
Purge time set according to the flush sequence assigned to
material A in re cipe .
NO
Is solvent flow switch 1 ON?
YES
NO
Purge time expired?
NO
Purge no flow timeout expired?
YES
No solvent flow detected.
Generate alarm.
YES
System Mode = Standby: Mix Not Ready
(Output Register 00 = ‘13’)
System closes color solvent valve at remote stack.
42
3A4486B
Operation Using a Programmable Logic Controller (PLC)
Purge Recipe Sequence
Purge Recipe System Command
Write ‘9’ to Input Re gis te r 00
Is Mix Unit #1 in Standby
or Pumps Of f?
NO
No action taken.
Either pumps are currently
running or an alarm condition
exists.
YES
System Mode = Purge B
(Output Register 00 = ‘10’)
System Mode = Purge A
(Output Register 00 = ‘9’)
System opens catalyst solvent
valve at remote stack to allow
solvent flow through mix manifold
and out gun.
System opens color solvent
valve at remote stack to allow
solvent flow through mix manifold
and out gun.
NOTE: System will automatically
skip Purge B if it is not necessary .
(i.e. working with one component
recipes)
Purge time set according to the
flush sequence assigned to
material B in recipe.
Purge time set according to the
flush sequence assigned to
material A in re cipe .
NO
Is solvent flow switch 2
ON?
YES
NO
NO
Purge no flow timeout
expired?
Is solvent flow switch 1
ON?
YES
YES
NO
NO
Purge no flow timeout
expired?
YES
NO
Purge time expired?
YES
No solvent flow detected.
Generate alarm.
Purge time expired?
No solvent flow detected.
Generate alarm.
YES
System Mode = Standby : Mix
Not Ready
(Output Register 00 = ‘13’)
System closes color solvent valve
at remote stack.
3A4486B
43
Operation Using a Programmable Logic Controller (PLC)
Inactive Pump Flush and Prime Sequences
Write Flush Sequence #
(1-5) to Input Register 05
Write Prime Material #
(1-40) to Input Register 05
NOTE: Be sure to read to
appropriate Output Register*
for the desired pump status:
Register 06 - Pump 1
Register 07 - Pump 2
Write
Flush Pump Command
(1,3) to Input Register 06
Write
Prime Pump Command
(2,4) to Input Register 06
Pump is either Off or Busy
(Output Register* = ‘0’ or ‘2’)
Is requested pump
status* = Standby?
(Output Register* = ‘1’)
NO
NO
Busy refers to a pump that is
currently involved in a mixing
operation. No action taken.
Is requested pump
status* = Standby?
(Output Register* = ‘1’)
YES
YES
Invalid request.
No action taken.
NO
Is selected material valid
for requested pump?
YES
Pump is flushed using
assigned sequence number
Pump is primed using
assigned material.
.
Pump Status = Flushing
(Output Register* = ‘3’)
NO
Pump Status = Priming
(Output Register* = ‘4’)
Is Flush complete?
NO
YES
Is Prime complete?
YES
Pump is returned to Standby
.
Pump Status = Standby
(Output Register* = ‘1’)
44
3A4486B
Operation Using a Programmable Logic Controller (PLC)
Line Fill and Flush Sequences
Write Material #
(1 - 40) to Input Register 05
Write Material #
(1 - 40) to Input Register 05
Write Line Flush Command
‘10’ to Input Register 06
Write Line Fill Command
‘9’ to Input Register 06
Is Current System Mode =
Standby ?
(Output Register 00 = 1 1,
12, 13)
NOTE: System must be in
Standby to flush or fill a hos e
line since it will run ma te ria l
from the pump all th e wa y
out the gun.
NO
NO
NOTE: The pump mu s t be
primed with the app ropria te
material before comma nding
to fill or flush a hos e line .
YES
Is corresponding pump
primed with solvent?
No
Noaction
actiontaken.
taken.
NO
No action taken.
YES
Is Current System Mode =
Standby ?
(Output Register 00 = 1 1,
12, 13)
YES
NO
Is corresponding pump
primed with selected material?
YES
Pump begins to run solvent out
the pump, through selected hose,
and out the gun.
Pump begins to run material out
the pump, through selected hose,
and out the gun.
Current System Status = Line
Filling/Flushing
(Output Register 00 = ‘15’)
Current System Status = Line
Filling/Flushing
(Output Register 00 = ‘15’)
NO
Write Stop Line Fill/Flush ?
(Write ‘11’ to Input Re gis te r 06)
YES
Current System Mode is set to
Standby: Mix Not Ready .
(Output Register 00 = ‘13’)
3A4486B
45
Operation Using a Programmable Logic Controller (PLC)
Color Change Sequence
NOTE: If using Cus tom Ma pping for color
cha nge va lve s , a nd the Inle t s ta ck is s e t to
S ingle , the Ma te ria l Re a dy fla g ne e ds to be
s e t prior to s ta rting a re cipe cha nge . If the
Ma te ria l Re a dy fla g is not s e t, the pump(s )
will not fill with the de s igna te d ma te ria l a nd
the re cipe cha nge will not comple te . S e e
“Write Ma te ria l Re a dy Fla g DCS
Comma nd a nd Cus tom Va lve Ma pping” for
more de ta ils .
Write Go to Re c ip e Nu m b e r
(0,1 - 30) t o Input Registe r 02
Recipe Chan g e System
Command
Write ‘3’ to Input Re gis te r 00
Syst em Mode = Re c ip e
Change
(Out put Re gis te r 00 = ‘2’)
NO
YES
Is system in Standb y
with no a la rm conditions ?
NO
No action taken.
Either pu mps a re curre ntly
running or an alarm condition
exists.
Is Material B
chang ing?
YES
Purge Material B out gun.
Syst em Mode = Re c ip e
Change: Purge B
(Out put Re gis te r 00 = ‘4’)
NO
Mix material out t o gun.
System Mode = Mix Fill
(Outpu t Register 00 = ‘6’)
Is purge com plete and
are p umps primed?
Pump will flus h the n prime .
YES
Is Material A
chang ing?
Fill mat erial out to mix
manifold.
Syst em Mode = Recipe
Change: Fi ll
(Out put Re gis te r 00 = ‘5’)
NO
NO
YES
Purge Material A out gun.
Syst em Mode = Re c ip e
Change: Purge A
(Out put Re gis te r 00 = ‘3’)
Is mix fill complete?
YES
NO
Is material fille d out to
mix ma nifold?
YES
System Mode = Stand by:
Mix Ready
(Output Register 00 = ‘11’)
Pump will flus h the n prime .
46
3A4486B
Operation Using a Programmable Logic Controller (PLC)
Recipe Change Alarm Recovery Sequences
Read Status of
Output Register 00
Output Register 00 =
‘14’?
Standby: Alarm
Output Register 00 =
‘13’?
Standby: Mix Not
Ready
Output Register 00 =
‘1’?
Pump Off
YES
YES
YES
YES
Clear Alarm
(See Alarm Clearing
Sequence)
Recipe Change
System Command
Write ‘3’ to Input
Register 00
Mix
System Command
Write ‘7’ to Input
Register 00
Power Pumps
System Command
Write ‘1’ to Input
Register 00
NOTE: Mix Unit #1 will
automatically run t hrough
necessary recipe ch a nge
steps based on it’ s curre nt
state. If Goto Reci p e
Number has not ch a nge d,
it does not have to be
rewritten here.
3A4486B
Output Register 00 =
‘11’?
Standby: Mix Ready
NOTE: System will
automatically perfo rm Mix
Fill if it needs to be comple te d
before transitioning dire ctly
into Mix mode.
47
Operation Using a Programmable Logic Controller (PLC)
Mixing Sequence
Mix Fill or Mix System
Command W rite ‘4’ or ‘5’
to Input Register 00
System Mode =
Standby: Mix Ready ?
(Output Register 00 = ‘1 1’)
YES
NO
No action taken.
Mix Unit #1 is not in valid
state for mixing. Confirm
pumps are on, a recipe
is loaded, and there are
no existing alarm
conditions.
NO
System Mode =
Standby: Fill Ready ?
(Output Register 00 = ‘12’)
System Mode = Mix
(Output Register 00 = ‘7’)
YES
NO
A re cipe is loa de d in the
pumps but not yet filled
out to the gun. Mixed
material is pumped out
to the gun.
System Mode = Mix Fill
(Output Register 00 = ‘6’)
NO
Mix Fill Complete?
YES
Gun Trigge r = ON?
NO
Mix Idle Time out
expired?
YES
No gun trigger signal
for longer than Mix Idle
timeout.
System Mode = Mix Idle
(Output Register 00 = ‘8’)
YES
Gun is filled, Mix Unit #1
is put into Standby .
System Mode =
Standby: Mix Ready
(Output Register 00 = ‘1 1’)
48
3A4486B
Operation Using a Programmable Logic Controller (PLC)
Alarm Clearing Sequence
NOTE: If an alarm condition is
active the System Mode will either
be Pump Off or Standby: Alarm
(Output Register 00 = ‘1’ or ‘14’),
and the Event Flag will be set
(Output Register 01 = ‘1’).
Clear Active Alarm
Write ‘1’ to Input Re gis te r 01
Is there an active
alarm or deviation?
NO
No action taken.
YES
Event Flag set
(Output Register 01 = ‘1’)
Clear most recent active
alarm or deviation.
Remaining alarm(s) or
deviation(s) still active.
YES
Is there more than 1
active alarm or deviation?
NO
Event Flag cleared
(Output Register 01 = ‘0’)
NOTE: If more than 1 active
alarm or deviation exists a
repeated write of ‘1’ to Input
Register 01 is required for each.
3A4486B
49
Operation Using a Programmable Logic Controller (PLC)
Network Communication - Dynamic Command Structure (DCS)
Dynamic Command Description
The Dynamic Command Structure (DCS) is used to 1) access data that requires some form of argument(s) or 2)
consolidate data that requires multiple registers. The DCS uses a static set of network communication input and output
registers (see Network Input Data Map (Write/Read), page 39 and Network Output Data Map (Read Only), page 31.
Use the following sequence for the DCS.
1. Write the appropriate command arguments to INPUT REGISTERS 20 – 28. These commands may be written
sequentially or sent all at once.
2. Once all arguments have been passed, write the command ID to INPUT REGISTER 29.
3. The ProMix PD2K will respond to a valid command by writing a 2 (Acknowledge) to OUTPUT REGISTER 61.
4. The ProMix PD2K will write appropriate return values to OUTPUT REGISTERS 52 – 60.
ProMix PD2K Inputs
(PLC Outputs)
[arg_0]
INPUT REGISTER 20
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
00
Can be written together
or sequentially .
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
0
INPUT REGISTER 20+ n
[arg_ n]
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
000
0
000
000
000
000
INPUT REGISTER 29
[id]
ProMix PD2K Outputs
(PLC Inputs)
OUTPUT REGISTER 61
ACK = 2
OUTPUT REGISTER 52
[rtn_0]
OUTPUT REGISTER 52+ n
[rtn_n]
Figure 14 Dynamic Command Structure Timing
50
3A4486B
Operation Using a Programmable Logic Controller (PLC)
List of DCS Commands
Table 5 Dynamic Commands with Command ID
ID
Command
0
No OP
1
Write User ID
2
Write Recipe
3
Write Flush Sequence
6
Write Material Ready Flag
10
Read User ID
11
Read Recipe
12
Read Flush Sequence
14
Read Job Info
15
Read Alarm Info
16
Read Event Info
Write User ID
The Write User ID command allows users to assign a User ID to a Job Log. See Usage Screen, page 66, for more
details on Job Log and User ID. The User ID can be up to ten ASCII characters in length and is packaged as three
little endian segments of ASCII characters. The return registers will echo the arguments received.
NOTE: The User ID character string must be terminated with a null character.
Example: Write a User ID of “John Doe” to Mix Unit #1 of the ProMix PD2K.
DCS Register
Parameter Description
Data
Type
Units
Value
Range
DCS
Command
Write User ID
uint32
NONE
1
0 - 16
Argument 0
Mix Unit
uint32
NONE
1
1–2
Argument 1
User ID characters [3:0]
(ASCII)
uint32
NONE
0x6E686F4A = [‘n’,
’h’, ’o’, ’J ‘]
N/A
Argument 2
User ID characters [7:4]
(ASCII)
uint32
NONE
0x656F4420 = [‘e’,
’o’, ’D’, ’ ‘]
N/A
Argument 3
User ID characters [9:8]
(ASCII)
unit32
NONE
0x0 = [null]
N/A
Acknowledge
Command Acknowledged
uint32
NONE
2 = ACK
0-4
Return 0
Mix Unit
unint32
NONE
1
1–2
Return 1
User ID characters [3:0]
(ASCII)
uint32
NONE
0x6E686F4A
N/A
Return 2
User ID characters [7:4]
(ASCII)
uint32
NONE
0x656F4420
N/A
Return 3
User ID characters [9:8]
(ASCII)
uint32
NONE
0x0
N/A
3A4486B
51
Operation Using a Programmable Logic Controller (PLC)
Write Recipe
The Write Recipe command allows users to configure an entire recipe remotely. See Recipe Screen, page 74, for
more details on recipes and recipe parameters. The return registers will echo the arguments received.
NOTE: The recipe must be enabled via the ADM before it can be loaded for mixing.
NOTE: If a recipe is Linked, writing to a recipe will also affect the same recipe for the other Mix Unit.
Example: Configure Mix Unit # 1 Recipe 6 for Color = 2, Catalyst = 1, Color Flush Sequence = 2, Catalyst Flush
Sequence = 3, Mix Ratio Set Point = 1.50:1, Potlife = 10 minutes, and Mix Pressure Tolerance = 40%.
DCS Register
Parameter Description
Data
Type
Units
Value
Range
DCS
Command
Write Recipe
uint32
NONE
2
0 - 16
Argument 0
Mix Unit
unint32
NONE
1
1-2
Argument 1
Recipe #
uint32
NONE
6
0 - 30
Argument 2
Material A
uint32
NONE
2
0 – 32
Argument 3
Material B
uint32
NONE
33
0, 33 – 40
Argument 4
Material A Flush Sequence
uint32
NONE
2
1-5
Argument 5
Material B Flush Sequence
uint32
NONE
3
1-5
Argument 6
Mix Ratio Set Point
uint32
NONE
150 = 1.50:1
0 - 5000
Argument 7
Potlife Time Set Point
uint32
min
10
0 - 999
Argument 8
Mix Pressure Tolerance
uint32
%
40
10 - 90
Acknowledge
Command Acknowledged
uint32
NONE
2 = ACK
0-4
Return 0
Mix Unit
uint32
NONE
1
1-2
Return 1
Recipe #
uint32
NONE
6
0 - 30
Return 2
Material A
uint32
NONE
2
0 - 32
Return 3
Material B
uint32
NONE
33
0, 33 – 40
Return 4
Material A Flush Sequence
uint32
NONE
2
1–5
Return 5
Material B Flush Sequence
uint32
NONE
3
1–5
Return 6
Mix Ratio Set Point
uint32
NONE
150
0 - 5000
Return 7
Potlife Time Set Point
uint32
min
10
0 - 999
Return 8
Mix Pressure Tolerance
uint32
%
40
10 – 90
52
3A4486B
Operation Using a Programmable Logic Controller (PLC)
Write Flush Sequence
The Write Flush Sequence command allows users to configure an entire flush sequence remotely. See
Flush Screen, page 77, for more details of flush sequence parameters. The return registers will echo the arguments
received.
Example: Configuring Flush Sequence 4 for Gun Purge Time = 10 sec, Initial Flush Volume = 125 cc, Final Flush
Volume = 250 cc, Wash Cycles = 1, Strokes per Cycle = 2.
DCS Register
Parameter Description
Data
Type
Units
Value
Range
DCS
Command
Write Flush Sequence
uint32
NONE
3
0 - 21
Argument 0
Flush Sequence #
uint32
NONE
4
1-5
Argument 1
Gun Purge Time
uint32
NONE
10
0 - 999
Argument 2
Initial Flush Volume
uint32
NONE
125
0 - 9999
Argument 3
Final Flush Volume
uint32
NONE
250
0 - 9999
Argument 4
# Wash Cycles
uint32
NONE
1
0 - 99
Argument 5
Strokes per Wash Cycle
uint32
NONE
2
0 - 99
Acknowledge
Command Acknowledged
uint32
NONE
2 = ACK
0-4
Return 0
Flush Sequence #
uint32
NONE
4
1-5
Return 1
Gun Purge Time
uint32
sec
10
0 - 999
Return 2
Initial Flush Volume
uint32
cc
125
0 - 9999
Return 3
Final Flush Volume
uint32
cc
250
0 - 9999
Return 4
# Wash Cycles
uint32
NONE
1
0 - 99
Return 5
Strokes per Wash Cycle
uint32
NONE
2
0 - 99
3A4486B
53
Operation Using a Programmable Logic Controller (PLC)
Write Material Ready Flag
The Write Material Ready Flag command is used to signal to the PD2K that the upstream material management has
the appropriate color/catalyst loaded at the inlet valve stack(s) of the pump(s) prior to a recipe change. This flag is
only used when multiple materials for a pump are fed to the PD2K via a single valve at the inlet valve stack (i.e. a
piggable system). See Custom Valve Mapping, page 80 for more info on Single inlet valve stacks.
NOTE: This flag should be cleared prior to or during a material change operation upstream of the inlet valve stack to
avoid having the wrong material being fed into the pump during a recipe change.
Example: Setting the Material Ready Flag for Mix Unit #1.
DCS Register
Parameter Description
Data
Type
Units
Value
Range
DCS
Command
Write Material Ready Flag
uint32
NONE
6
0 - 21
Argument 0
Mix Unit #
uint32
NONE
1
1-2
Argument 1
Material Ready Status
uint32
NONE
1
0 := Not
Ready/No OP
1 := Material
Ready
Acknowledge
Command Acknowledged
uint32
NONE
2 = ACK
0-4
Return 0
Mix Unit #
uint21
NONE
1
1-2
Return 1
Material Ready Status
uint32
NONE
1
0 := Not
Ready/No OP
1 := Material
Ready
Read User ID
The Read User ID command reads back the current User ID. See Usage Screen, page 66, for more details on Job
Log and User ID. The User ID can be up to ten ASCII characters in length and is packaged as three little endian
segments of ASCII characters. No arguments are required.
Example: Read Mix Unit #1 User ID that is currently “John Doe”.
DCS Register
Parameter Description
Data
Type
Units
Value
Range
DCS
Command
Read User ID
uint32
NONE
10
0 - 16
Argument 0
Mix Unit
uint32
NONE
1
1-2
Acknowledge
Command Acknowledged
uint32
NONE
2 = ACK
0-4
Return 0
Mix Unit
uint32
NONE
1
1-2
Return 1
User ID characters [3:0]
(ASCII)
uint32
NONE
0x6E686F4A = [‘n’,
’h’, ’o’, ’J’]
N/A
Return 2
User ID characters [7:4]
(ASCII)
uint32
NONE
0x656F4420 = [‘e’,
’o’, ’D’, ’ ‘]
N/A
Return 3
User ID characters [9:8]
(ASCII)
uint32
NONE
0x0 = [null]
N/A
54
3A4486B
Operation Using a Programmable Logic Controller (PLC)
Read Recipe
The Read Recipe command returns all configured recipe parameters for a desired recipe number. The number of
the recipe to be read is the only argument.
Example: Read Mix Unit #1 Recipe 5 data as it is currently configured with Color = 3, Catalyst = 2 (34), Color Flush
Sequence = 1, Catalyst Flush Sequence = 4, Mix Ratio Set Point = 3.25:1, Potlife = 35 min, and Mix Pressure
Tolerance = 30%.
DCS Register
Parameter Description
Data
Type
Units
Value
Range
DCS
Command
Read Recipe
uint32
NONE
11
0 - 16
Argument 0
Mix Unit
uint32
NONE
1
1-2
Argument 1
Recipe #
uint32
NONE
5
0 - 30
Acknowledge
Command Acknowledged
uint32
NONE
2 = ACK
0-4
Return 0
Mix Unit
uint32
NONE
1
1-2
Return 1
Recipe #
uint32
NONE
5
0 - 30
Return 2
Material A
uint32
NONE
3
0 - 32, 61
Return 3
Material B
uint32
NONE
34
0, 33 - 40, 61
Return 4
Material A Flush Sequence
uint32
NONE
1
1-5
Return 5
Material B Flush Sequence
uint32
NONE
4
1-5
Return 6
Mix Ratio Set Point
uint32
NONE
325
0 - 5000
Return 7
Potlife Time Set Point
uint32
min
35
0 - 999
Return 8
Mix Pressure Tolerance
uint32
%
30
10 - 90
Read Flush Sequence
The Read Flush Sequence command returns all configured parameters for a desired flush sequence. The number of
the flush sequence to be read is the only argument.
Example: Read Flush Sequence 1 as it is currently configured with Gun Purge Time = 20 sec, Initial Flush Volume =
0 cc, Final Flush Volume = 500 cc, Wash Cycles = 2, and Strokes per Cycle = 1.
DCS Register
Parameter Description
Data
Type
Units
Value
Range
DCS
Command
Read Flush Sequence
uint32
NONE
12
0 - 21
Argument 0
Flush Sequence #
uint32
NONE
1
1-5
Acknowledge
Command Acknowledged
uint32
NONE
2 = ACK
0-4
Return 0
Flush Sequence #
uint32
1
1-5
Return 1
Gun Purge Time
uint32
NONE
sec
20
0 - 999
Return 2
Initial Flush Volume
uint32
cc
0
0 - 9999
Return 3
Final Flush Volume
uint32
cc
500
0 - 9999
Return 4
# Wash Cycles
uint32
NONE
2
0 - 99
Return 5
Strokes per Wash Cycle
uint32
NONE
1
0 - 99
3A4486B
55
Operation Using a Programmable Logic Controller (PLC)
Read Job Info
The Read Job Info command is used to access data from any of the most recent 200 job logs. The argument is the
chronological index of the job log, where 0 is the most recent job log and 199 is the 200th most recent.
The date is returned as four-byte packet with each byte holding a two-digit value for (from MSB to LSB) year, month,
day, and day of the week (Monday = 01).
The time is returned as a three-byte packet with each byte holding a two-digit value. Starting from the MSB, the first
byte can be ignored, then hour, minute, and second.
NOTE: The argument is an index not a job number. The actual job number will, however, be one of the returned
parameters. These records will match what is reported on the Jobs screen of the ADM.
(See Usage Screen, page 66, for more details on Job Log)
Example: Read back the most recent job log, job 25, which ran recipe 2 for a total of 1234 cc’s of material under User
ID “John Doe”. The job was logged on Thursday May 29, 2014 at 11:22:14 AM with Mix Unit #1.
DCS Register
Parameter Description
Data Type
Units
Value
Range
DCS
Command
Read Job Info
uint32
NONE
14
0 - 16
Argument 0
Job Index
uint32
NONE
0
0 – 199
Acknowledge
Command
Acknowledged
uint32
NONE
2 = ACK
0-4
Return 0
Job Date
uint32
[YY:MM:DD:DW]
0x0E051D04 =
[14:05:29:04]
N/A
Return 1
Job Time
uint32
[xx:HH:MM:SS]
0x0B160E =
[11:22:14]
N/A
Return 2
Job Number
uint32
NONE
25
0 - 9999
Return 3
Mix Unit
uint32
NONE
1
1-2
Return 4
Recipe #
uint32
NONE
2
0 - 30
Return 5
A+B Volume
uint32
cc
1234
N/A
Return 6
User ID [3:0] (ASCII)
uint32
NONE
0x6E686F4A = [‘n’,
’h’, ’o’, ’J’]
N/A
Return 7
User ID [7:4] (ASCII)
uint32
NONE
0x656F4420 = [‘e’,
’o’, ’D’ ‘ ’]
N/A
Return 8
User ID [9:8] (ASCII)
uint32
NONE
0
N/A
56
3A4486B
Operation Using a Programmable Logic Controller (PLC)
Read Alarm Info
The Read Alarm Info command allows remote access to any of the last 200 alarms logged by the ProMix PD2K. The
argument is the chronological index of the alarm log, where 0 is the most recent alarm and 199 is the 200th most recent.
The date is returned as a four-byte packet with each byte holding a two-digit value for (from MSB to LSB) year, month,
day, and day of the week (Monday = 01).
The time is returned as a three-byte packet with each byte holding a two-digit value. Starting from the MSB, the first
byte can be ignored, then hour, minute, and second.
The alarm code is a four-character little endian ASCII string
See System Errors, page 97, for more details on these Event Types.
An example decoding algorithm is provided below.
Example: Read back the second most recent alarm, which was a Position Pump 1 (DK01) recorded on Tuesday
June 3, 2014 at 8:11 AM.
DCS Register
Parameter Description
Data
Type
Units
Value
Range
DCS
Command
Read Alarm Info
uint32
NONE
15
0 - 16
Argument 0
Alarm Index
uint32
NONE
1
0 - 199
Acknowledge
Command Acknowledged
uint32
NONE
2 = ACK
0-4
Return 0
Alarm Date
uint32
[YY:MM:DD:DW]
0x0E060302 =
[14:06:03:02]
N/A
Return 1
Alarm Time
uint32
[xx:HH:MM:SS]
0x080B0B =
[08:11:11]
N/A
Return 2
Alarm Code Char[3:0]
uint32
NONE
0x31304B44 = [‘1’,
’0’, ’K’, ’D’]
N/A
Example ASCII Character String Decode Algorithm:
character_str[0] = Return_2 & 0xFF;
character_str[1] = (Return_2 >> 8) & 0xFF;
character_str[2] = (Return_2 >> 16) & 0xFF;
character_str[3] = (Return_2 >> 24) & 0xFF;
character_str[4] = ‘\0’;
3A4486B
57
Operation Using a Programmable Logic Controller (PLC)
Read Event Info
The Read Event Info command allows remote access to any of the last 200 events logged by the ProMix PD2K.
The argument is the chronological index of the events log, where 0 is the most recent event and 199 is the 200th
most recent.
The date is returned as a four-byte packet with each byte holding a two-digit value for (from MSB to LSB) year, month,
day, and day of the week (Monday = 01).
The time is returned as a three-byte packet with each byte holding a two-digit value. Starting from the MSB, the first
byte can be ignored, then hour, minute, and second.
The event code is a four-character little endian ASCII string.
The example decoding algorithm provided above for the Alarm Code may be used for Events equivalently.
Example: Read back the fifth most recent event, which was a Setup Value(s) Changed (EC00) recorded on Tuesday
June 3, 2014 at 8:11 AM.
DCS Register
Parameter Description
Data
Type
Units
Value
Range
DCS
Command
Read Event Info
uint32
NONE
16
0 - 16
Argument 0
Event Number
uint32
NONE
4
0 - 199
Acknowledge
Command
Acknowledged
uint32
NONE
2 = ACK
0-4
Return 0
Event Date
uint32
[YY:MM:DD:DW]
0x0E060302 =
[14:06:03:02]
N/A
Return 1
Event Time
uint32
[xx:HH:MM:SS]
0x080B0B =
[08:11:11]
N/A
Return 2
Event Code Char[3:0]
uint32
NONE
0x30304345 = [‘0’,
’0’, ’C’, ’E’]
N/A
58
3A4486B
Operation Using a Programmable Logic Controller (PLC)
PLC Diagnostic Screens
These screens may be used to verify PLC
communications by providing a real-time status of all
Network Inputs and Outputs.
PLC Diagnostic Screens 11
These screens show all PD2K Network Outputs with
their associated register ID, Modbus TCP address,
current value, and any relevant state information.
This screen encapsulates all the registers used
in the Dynamic Command Structure. Arguments
and Command registers are shown on the left.
Acknowledge and Return registers are shown on
the right. When a valid DCS command is sent, the
Return registers will display the appropriate data on
the right side of the screen. This can be used to test
and verify DCS commands with the PLC.
Figure 15 PLC Diagnostic Screen 1
Figure 17 PLC Diagnostic Screen 11
PLC Diagnostic Screens 1–7
PLC Diagnostic Screens 8–10
These screens show all PD2K Network Inputs with
their associated register ID, Modbus TCP address,
last value written, and any relevant state information.
NOTE: If a Network Input has not been written, it will
show a value of 4294967295 (0xFFFFFFFF) and
state as invalid.
Figure 16 PLC Diagnostic Screen 8
3A4486B
59
Operation Using a Programmable Logic Controller (PLC)
Flow Control System
Overview
Pressure Control
Flow control is an optional feature that precisely
regulates the flow of material to an automatic spay
device, to help ensure adequate coverage and avoid
sags or runs in the finish coat. The ProMix PD2K
system can control fluid flow by directly controlling
the proportioning pumps. The pumps accurately
dispense a fixed volume of fluid during each stroke.
For this reason, the flow rate of a given pump is
directly proportional to the velocity of the pump. As
long as the gun is open and the system is stable, flow
control is the most effective method for controlling
flow rate.
When the gun trigger signal is removed the system
automatically switches to pressure control mode to
avoid over pressurizing the fluid lines and to allow
smooth transition to flow control if the gun trigger
signal returns. It also works to maintain a consistent
flow rate even though it has transitioned to pressure
control mode if the gun trigger signal is inadvertently
lost.
The flow control system relies on two main inputs for
controlling flow rate: Gun Trigger and Control Set
Point. NOTE: These inputs are timing critical. Graco
The pressure table also is used to predict if the gun
has been turned on or off (without a change to the
gun trigger input). The flow control system continually
monitors the desired outlet pressure compared to the
actual outlet pressure. If the actual pressure remains
50% or 50 psi higher than the desired pressure,
whichever is larger, for longer than 10 msec, then
the system predicts that the gun trigger has been
released. If the actual pressure drops below the
desired pressure longer than 10 msec, then the
system predicts that the gun has been triggered.
recommends that users wire them discretely to the
controller. Alternatively these two inputs can be
driven by the network communications, but latency
could be an issue for systems requiring precise
timing.
See System Screen 4, page 71, for more details on
configuring these options for ‘Discrete’ or ‘Network’.
NOTE: Flow control cannot be selected with a
manual gun system.
Normal Flow Control
The ProMix PD2K will directly control the speed of
the pump(s) to the programmed flow control set point
to maintain accurate flow rate and ratio. The flow
control set point is set by Network Communications
or the Discrete Input.
The system is considered to be stable when the
pressure readings do not fluctuate and the flow rate
is maintained. While the system is considered stable
it will store (“learn”) the associated pump pressures
to a table that is used if the gun trigger signal is lost
or removed.
60
Gun On/Off Prediction
The gun on/off prediction is used in the flow control
algorithm to prevent the fluid pressure from becoming
too high or too low due to a system disturbance. For
example, if a gun off prediction occurs while the gun
trigger input is high, the system will begin to control
to the pressure value last stored in the pressure table
for the current flow set point.
System Startup and Defaults
The pressure table is reset for every mix cycle, or
after a power cycle of the ProMix PD2K controller.
This issue is not significant because the system
generally is able to recalculate new pressure table
values within a few seconds (depending on the
stability of the fluid system).
3A4486B
Run Mode Screens
Run Mode Screens
NOTE: Selection fields and buttons that are
grayed-out on the screens are not currently active.
Opening Screen
At power up, the Graco logo will display for
approximately 5 seconds, followed by the Home
screen.
Figure 18 Opening Screen
Home Screen
The Home screen displays the current status of the
system. The following table details the information
shown. Only one of the two Mix Units is shown
as active on the Home screen (regardless of the
Mix Unit’s status). The active Mix Unit’s pumps will
appear highlighted. The other Mix Unit’s pumps will
be muted with an arrow icon indicating the user must
toggle mix units by pressing the Up/Down Arrow key.
To view pump flow rates and pressures
(as shown), select “Diagnostic Mode” on
System Screen 1, page 68. The Status Bar (C), Error
Status (D), Solvent Gun (S), Gun Animation (T), and
Recipe Information (U) apply to the active Mix Unit.
Figure 19 Home Screen, in Mix Mode with
Diagnostics On
3A4486B
61
Run Mode Screens
Home Screen Key
Key
Description
Details
A
Date and Time
See Advanced Screen 1, page 90, to set.
B
Menu Bar
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 64)
• Fill (see Fill Screen, page 65), available only if Manual Override is
enabled on System Screen 1, page 68.
• Usage (see Usage Screen, page 66)
• Jobs (see Jobs Screen, page 67)
• Errors (see Errors Screen, page 67)
• Events (see Events Screen, page 67)
C
Status Bar*
System Status: Displays the current mode of operation:
• Pump Off
• Change Recipe
• Standby
• Idle
• Startup
• Prime Pump
• Mix (Dispense in 1K Mode)
• Calibrate
• Mix Fill
• Stall Test
• Purge
• Maintenance Test
• Shutdown
D
Error Status*
E
Pump Animation and
Diagnostic Information
F
Pump Number (1–4)
G
Material (A or B)
H
Available Colors
J
Pump Inlet Color
L
Pump Flow Rate
M
Pump Outlet Color
N
Pump Outlet Pressure
P
Pump Indicator Light
Displays any active error code.
• Clear = power off
• Yellow = standby
• Green = active
S
62
Solvent Flow Rate*
Shows solvent flow rate, if a solvent meter is attached.
3A4486B
Run Mode Screens
Key
Description
Details
T
Spray Device Animation*
Shows mixed material in the spray device and displays active recipe at
the spray device. Gun animation changes to show:
•
•
(Mix Fill)
•
(Purge)
•
(Mix With Gun Triggered)
• (Solvent Standby)
•
•
(Mix With
Gun Not Triggered)
(Recipe Standby)
U
Active Recipe (
)*
V
Current Ratio (
in 1K Mode.)*
) (Not shown
W
Potlife Time Remaining (
X
Total Volume for the Current
Job ( )*
Y
Current Flow Rate (
Z
Current Pressure (
*
)*
)*
)*
Applies specifically to the active Mix Unit on the display. To toggle between Mix Units, use the Up/Down
arrows on the Navigation keypad (
3A4486B
).
63
Run Mode Screens
Spray Screen
NOTE: In normal operating mode, controlled by a
PLC, the Spray Screen is display only. No changes
can be made. This section provides information
about the Spray Screen if Manual Override is enabled
on System Screen 1, page 68. The screens show a
system in Manual Override mode.
The Spray screen includes the following information
for the selected Mix Unit:
• Active Recipe (can be changed on this screen)
• Target Ratio (not shown in 1K Mode)
• Actual Ratio (not shown in 1K Mode)
• Target Pressure (if Pressure Mode is selected on
System Screen 4) or Target Flow (if Flow Mode is
selected). Target pressure or flow can be changed
on this screen).
Figure 20 Spray Screen, in Standby Mode
• Actual Pressure
• Actual Flow
• Potlife Remaining
• Gun Animation
In addition, the Spray screen includes four soft keys:
Press to put the system in
Standby.
Press to spray mixed material.
Figure 21 Spray Screen, in Mix Mode
Press to purge the gun.
Press to switch between Mix
Units
Figure 22 Spray Screen, in Idle Mode
64
3A4486B
Run Mode Screens
Fill Screen
NOTE: This screen is visible only if Manual Override
is enabled on System Screen 1, page 68.
The Fill screen displays the following information for
the pump assigned to the current color:
• Material. Select Color (A), Catalyst (B), or Solvent.
The pump animation at the top of the screen will
show the selected material.
• Flush Line (only for systems with color change).
Select this box if you want to flush the specified
material line. The system uses flush sequence 1.
NOTE: Use the toggle softkey to switch between Mix
Units.
To prime the pumps and fill the lines, first read
Prime and Fill the System, page 20.
Figure 24 Fill Screen, Solvent Selected
Pre-Fill Pump
1. Press the Edit softkey
for editing.
to open the screen
2. Select Color (A).
3. If the selected material is not already loaded,
press the Prime softkey
. The system will
prime Color (A) into the selected pump through
the selected color valve and out the outlet dump
valve.
The pump pre-fill option is available for pumps that
have color change, but only a single material (color or
catalyst). The pre-fill option may be used for pumps
that remain filled with material when the system was
powered down.
to “prime” the
Press the Pre-Fill softkey
pump without flushing or expelling any material
unnecessarily.
. The system will
4. Press the Fill softkey
attempt to fill the Color (A) lines until the user
presses Stop
container.
. Trigger the gun into a waste
5. Repeat for Catalyst (B).
Figure 25 Fill Screen, Pre-Fill Option
Figure 23 Fill Screen, Color (A) Selected
3A4486B
65
Run Mode Screens
Usage Screen
The first Usage screen displays the current job
usage of component A, B, A+B, and solvent (S). The
second Usage screen displays grand total usage of
component A, B, A+B, and solvent (S). Edits may
be made only if Manual Override is enabled on
System Screen 1, page 68. The third Usage screen
displays the total volume pumped for all available
materials.
NOTE: In 1K Mode, the B and A+B components are
not shown.
1. Press the Edit softkey
for editing.
to open the screen
2. To enter or change the User ID ( ), select the
field to open the User ID Keyboard screen,
and enter the desired name (10 characters
maximum).
Figure 28 User ID Keyboard Screen
3. To log the current job for the appropriate Mix Unit,
press the corresponding Job Complete softkey,
or
. This will clear the current usage
fields and increment to the next job number.
The Grand Totals cannot be cleared. See the
Jobs Screen, page 67, to review past jobs.
4. Press the Edit softkey
to close the screen.
Figure 29 Usage Grand Total
Figure 26 Usage Screen
Figure 30 Usage Log
Figure 27 Usage Screen, 1K Mode
66
3A4486B
Run Mode Screens
Jobs Screen
The Jobs screen displays the 200 most recent job
numbers, recipes, Mix Unit, and A+B volumes in a
log, with date, time, and User ID.
Figure 33 Errors Screen, Edit Mode
Events Screen
Figure 31 Jobs Screen
The Events screen displays the 200 most recent
Event Codes in a log, with date, time, and description.
Errors Screen
The Errors screen displays the 200 most recent Error
Codes in a log, with date, time, and description.
Additional information is available for system errors
to assist with troubleshooting. To access this
information for a system error that has occurred, first
to enter edit mode; the first error will be
press
highlighted. Using the Up and Down arrow keys,
again
navigate to the desired error code, press
(see System Errors, page 97, for more information on
the troubleshooting information screens).
Figure 34 Events Screen
Figure 32 Errors Screen
3A4486B
67
Setup Mode Screens
Setup Mode Screens
Press
screens.
on any Run screen to enter the Setup
Most parameters on the Setup screens may be
configured individually for each Mix Unit, while some
are global. Those that may be set individually appear
in two columns.
System Screen 1
System screen 1 includes the following fields which
define your system.
NOTE: Selection fields and buttons that are
grayed-out on the screens are not currently active.
If the system has a password lock, the Password
screen displays. See Password Screen, page 68.
Password Screen
Figure 36 System Screen 1, During Standby
Diagnostic Mode
Select this box to display flow rate and pressure for
each pump on the Home Screen, page 61.
Recipe Linking
Figure 35 Password Screen
Enter the 4 digit password, then press
. System
screen 1 will open, allowing access to the other
Setup screens.
Entering an incorrect password clears the field.
Reenter the correct password.
To assign a password, see
Advanced Screen 1, page 90.
Select this box to enable recipe linking on the
Recipe Screen, page 74.
Manual Override
Check this box to give users system control at the
ADM. Leave the box unchecked if all system settings
are controlled through a PC, PLC, or other networked
device.
Solvent Meter
Select this box if your system uses a solvent meter.
The Solvent K-Factor field will then become active.
68
3A4486B
Setup Mode Screens
System Screen 2
System screen 2 sets the following system operating
parameters.
spray device. Once the spray device is filled, the
system will use the target set point as set by the PLC.
The default value is ‘0’. When set to ‘0’, the system
ignores the Mix Fill Set Point and instead uses the
target set point as set by the PLC.
The value will be a flow rate if Fluid Control is set
to ‘Flow’, or a pressure if Fluid control is set to
‘Pressure’.
Mix Idle Timeout (Idle Timeout - 1K Mode)
Figure 37 System Screen 2, in Standby Mode
Color Pumps
Enter the number of color pumps in your system.
The Gun Trigger Input signals that the device is
triggered. If you are not using a gun trigger signal,
the system does not know if the spray device is
spraying. If a pump failed you could spray pure resin
or catalyst without knowing. This should be caught
by the Mix No Flow Timeout; the default is 5 seconds.
The Mix Idle Timeout will trigger Idle mode, which
will run a pump stall test to check for leaks, then put
the pumps in Standby (holding their current position)
after the designated period of time. Enter the desired
Mix Idle Timeout in this field.
Catalyst Pumps
See Digital Inputs, page 24.
Enter the number of catalyst pumps in your system.
Mix No Flow Timeout (No Flow Timeout 1K Mode)
NOTE: Changing the number of catalyst pumps to “0”
will put the mix unit into 1K Mode.
Non--Mix Pressure (Fill Pressure - 1K Mode)
Non
Enter a lower pressure for use when not mixing and
spraying (for example during fill or flushing).
NOTE: Low pressure systems may be set 100 psi
(0.7 MPa, 7 bar) lower than target pressure; high
pressure systems may be set 300 psi (2.1 MPa, 21
bar) lower than target pressure.
The Gun Trigger Input signals that the gun is
triggered. If the Gun Trigger Input indicates that the
gun is triggered, but there is no fluid flow through a
pump, you could spray pure resin or catalyst without
knowing. The Mix No Flow Timeout will cause the
system to shutdown after the designated period of
time. The default is 5 seconds. Enter the desired
shutdown time in this field.
See Digital Inputs, page 24.
Mix Fill Set Point (Fill Set Point - 1K Mode)
Disable Mix Unit
Set a higher flow rate or pressure for use while mix
filling to decrease the time needed to fill the hose and
Select this box if you wish to prevent a mix unit from
being powered up and to suppress all related alarms.
3A4486B
69
Setup Mode Screens
System Screen 3
System screen 3 sets the following system operating
parameters.
Gun Hose Diameter
Enter the diameter of the hose from the remote mix
manifold to the spray device. The minimum diameter
is 1/8 in. (3 mm).
Mix At Wall
Deselect this box only if your system is not using a
remote mix manifold.
Hose Length and Diameter
Enter the length and diameter of the hose from the
remote color stack to the remote mix manifold, for
both A and B hoses.
Figure 38 System Screen 3
Gun Hose Length
Enter the length of the hose from the remote mix
manifold to the spray device.
70
Mix at Belt Circ.
This option is for systems that have fluid circulation
and use mix-at-belt manifolds. This should not be
used with Automatic systems.
3A4486B
Setup Mode Screens
System Screen 4
System screen 4 sets the following system operating
parameters.
Flow Control (Setpoint Signal)
Select the format of the signal that indicates system
flow rate or pressure.
• Discrete — the signal is sent via a direct,
hard-wired connection. This selection will make
the Max Set Point field active.
• Network — the signal is sent via a PC, PLC, or
other networked device.
• Recipe — flow rate or pressure is set according to
user-entered value on each recipe screen.
Max Set Point
Figure 39 System Screen 4
Set the scaling factor for the 4–20 mA discrete Flow
Control Signal (see Analog Inputs, page 24).
Fluid Control
Low Flow Tolerance
Select the desired operating mode (pressure or flow),
using the pull-down menu.
• In Pressure Mode, the motor will adjust the pump
speed to maintain the fluid pressure set by an
external control device.
• In Flow Mode, the motor will maintain a constant
speed to maintain the target flow rate set by an
external control device.
Gun Trigger Signal
Select the format of the signal indicating whether the
spray device is triggered.
• Discrete — the signal is sent via a direct,
hard-wired connection
• Network — the signal is sent via a PC, PLC, or
other networked device.
3A4486B
This field is active if Fluid Control is set to ‘Flow’.
The system will detect if the flow rate falls below a
designated percentage of the target flow rate. Set
that percentage in this field. For example, you might
want the system to time out if it detects a flow rate
that is 10 percent of the target, rather than waiting
until a no flow timeout occurs.
Low Flow Timeout
The low flow timeout causes the system to shut down
after the designated period of time if the flow rate
continues to be at or below the low flow tolerance set
in the previous section. The default is 5 seconds.
Enter the desired shutdown time in this field.
Solvent K-Factor
Enter the solvent meter K-Factor.
71
Setup Mode Screens
System Screen 5
Auto Park Pumps
System screen 5 sets the following operating
parameters.
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.
NOTE: The timer only runs while the system is in
Standby and all guns are purged to prevent volumes
from going off ratio.
Mix Balance Interval (Not used in 1K Mode)
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.
Figure 40 System Screen 5
Stall Test Pressure
Set the minimum stall test pressure. The setting
should be approximately 50 psi (0.35 MPa, 3.5 bar)
higher than the highest inlet pressure.
NOTE: If the material supply pressure at the pump
inlet is greater than 90% of the Stall Test Pressure, the
system will generate an alarm and will not complete
the stall test. See Calibrate Screen 1, page 86.
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.
NOTE: The Mix Balance Interval timer only runs
while the gun is triggered. Setting this time to zero
turns the timer off.
Solvent K-Factor
Enter the solvent meter K-Factor.
Pump Stall Test
Set the duration for the pump stall test. See
Calibrate Screen 1, page 86.
Maximum Leak Rate
Enter the maximum allowable leak rate for a pump
stall test.
72
3A4486B
Setup Mode Screens
Gateway Screen
Enable
The Gateway screen sets the following system
operating parameters for the CGM protocol installed.
Uncheck Enable while setting the IP Address, Subnet
mask, Gateway, DNS1 or DNS2. When the settings
are loaded, check the Enable box to write the new
settings to the selected Gateway.
Check this box to enable the selected Gateway so
that the PLC can communicate with it.
DHCP
Select this box if your system has a Dynamic Host
Configuration Protocol (DHCP). This protocol assigns
unique IP addresses to devices, then releases and
renews these addresses as devices leave and rejoin
the network. If selected, the IP Address, Subnet, and
Gateway fields will not be editable and will display
the addresses supplied by the DHCP.
Figure 41 Gateway Screen
TCP/IP
Gateway ID
Select the desired Gateway ID from the dropdown
menu.
3A4486B
Use the remaining fields to set the IP address, subnet
mask, Gateway, DNS1, and DNS2.
73
Setup Mode Screens
Recipe Screen
Each Mix Unit has its own chapter of Recipe screens
(0–30): #1 Recipes for Mix Unit #1 and #2 Recipes
for Mix Unit #2. These recipes can be set up
entirely unique, or for systems that will be mixing two
equivalent recipes at the same time, recipes can be
linked between two Mix Units.
Figure 44 Linked #2 Recipes Screen
Recipe
Enter the desired recipe number (1-30).
Figure 42 Valid Recipe Screen
Recipe 0
Linked Recipes
Use Recipe 0 to flush the system.
• If a recipe (1–30) is loaded: Select Recipe 0 to flush
the previously active pumps and purge the gun.
Pressing the Link softkey on a Recipe screen will
copy data from the equivalent recipe number of the
other Mix Unit to the screen currently displayed.
The softkey will then change states to indicate the
two recipes are linked. Once linked, changing a
recipe parameter will affect both Mix Unit recipes
concurrently. Recipes may be un-linked by simply
pressing the Link softkey again.
• If Recipe 0 or 61 is loaded: Select Recipe 0 to
flush all pumps and purge the gun.
Recipe linking must be enabled on
System Screen 1, page 68. If recipe linking
is not enabled, the Link softkey will not be shown on
the Recipe screen.
Selecting “Enabled” makes the selected recipe
accessible from the Spray screen on the ADM or to
the PLC.
Note: Recipe 0 is always enabled.
NOTE: Material numbers are still unique, so those
numbers will appear different, but are equivalent
relative to each Mix Unit (i.e., Color 1 = Color 17,
Catalyst 1 = Catalyst 5).
Color (A) Valve
NOTE: Recipes cannot be linked unless both or
neither Mix Unit is configured for mix-at-wall.
Enabled
Enter the desired color valve number (1-32).
NOTE: If you enter a number which is not valid in
your system configuration, the field will be highlighted
and the recipe becomes invalid. For example, if your
configuration has 8 color valves and you enter 14,
the field will appear as shown below.
Flush Sequence
Figure 43 Linked #1 Recipes Screen
74
Enter the desired flush sequence (1-5) for the color
(A) valve and the catalyst (B) valve. The gun purge
time for each material depends on the flush sequence
assigned to each. See Flush Screen, page 77. If
materials A and B require different purge times,
assign separate flush sequences. Set the necessary
gun purge time for each. For hard to flush colors,
select a longer sequence. 1 is the default, and should
be designated for the longest, most thorough flush
duration.
3A4486B
Setup Mode Screens
Catalyst (B) Valve (Disabled in 1K Mode)
Potlife Time
Enter the desired catalyst valve number (1-8).
Enter the potlife time (0 to 999 minutes). Entering
0 disables this function.
NOTE: If you enter a number which is not valid in
your system configuration, the field will be highlighted
and the recipe is invalid. For example, if your
configuration has 1 catalyst valve and you enter 4,
the field will be highlighted and the recipe is invalid.
Target Pressure/Flow
Enter the desired target spray pressure or flow rate,
depending on whether the Mix Unit is configured for
Pressure Control or Flow Control (see Fluid Control
on System Screen 4). This is the pressure or flow
rate the pumps will maintain while mixing. This field
is only available when the Flow Control is set to
‘Recipe’ (see Flow Control on System Screen 4).
Mix Pressure Tolerance (Disabled in 1K
Mode)
The pressure of one component must be within
a percentage (±) of the pressure of the other
component during spray or mix. Set the desired Mix
Pressure Tolerance in this field. The default is 25%.
Figure 45 Invalid Recipe Screen
Mix Ratio (Disabled in 1K Mode)
Enter the desired mix ratio (0 to 50.0):1.
3A4486B
75
Setup Mode Screens
Differential Pressure and the Mix Pressure Tolerance Set Point
A primary means of maintaining ratio assurance for
the ProMix PD2K system is through monitoring of
the differential pressure between the A-pump and
B-pump outlets. Ideally, these two pressures would
be identical, but factors such as line sizing, viscosity,
and mix ratio lead to some variation. Understanding
where your system typically operates is imperative
when setting up an effective differential pressure
check that notifies the user of potential mix ratio
inaccuracies while avoiding nuisance alarms.
75 and 125 psi (100 psi ± 25%) without generating
an alarm.
140
120
100
A
80
B
60
It is recommended that, once the system is fully
installed and ready to use, the user load a recipe and
then spray the mixed material. While spraying, note
the outlet pressures of both the A and B pumps (per
the ADM’s main screen or the PLC) and spray long
enough to ensure the pressures have stabilized to
a nominal value. The difference between the outlet
pressures of the A and B pumps is an established
baseline for the Mix Pressure Tolerance set point.
Figure 46 The acceptable B-side pump outlet
pressure range for a system with a target spray
pressure (A) of 100 psi and a Mix Pressure Tolerance
of 25%.
The Mix Pressure Tolerance set point allows the
B-side pump outlet pressure to vary a specified
percentage away from the A-side pump outlet (spray)
pressure. For example: In the following figure, if the
spray pressure (A-side pump outlet pressure) is 100
psi, and the Mix Pressure Tolerance is set to 25%,
the B-side outlet pressure is allowed to float between
It is recommended that you keep the Mix Pressure
Tolerance set point as low as possible to alert the
user of anything affecting the mix ratio accuracy.
However, if your system is generating several
differential pressure alarms, or will be mixing a wide
variety of materials at different mix ratios, you may
need to increase the Mix Pressure Tolerance.
40
20
0
Dual Solvent
Purge 1, 2, and 3
Select the sequence for purging the mixed material
from the mix hose and spray device. Each stage
of the sequence can be set to either ‘A’ or ‘B’.
The solvent corresponding to each material will be
dispensed out the spray device for the Gun Purge
Time of the Flush sequence assigned to that material
for each stage. See Table 6 for a progression of the
successive stages of the purge sequence.
Fill
Select the sequence for dispensing material into the
mix hose and spray device. The choices are: ‘A
then B’, ‘B then A’, and ‘Parallel’, if no fill sequencing
is necessary. The fill sequence is typically dictated
by the last material used in the purge sequence.
See Table 6 for a progression of the fill sequence
following the last stage of the purge sequence.
Figure 47 Dual Solvent Recipe Screen
If Mix-at-Wall is enabled on System Screen 3, Dual
Solvent becomes an option on the Recipe screen.
Selecting ‘Dual Solvent’ enables the sequencing of
flushing mixed material for a system using two types
of solvent (i.e., water and solvent based) that should
not be mixed together.
Table 6 The Progression of Purge Sequence and Fill Sequence in a Dual Solvent System
➜
76
Mixed
Material
2nd Fill
Material
(if applicable)
1st Fill Material (If
applicable)
Purge 3
Solvent
Purge 2
Solvent
Purge 1
Solvent
Mixed
Material
➜
3A4486B
Setup Mode Screens
Flush Screen
NOTE: Air/solvent chop requires additional hardware
for the air purge valve. See manual 333282 for kit
numbers and installation details.
Initial Flush
Enter the initial flush volume (0 to 9999 cc).
Wash Cycles
Figure 48 Flush Screen
Flush Number
Enter the desired flush sequence (1-5). For hard
to flush colors, select a longer sequence. 1 is the
default, and should be designated for the longest,
most thorough flush duration.
A Wash Cycle activates the pump with the valves
closed, to use pumping motion to thoroughly clean
the pump. Enter the desired number of wash cycles
(0 to 99). Entering a number will make the Strokes
per Cycle field active.
Strokes per Wash Cycle
Enter the desired pump strokes per wash cycle (0
to 99). Default is 1.
Final Flush
Air/Solvent Chop
This option is available if Mix At Wall is enabled on
System Screen 3, page 70. Enable an air and solvent
chop for flushing the gun rather than just a solvent
purge. See Air/Solvent Chop, page 78.
Air and solvent chop may also be enabled for flushing
out a pump. See Custom Valve Mapping, page 80,
for more information.
3A4486B
Enter the final flush volume (0 to 9999 cc).
Gun Purge Time
Enter the spray device purge time (0 to 999 seconds).
77
Setup Mode Screens
Air/Solvent Chop
Air/Solvent Chop replaces the standard Gun Purge
Time parameter on the Flush screen. Instead the
purge is split into three phases: First Purge, Chop,
and Final Purge. The Chop Phase will always start
with Air and each phase has multiple configuration
parameters.
First Purge
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.
Air Chop
Set the air chop duty cycle for the chop phase.
Solvent Chop
Set the solvent chop duty cycle for the chop phase.
Total Chop
Figure 49 Flush Screen with Air/Solvent Chop
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.
Final Purge
Select the material to be either Air or Solvent and
the length of time for the final purge phase, which
dispenses only the material selected.
Figure 50 Air/Solvent Chop Timing Diagram
78
3A4486B
Setup Mode Screens
Pump Screen 1
NOTE: Your system will include 4 pumps. Information
for each pump is accessible under a separate tab in
the menu bar at the top of the screen. Select the tab
for the desired pump. Each pump has three screens.
Only the screens for Pump 1 are shown here, but the
same fields appear on all.
Pump screen 1 includes the following fields which
define the pump.
Materials
Enter the number of materials used in your system.
Each color change module controls 8 colors.
Hose Length
Compute the length of the hoses from the supply
stack to the pump and from the pump to the outlet
stack. Enter the total length.
Hose Diameter
Enter the diameter of the supply and output hoses.
Available Colors
The module displays the number of colors available
in your system. This field is not editable.
Figure 51 Pump Screen 1
Pump Size
Select 35cc or 70cc, as appropriate.
Inlet Pressure
Select one of the following:
• Disabled
• Monitor, to track inlet pressure
Valve Mapping
Select whether to use Standard, static valve mapping,
or fully configurable Custom valve mapping. The
color change valve mapping is the assignment of
the location of the solenoids in the color change
control modules. A static, pre-determined map layout
makes for an easily predictable and hands-free
option. However, an application and user may benefit
from laying out the valve mapping on their own
for consolidation of equipment, reduced hardware
complexity, or simply to lay out valves according to
what makes most sense.
See Custom Valve Mapping, page 80 for more
detailed information.
Select Color Change
Select this box if your system uses color change.
3A4486B
79
Setup Mode Screens
Custom Valve Mapping
For a PD2K system that has color change, the user
has an option for how the control solenoids are
mapped on the control modules. Selecting Standard
(default) will use the traditional, static valve mapping.
The static maps are laid out logically and established
for retro-fitting. If Standard is selected no additional
set up for the color change valves is required at the
ADM. For more information or to see the static map
layouts, refer to manuals 332455 and 333282.
By selecting Custom, every color change solenoid
may be assigned to any unique, valid control module
location. This option offers the ultimate customization
as well as the benefit of consolidation of equipment.
Additionally, custom valve mapping enables some
advanced color change valve features.
NOTE: This option applies to all pumps, so changing
it for one will change it for all.
NOTE: When going from Standard to Custom,
the PD2K will automatically pull in the static map
assignments for all valves as a starting point. When
going from Custom to Standard, the PD2K will clear
all custom valve assignments and revert to the static
mappings.
Pump Screen - Advanced Configuration
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.
NOTE: For systems that select Single, it is expected
the user knows when a particular material is plumbed
and filled to the inlet stack before performing a color
change. The PD2K system does not know what
material is connected up stream of the inlet valve
stack.
Pump Air Purge
Select Enable to add an air purge valve to the pump
inlet stack to allow for an air/solvent chop flush of the
pump out the dump valve. Select Disable if no air
purge valve will be used for the pump. This option is
only available for color pumps. See Pump Air/Solvent
Chop on Pump Screen - Valve Assignment, page 82,
for further detail.
Outlet Color Change
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.
NOTE: If Single is selected, the hose connected
to the outlet stack will need to be purged before
completing a color change.
Remote Color Change
Select Multiple if each individual material has its own
valve on the remote color stack for a particular pump.
Select Single if there is more than one material
using a single hose connected to the remote color
stack. Select Disable if there are no remote color
change valves (only solvent and air) for the pump.
The Disable option is only available if Mix-at-Wall is
enabled, and Single is only available for pumps that
have more than one color change material.
Figure 52 Pump Screen, Advanced Configuration
NOTE: Unless Disabled is selected, this must match
the selection for Outlet Color Change unless.
Inlet Color Change
NOTE: If Single is selected, the hose connected
between the outlet stack and remote stack will need
to be purged before completing a color change.
Select Multiple if each individual material has its own
valve on the inlet color stack for a particular pump.
80
3A4486B
Setup Mode Screens
Auxiliary
Select Enable to add an auxiliary valve downstream
of the remote valve stack for the pump. The Auxiliary
valve is only opened when that particular pump is
dispensing (either mixing or purging). This option is
only available if Mix-at-Wall is enabled.
The following figure illustrates an example application
of the auxiliary valve. Pumps 1 and 3 both dispense
color, but one is solvent based and one is water
based. (Pump 2 dispenses a catalyst.) With the
auxiliary valves in place for both pumps, only one will
flow through the A-side of the remote mix manifold,
and the other is completely isolated by the auxiliary
valve.
Figure 53 Example Application of the Auxiliary Valve
Clear Valve Map
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
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any that were automatically set based on the static
mapping.
81
Setup Mode Screens
Pump Screen - Valve Assignment
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.
NOTE: Some remote stack valves may be shared by
more than one pump. They will show up on the valve
list for all pumps to which they apply.
Figure 54 Pump Screen, Valve Assignment
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.
This screen allows the user to assign each individual
color change valve solenoid in the system to a unique
Figure 55 Solenoid Location Enumeration
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3A4486B
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.
NOTE: Air/solvent chop requires additional hardware
for the air purge valve. See manual 333282 for kit
numbers and installation details.
Figure 56 Pump Screen, Valve Assignment with
duplicates
Figure 58 Flush Screen with pump air/solvent chop
A value of 0 for the control module, or 00 for the
solenoid, indicates no previous location assignment
and both are also invalid assignments.
If a valve location is considered invalid, any operation
that uses that valve will be prevented from running.
This is easily identified on the Recipe screens. If any
of the material’s valves are considered invalid, that
material will be highlighted red. If any of the valves
used in the flush procedure are considered invalid,
the flush sequence will be highlighted red.
Figure 59 Flush Screen with both air/solvent chops
Figure 57 Recipe Screen with invalid valve location
To enable air/solvent chop for a pump flush, check
the Air/Solvent Chop box on the Flush screen.
Because air/solvent chop may also be used for
purging the gun, if Mix-at-Wall is enabled, the
Air/Solvent Chop option becomes a pull-down
selection where the user may choose None, Pump,
Gun, or Both. If air/solvent chop is enabled for the
gun purge, all gun purge parameters will appear on
the right side, and pump flush parameters are on the
left side. The following parameters apply to the pump
flush. For details on air/solvent chop for the gun, see
Flush Screen, page 77.
Pump Air/Solvent Chop
Air Chop
Enabling an air purge valve on the inlet stack of a
color pump allows for an air/solvent chop during
the pump flush process. The air/solvent chop will
replace the wash cycles in a pump flush. Instead, the
pump will run at a steady speed for the set number
of strokes (full length travel in one direction) while
alternating between air and solvent for the desired
duty cycles. One pump stroke takes approximately 2
seconds during this phase.
Set the air chop duty cycle for the chop phase of the
pump flush.
3A4486B
Solvent Chop
Set the solvent chop duty cycle for the chop phase
of the pump flush.
83
Setup Mode Screens
Pump Screen 2
Pump screen 2 sets the pressure transducer settings
for the pump.
Default Settings Selected
When the “Use Default Settings” box is selected,
default settings are used for the calibration values,
and the fields are grayed out.
Default Settings Not Selected
When the “Use Default Settings” box is not selected,
the following calibration values must be entered.
Invalid values will be over-ridden and the system will
automatically select the default settings.
• Inlet Offset Factor: This field is only used if Inlet
Pressure in Pump Screen 1, page 79 is set to
Monitor; it is grayed out if set to Disabled. The
valid range is -01.20 to +01.20 mV/V.
Figure 60 Pump Screen 2, Default Settings Enabled
• Inlet Sensitivity Factor: This field is only used if
Inlet Pressure in Pump Screen 1, page 79 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 61 Pump Screen 2, Default Settings Disabled
84
3A4486B
Setup Mode Screens
Pump Screen 3
Pump screen 3 sets the pressure alarm limits for the
pump.
When Inlet Pressure in Pump Screen 1, page 79 is
set to Disabled, the inlet limit fields are grayed
out and only the outlet limit fields are active. See
Pressure Alarm and Deviation Limits, page 85.
Pressure Alarm and Deviation Limits
Inlet fields are only active if Inlet Pressure
in Pump Screen 1, page 79 is set to Monitor; they
are grayed out if set to Disabled. Outlet fields are
active at all times.
• Alarm and Deviation ranges are 0-300 psi for
low pressure systems, and 0-1500 psi for high
pressure systems.
• Setting to 0 will disable the alarm. The Inlet Alarm
High and Outlet Alarm High cannot be disabled.
• Alarms and Deviations will display when the inlet
or outlet pressure drops below the low limit or
exceeds the high limit.
NOTE: Outlet Alarm Low is only enabled for systems
using Flow Control.
Figure 62 Pump Screen 3, Pressure Monitoring
Disabled
When Inlet Pressure in Pump Screen 1, page 79 is
set to Monitor, all fields are active. See
Pressure Alarm and Deviation Limits, page 85.
Figure 63 Pump Screen 3, Pressure Monitoring
Enabled
3A4486B
85
Setup Mode Screens
Calibration Screens
Calibrate Screen 1
Calibrate Screen 2
Calibrate Screen 1 initiates a pump pressure check
(stall test) for the selected pump. During the test, the
Stall Test screen will appear.
Calibrate Screen 2 initiates a volume test for the
selected pump. During the test, the Volume Check
screen will appear.
The pump and lines must be primed with color
or catalyst before doing the stall test. See
System Screen 2, page 69, to set test parameters.
See Pump Pressure Check, page 94 for complete
test instructions.
The pump and lines must be primed with color
or catalyst before doing the Volume Check. See
Pump Volume Check, page 95 for complete test
instructions.
To initiate the test, press the Pressure Check
button for the desired pump. The system will first
check the inlet pressure due to the material supply
pressure. If this pressure is greater than 90% of
the Stall Test Pressure, the system will generate an
alarm and halt the stall test. The pump will build
pressure in the line to a minimum of the Stall Test
Pressure. The pump will then move to the center
stroke position and stall test the upstroke, followed
by the downstroke.
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
NOTE: The Last Passed log can only be reset by
successfully completing the test.
The screen displays the number of days since the
last stall test was passed for each pump.
Figure 66 Calibrate Screen 2
Figure 64 Calibrate Screen 1
Figure 67 Volume Check Screen
Figure 65 Stall Test Screen
86
3A4486B
Setup Mode Screens
Calibrate Screen 3
Calibrate Screen 3 initiates a calibration of an
accessory solvent meter. During the test, the Volume
Verification screen will appear.
The meter and lines must be primed with
solvent before doing the calibration. See
Solvent Meter Calibration, page 95 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
Figure 69 Enter Measured Volume of Solvent
to end the test.
After the Measured Volume is entered, the Accept
Calibration window will appear. Press
to accept
the calibration. Press
to cancel the calibration
and retain the previous K-factor.
Press and hold the Reset button
seconds to reset the volume counter.
for 1-2
Figure 70 Accept Calibration
Figure 68 Calibrate Screen 3
3A4486B
87
Setup Mode Screens
Maintenance Screens
Maintenance Screen 1
Maintenance Screen 3
Use this screen to set maintenance intervals. Set
to 0 to disable the alarm.
Maintenance screen 3 shows the current interval
status of the pump maintenance tests.
NOTE: The Pump Stall Test cannot be disabled. You
must enter a value other than 0.
Press and hold the Reset button
for 1-2
seconds to clear the alarm and reset the counter.
NOTE: The Pump Stall Test can only be reset by
successfully completing the test.
Figure 71 Maintenance Screen 1, Interval Settings
Maintenance Screen 2
Maintenance screen 2 shows the current interval
status of the solvent meter, fluid filter, and air filter.
Figure 73 Maintenance Screen 3, Current Pump
Status
Press and hold the Reset button
for 1-2
seconds to clear the alarm and reset the counter.
Figure 72 Maintenance Screen 2, Current Status
Solvent Meter
If two solvent meters are used, enter the desired
solvent meter number.
88
3A4486B
Setup Mode Screens
Maintenance Screen 4
Maintenance Screen 5
Maintenance Screen 4 provides the ability to relieve
pump outlet pressure. This feature is only functional
for pumps that have color change valves (fluid
pressure is relieved via the dump valve).
Maintenance screen 5 displays cycle counts for a
selected color, catalyst, or solvent valve.
NOTE: This function is particularly useful if your paint
kitchen is in a controlled environment, but the PD2K
Dual Panel unit is not and is subject to warm, or even
hot, conditions.
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 74 Maintenance Screen 4, Pump Pressure
Relief
Figure 75 Maintenance Screen 5, Color Valve Resets
Manual Pressure Relief
Enter the number of the pump for which you wish
to relieve outlet pressure (pump must have a dump
valve) and press the Pressure Relief softkey. The
system will briefly open the pump’s dump valve,
which will allow trapped fluid pressure to evacuate.
Automatic Pressure Relief
Select the Autodump checkbox to enable the
automated pressure relief functionality. The
automatic pressure relief will perform the same
function as the manual pressure relief, but will
trigger on its own once the pump’s outlet pressure
rises above the set Pressure Limit. The system will
only perform a pressure dump when the pump is in
Standby or Off.
NOTE: It is recommended to set the Pressure Limit
significantly above the spray pressure to avoid
unnecessarily dumping fluid.
3A4486B
Figure 76 Maintenance Screen 5, Solvent Valve
Resets
NOTE: In Fig. 48, the number to the right of “Solvent”
is the pump number, not the material number.
89
Setup Mode Screens
Advanced Screen 1
Advanced screen 1 sets the following display
parameters.
Date Format
Select mm/dd/yy, dd/mm/yy, or yy/mm/dd.
Date
Enter the date, using the format selected. Use two
digits for the month, day, and year.
Time
Enter current time in hours (24 hour clock) and
minutes. Seconds are not adjustable.
Password
Figure 77 Advanced Screen 1
Language
Defines the language of the screen text. Select:
• English (default)
The password is only used to enter Setup mode.
The default is 0000, which means no password is
required to enter Setup. If a password is desired,
enter a number from 0001 to 9999.
NOTE: Be sure to write down the password and keep
it in a secure location.
• Spanish
• French
Screen Saver
• German
Select the desired screen timeout in minutes (00-99).
5 is the default. Select zero (0) to disable the screen
saver.
• Japanese
• Chinese
• Korean
• Dutch
• Italian
Silent Mode
Select Silent Mode to disable the alarm buzzer and
audible feedback.
• Portuguese
• Swedish
• Russian
90
3A4486B
Setup Mode Screens
Advanced Screen 2
Advanced Screen 3
Advanced screen 2 sets display units (US or metric).
Advanced screen 3 enables USB downloads and
uploads.
Figure 78 Advanced Screen 2
Figure 79 Advanced Screen 3
Display Units
Enable USB Downloads/Uploads
Select the desired display units:
• Grand Total Volume (US gallon or liter)
• Pressure (psi, bar, or MPa)
Select this box to enable USB downloads and
uploads. Enabling USB activates the Download
Depth field.
• Length (ft or m)
Download Depth
Enter the number of days for which you want to
retrieve data. For example, to retrieve data for the
previous week, enter 7.
Log 90% Full Advisory Enabled
This selection is enabled by default. When enabled,
the system will issue an advisory if the memory log
has reached 90% of capacity. Perform a download to
avoid loss of data.
3A4486B
91
Setup Mode Screens
Advanced Screen 4
Advanced screen 4 displays the software part
numbers and versions for the system components.
This is not an editable screen.
Figure 80 Advanced Screen 4
92
3A4486B
Setup Mode Screens
Diagnostic Screens
Diagnostic Screen 1
Diagnostic Screen 2
Figure 81 Diagnostic Screen 1
Figure 82 Diagnostic Screen 2
Use this screen to test and verify proper wiring for
all inputs to the EFCM. (See installation manual for
details.) The screen shows all available inputs to the
EFCM, but only highlights those that are relevant
to the system configuration. All inputs are normally
open. When the input sees a switch closure the
status indicator on the screen will turn green.
This screen can be used to determine whether any of
the EFCM outputs are currently on or off. The screen
shows all available outputs from the EFCM, but
only highlights those that are relevant to the system
configuration. The status indicator next to each
output indicates the output is ON when it is green.
Diagnostic Screens 3–10
Figure 83 Diagnostic Screen 1
Diagnostic screens 3–10 are only available for color
change modules that are currently connected to
the PD2K system. These screens provide real time
status of the color change valve outputs by changing
the status indicator from white to green when the
system energizes that solenoid. The user may scroll
through the boards with the up and down arrows, or
jump directly to a specific color change module by
selecting it from the drop-down box.
3A4486B
93
Calibration Checks
Calibration Checks
Pump Pressure Check
NOTE: Enter the transducer calibration data before
doing the pressure check.
1. The pump and lines must be primed with color or
catalyst before doing the Pressure Check. See
Prime and Fill the System, page 20.
2. If the display is on a Run Mode screen, press
to access setup screens.
Perform the pressure check:
3. Scroll to Calibrate to display
Calibrate Screen 1, page 86.
• The first time the system is operated.
• Whenever new materials are used in the system,
especially if the materials have viscosities that
differ significantly.
• At least once per month as part of regular
maintenance.
• Whenever a pump is serviced or replaced.
During each pressure test, the dose valve will close
during an up stroke and a down stroke (in either
order). This test is to verify that the valves are
seating properly and not leaking. If leaking occurs,
the system will alarm after the test for that particular
pump direction.
NOTE: Do not trigger the spray device during the
pressure check.
94
4. Press the Pressure Check
button for the
desired pump. The pump will build pressure in
the line to a minimum of the Stall Test Pressure.
The pump will then move to the center stroke
position and stall test the upstroke, followed by
the downstroke.
5. The pressure and flow that the unit measured
are displayed on the screen. Compare
with the maximum leak rate entered on
System Screen 5, page 72. If the values are
substantially different, repeat the test.
NOTE: The stall test pressure set point is a
minimum. The system may stall at a higher
pressure depending on hose lengths and fluid
composition.
3A4486B
Calibration Checks
Pump Volume Check
Solvent Meter Calibration
1. The pump and lines must be primed with color or
catalyst before doing the Volume Check. See
Prime and Fill the System, page 20.
1. The meter and lines must be primed with
solvent before doing the calibration. See
Prime and Fill the System, page 20.
2. If the display is on a Run Mode screen, press
2. If the display is on a Run Mode screen, press
to access setup screens.
to access setup screens.
3. Scroll to Calibrate in the menu bar.
3. Scroll to Calibrate in the menu bar.
4. Scroll to Calibrate Screen 2, page 86.
4. Scroll to Calibrate Screen 3, page 87.
5. Press the soft key
to check.
5. Press the soft key
for the pump you want
NOTE: For maximum accuracy, use a gravimetric
(mass) method to determine the actual volumes
dispensed. Verify that the fluid line is filled and
at the proper pressure before checking. Air in
the line or pressure that is too high may cause
incorrect values.
6. Press the Reset key
will reset to 0.
. The volume counter
7. Trigger the gun into a graduated cylinder.
Dispense a minimum of 500cc of material.
8. The volume that the unit measured displays on
the screen.
9. Compare the amount on the screen to the
amount in the graduated cylinder.
NOTE: If the value is substantially different,
repeat the test. If the dispensed volume and
measured volume still do not match, check that
the A and B pump positions are not reversed.
NOTE: Stop triggering the gun and press
to cancel the test.
to initiate the calibration.
NOTE: For maximum accuracy, use a gravimetric
(mass) method to determine the actual volumes
dispensed.
NOTE: Verify that the fluid line is filled and at the
proper pressure before calibrating. Air in the line
or pressure that is too high may cause incorrect
calibration values.
6. Trigger the gun into a graduated cylinder.
Dispense a minimum of 500cc of material.
7. The volume that the unit measured displays on
the screen.
8. Compare the amount on the screen to the
amount in the graduated cylinder.
NOTE: If the value is substantially different,
repeat the calibration process.
9. Enter the amount of solvent dispensed in the
Measured Volume field on the screen.
10. After the measured volume is entered, the
controller calculates the new solvent meter
K-factor and displays it on the screen. The
standard meter K-factor is 0.021 cc/pulse.
11. Press
to accept the calibration. Press
to cancel the calibration and retain the previous
K-factor.
NOTE: Solvent meters must be enabled individually
by Mix Unit. Solvent Meter 1 applies to Mix Unit #1
only, Solvent Meter 2 applies to Mix Unit #2 only.
3A4486B
95
Color Change
Color Change
3. Select the new recipe on the
Spray Screen, page 64. This will change
colors in the pump and initiate a gun purge.
4. The system will purge material B then material
A out of the gun. Each material will purge for
the amount of time designated by the Flush
Sequence selected for each material on the
Recipe Screen, page 74.
Color Change Module Kits are available as an
accessory. See manual 333282 for complete
information.
Multiple Color Systems
1. Command the system to Standby.
2. Enable manual override on
System Screen 1, page 68.
96
5. Wait for the color change to complete. The
system automatically goes from Color Change to
Mix Fill and the remote mix manifold automatically
selects the correct color.
6. Trigger the gun to complete the Mix Fill.
NOTE: There is a 10 second delay without flow
before the system will fault.
7. Wait for the system to complete the Mix Fill
operation. Command the system to Mix and
begin spraying..
3A4486B
System Errors
System Errors
System errors alert you of a problem and help
prevent off-ratio spraying. There are three types:
Advisory, Deviation, and Alarm.
An Advisory records an event in the system, and will
clear itself after 60 seconds. 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.
A Deviation records an error in the system but does
not shut down the equipment. The deviation must be
acknowledged by the user. The four-digit error code
will be followed by ‘-D’.
If an Alarm occurs, operation stops. The four-digit
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 99).
• Status bar on the Advanced Display Module shows
the active alarm code.
Figure 85 QR Code Screen
• Alarm is saved in the date/time stamped log.
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
A Record saves relevant system events in the
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.
pressing
.
NOTE: Most system errors apply only to a specific Mix
Unit and therefore only show up on the appropriate
menu bar and Event Flag PLC register when that Mix
Unit is active. All alarms will generate a pop-up on
the ADM regardless of the active Mix Unit.
On--Screen Help
On
When a system alarm occurs, a help screen
is available to provide timely and relevant
troubleshooting information for the user. On the
to access the help
alarm popup screen, press
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 67).
Figure 86 Troubleshooting Screen
Figure 84 Alarm Popup
3A4486B
97
System Errors
To Clear Error and Restart
Gun Trigger Input Function
NOTE: When a deviation or alarm occurs, be
sure to determine the error code before resetting
it. If you forget which code occurred, go to the
Errors Screen, page 67, to view the last 200 errors,
with date and time stamps.
The Gun Trigger Input signals the controller when
the gun is triggered. The gun icon on the Advanced
Display Module shows spray when the Gun Trigger
Input is activated.
If an alarm has occurred, correct the cause before
resuming operation.
To acknowledge a deviation or clear an alarm, press
on the Advanced Display Module. Users also
may acknowledge and clear errors via a network
device (see INPUT REGISTER 01 and 11: Clear
Active Alarm/Deviation, page 35).
98
If a pump fails, pure resin or catalyst could spray
indefinitely if the unit does not detect the condition
and intervene, which is why the Gun Trigger Input
is so important.
If the unit detects through the Gun Trigger Input
signal that the gun is triggered, yet one or both of the
pumps are not running, a Flow Not Detected Alarm
(F8D1) occurs after 10 seconds (default) and the
system goes into Standby.
3A4486B
System Errors
Error Codes
NOTE: When an error occurs be sure to determine the code before resetting it. If you forget which code occurred, use
the Errors Screen, page 67 to view the last 200 errors, with date, time, and description.
Purge Errors
Code
Type
Description
Problem
Cause
Solution
EJS#
Record
Purge Not
Complete
The Mix Unit was unable
to complete a purge
sequence.
An indication that Mix
Unit # either could
not complete or was
interrupted before
completing a gun purge.
No action required.
SPD#
Alarm
Gun Purge
Incomplete
The Mix Unit timed out
without reaching the
user-specified volume of
solvent for a purge.
Solvent flow switch not
working.
Replace switch.
Solvent flow is too low
to actuate the solvent
switch.
Increase solvent
pressure to drive a
high purge flow rate
Gun is not triggered.
Operator must continue
flushing for configured
time, until the booth
control indicates purge is
completed.
Mix manifold was not set Set manifold to flush
to flush position, blocking position.
solvent flow to the spray
gun.
Mix Errors
Code
Type
Description
F7S1
F7S2
Alarm
Flow
The solvent flow switch
Detected
is indicating unexpected
Solvent Gun solvent flow for Mix Unit
(1) or Mix Unit (2).
F7S3
F7S4
QPD#
SND#
3A4486B
Alarm
Flow
Detected
Solvent Mix
Alarm,
then
Deviation
Potlife
Expired
Alarm
Mix Fill
Incomplete
Problem
The solvent flow switches
indicate that both are
flowing solvent at the
same time for Mix Unit
#1 (3) or Mix Unit #2 (4).
Potlife time has expired
before the Mix Unit has
moved the required
amount of material
(potlife volume) through
the mixed material line.
Mix Unit # timed out
before the mix fill cycle
loaded the gun with
mixed material.
Cause
Solution
Solvent flow switch is
stuck in flow position.
Clean or replace switch.
There is a leak through
the solvent cutoff valve.
Check for leaks and
repair valve.
One or both solvent flow Clean or replace the
switches are stuck in flow switch(es).
position.
There is a leak through
Check for leaks and
one or both of the solvent repair valve(s).
cutoff valves.
Purge process was not
completed.
Make sure purge process
is completed.
Solvent supply shut off or Verify solvent supply is
empty.
available and on, supply
valves are open.
Mix manifold not set to
spray position.
Set manifold to spray.
Spray gun was not
triggered.
Allow flow through gun
during fill process until
the fill complete LED
stops flashing.
Restrictions in mixer,
manifold, or spray gun.
Fix restrictions.
99
System Errors
Pumping Errors
NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable
component number, which can vary. The unit’s display will show the applicable number as the last digit in the
code. For example, the F1S# code listed in this table will be displayed as F1S1 if the affected component is pump
1, F1S2 for pump 2, and so on.
Code
Type
Description
Problem
Cause
Solution
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.
Inspect system for leaks.
Pump is cavitating,
cycling without
restriction.
Verify that the pump
is being supplied with
material.
Viscosity of material is
too thin for nozzle size.
Reduce nozzle size to
create more restriction.
Reduce paint pressure to
lower the flow rate.
System pressure or
Flow Setpoint is too high
(causing the pump to
work too hard).
Reduce the pressure or
the Flow Setpoint.
This is a manual stall test
failure when the pump
cannot build pressure
to the target “Stall Test
Pressure.” Will fault after
30 seconds.
No material in the pump
or line.
Make sure the pump and
down stream color line
are loaded with material.
Leak in the system.
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.
DE0#
Alarm
Leak
Detected
Pump #
DF0#
Alarm
No Stall Up
Pump #
Pump failed the stall
test; did not stall on the
upstroke.
Valve failure, seal failure,
worn rod or cylinder.
Replace inlet and outlet
valve and seal for
up stroke. Replace
piston and throat seals.
Replace rod and cylinder
as necessary.
DG0#
Alarm
No Stall
Down Pump
#
Pump failed the stall
test; did not stall on the
downstroke.
Valve failure, seal failure,
worn rod or cylinder.
Replace inlet and
outlet valve and seal
for down stroke. Replace
piston and throat seals.
Replace rod and cylinder
as necessary.
DH0#
Alarm
No Stall
Pump #
Pump failed the stall
Valve failure, seal failure,
test; did not stall on
worn rod or cylinder.
either the upstroke or the
downstroke.
Replace inlet and outlet
valve and seal for up and
down strokes. Replace
piston and throat seals.
Replace rod and cylinder
as necessary.
100
3A4486B
System Errors
Code
Type
Description
Problem
Cause
Solution
DKD#
Alarm
Position
Failed Pump
#
Pump was unable to
reach its drive position.
Not enough air is
supplied to the dosing
valves.
Ensure that at least 85
psi is being supplied to
the dosing valves.
The pressure at the
pump outlet is too high.
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
DKF#
Alarm
Position
Overspeed
Pump #
Pump moved beyond its
drive position.
The pump was knocked
out of position.
There is no fluid pressure
at the outlet of the pump;
run the pump at a lower
pressure to fill the lines.
Check that the feed
pressure is not more
than the target pressure.
EBH#
Record
Home
Complete
Pump #
Record of pump homing
is complete.
An indication on the
display that the pump
completed the home
function
No action required.
EF0#
Alarm
Timeout
Startup
Pump #
Pump tried but was not
Pump dose valves did
able to move to the
not actuate.
home position within a
specified amount of time.
Motor could not drive
pumps and linear
actuator.
Verify air pressure to
solenoid valves. Verify
the valves are actuating.
Verify motor is driving
the pump.
Pump stroke length is
Verify correct assembly
shortened by mechanical of linear actuator and
system tolerance.
pump piston rods. See
pump manual.
EF1#
Alarm
Timeout
Shutdown
Pump #
Pump tried but was not
Pump dose valves did
able to move to the park not actuate.
position within a specified
amount of time.
Visually inspect valves
to ensure they are
operating properly; verify
they have air pressure
above 85 psi (0.6 MPa,
6.0 bar).
Pump is filled with thick
paint and could not drive
piston to end of stroke.
Motor or drive is worn or
damaged.
Observe motor and drive
assembly to verify that
the motor is generating
force.
ETD#
Record
Auto
Pressure
Relief Pump
#
Record of pump
completing an auto
pressure relief.
Pump outlet pressure
exceeded relief
threshold.
No action required.
EP0#
Record
Auto Pump
Parked Mix
Unit #
Record of pumps being
auto parked.
The auto pump
park operation was
completed.
No action required.
F1A#
Alarm
Flow Low
Dispense
Pump #
The pump was unable to
maintain its target flow
rate.
There is a restriction
in the hose or gun that
is preventing the pump
from dispensing at its
target rate.
Check that the gun
is triggered and for
restrictions in the hose.
F1D#
Alarm
Flow Low Mix The Mix Unit was unable There is a restriction
Unit #
to maintain it's target flow in the hose or gun that
rate.
is preventing the pump
from dispensing at it's
target rate.
Check that the gun
is triggered and for
restrictions in the hose.
3A4486B
101
System Errors
Code
Type
Description
Problem
F1F#
Alarm
Flow Low Fill
Pump #
There is a restriction on
There has been no flow
or low flow during a pump the outlet side of the
pump or color stack.
fill operation.
Make sure there are no
restrictions in the color
stack and that the dump
valve is actuating.
Thick viscosity paint
requires more pressure
to pump.
Increase non-mix
pressure if necessary
to create flow during the
fill function.
The pumps do not have
to move for the system to
build enough pressure to
meet the setpoint.
Increase non-mix
pressure if necessary
to create flow during the
fill function.
Cause
Solution
F1S#
Alarm
Flow Low
Purge Pump
#
Restriction in the outlet
There has been no flow
or low flow during a pump side of the pump or color
stack resulting in the
purge operation.
solvent flow being too
low.
F7D#
Alarm
Flow
Detected
Pump #
The pump flow exceeded
20 cc/min flow coming
into Idle mode.
There is a leak in the
system or the gun was
open when the system
went into Idle mode.
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.
F8D#
Alarm
Flow Not
Detected Mix
Unit #
No flow while mixing.
Restriction in the outlet
side of the pump or color
stack.
Make sure there are no
restrictions in the system.
F9D#
Alarm
Flow
Unstable
Pump #
The pump flow rate
did not stabilize while
entering Idle mode.
Potential leak in the
system.
Check the system for
leaks and run manual
stall test.
102
Make sure there are
no restrictions in the
system. Increase
non-mix pressure if
necessary to create flow
during the purge function.
3A4486B
System Errors
Pressure Errors
NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable
component number, which can vary. The unit’s display will show the applicable number as the last digit in the
code. For example, the P6F# code listed in this table will be displayed as P6F1 if the affected component is pump
1, P6F2 for pump 2, and so on.
Code
Type
Description
Problem
Cause
P1D#
Alarm
Presure Low
Oultet Pump
#
The outlet pressure on
pump # is less than
the user-entered alarm
limit. *This alarm is
only enabled with Flow
Control.
There is no fluid pressure Check supply for pump
or pump is cavitating.
#, increase supply
pressure.
P1F#
Alarm
Pressure
Low Inlet
Pump #
The inlet pressure on
pump # is less than the
user-entered alarm limit.
Increase inlet pressure.
P2F#
Deviation
Pressure
Low Inlet
Pump #
The inlet pressure on
pump # is less than the
user-entered deviation
limit.
Increase inlet pressure.
P3D#
Deviation
Pressure
High Outlet
Pump #
The outlet pressure
on pump # is greater
than the user entered
deviation limit.
Relieve system pressure.
P3F#
Deviation
Pressure
High Inlet
Pump #
The inlet pressure on
pump # is greater
than the user-entered
deviation limit.
Decrease inlet pressure.
P4D#
Alarm
Pressure
High Outlet
Pump #
The outlet pressure on
pump # is greater than
the user entered alarm
limit.
Relieve system pressure.
P4F#
Alarm
Pressure
High Inlet
Pump #
The inlet pressure on
pump # is greater than
the user-entered alarm
limit.
Decrease inlet pressure.
P4P#
Alarm
Pressure
High Supply
Pump #
The supply pump fluid
pressure for pump # is
greater than 90% of the
user-entered Stall Test
Pressure.
The supply pump
pressure is too high.
Check supply for pump
#, decrease supply
pressure.
P6D#
Alarm
Press. Sens.
Removed
Outlet #
No outlet pressure
transducer is detected
when the system is
expecting one.
Disconnected
transducer.
Verify transducer is
connected properly.
Replace if reconnecting
does not eliminate the
alarm.
P6F#
Alarm
Press. Sens.
Removed
Inlet #
No inlet pressure
transducer is detected
when the system is
expecting one.
Disconnected
transducer.
Verify transducer
is connected
properly. Replace if
reconnecting does not
eliminate the alarm.
P9D#
Alarm
Press. Sens.
Failed Outlet
#
Outlet pressure
transducer has failed.
Outlet pressure
transducer has failed
or the pressure is above
the readable range.
Relieve system pressure.
Verify connections, or
replace if reconnecting
does not eliminate the
alarm.
P9F#
Alarm
Press. Sens.
Failed Inlet #
Inlet pressure transducer
has failed.
Inlet pressure transducer
has failed or the pressure
is above the readable
range.
Relieve system pressure.
Verify connections, or
replace if reconnecting
does not eliminate the
alarm.
3A4486B
Solution
103
System Errors
Code
Type
Description
Problem
Cause
Solution
QAD#
Alarm
Differential
Pressure A
Over B
Mix Unit # low differential
pressure. This alarm is
active only during Mix
mode.
There is a leak on the B
side.
Check the system for
internal and external
leaks on all catalyst
manifolds and plumbing.
The B side pump is
cavitating.
Check paint supply on
the B side, increase paint
supply pressure.
QBD#
Alarm
Differential
Pressure B
Over A
Mix Unit # high differential There is a leak on the A
side.
pressure. This alarm is
active only during Mix
mode.
Check the system for
internal and external
leaks on all color
manifolds and plumbing.
The A side pump is
cavitating.
Check paint supply on
the A side, increase paint
supply pressure.
System Errors
Code
Type
Description
Problem
Cause
Solution
EB00
Record
Stop Button
Pressed
Record of a stop button
press.
Indicates system stop
key on ADM was
pressed.
n/a
EBC#
Record
PLC Power
Command
for Mix Unit #
Record of pumps
powered off by PLC
command.
The PLC command was
used to shut down pump
power.
No action required.
EBI#
Record
Power Button Record of pumps
Pressed Mix powered off by button
Unit #
press.
The power button on the
ADM was used to shut
down pump power.
No action required.
EC00
Record
Setup
Value(s)
Changed
Record of changing
setup variables.
Indicates date and time
when setup values were
changed.
n/a
EL00
Record
System
Power On
Record of power cycle
(ON).
Indicates date and
time when system was
started.
n/a
EM00
Record
System
Power Off
Record of power cycle
(OFF).
Indicates date and time
when system was turned
off.
n/a
EMI#
Advisory
Pump Off Mix The pumps are not
powered and are unable
Unit #
to move for Mix Unit #.
Pump power was turned
off or an error occurred.
Start pumps by pressing
pump start key on
Advanced Display
module.
ES00
Advisory
Factory
Defaults
104
Record of defaults being
loaded.
n/a
3A4486B
System Errors
Communication Errors
NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable
component number, which can vary. The unit’s display will show the applicable number as the last digit in the
code. For example, the CAC# code listed in this table will be displayed as CAC1 if the affected component is
color change board 1, CAC2 for board 2, and so on.
Code
Type
Description
Problem
Cause
Solution
CA0X
Alarm
Comm. Error
ADM
System does not detect
the Advanced Display
Module (ADM).
This communication
error indicates that
the Network has lost
communication with
the Advanced Display
Module.
Check CAN cable
connecting ADM to the
EFCM.
CAC#
Alarm
Comm. Error
Color Change
#
System does not detect
the Color Change
Module #.
This communication
error indicates that
the network has lost
communication with
the Color Change
Module #.
Check CAN cable
connections to
the Color Change
Module # and any
interconnected
modules.
CADX
Alarm
Comm. Error
Fluid Module
System does not
see the Enhanced
Fluid Control Module
(EFCM).
This communication
error indicates that
the Network has lost
communication with
the EFCM.
Check CAN cables
connecting ADM to the
EFCM. Replace Cable
or EFCM as necessary.
CAGX
Alarm
Comm. Error
Gateway
System does not
detect a CGM that was
registered as being
connected at power
up.
CAG#
Alarm
Comm. Error
Modbus
Gateway
System does not detect
a Modbus CGM that
was registered as
being connected at
power up.
The Modbus CGM
address dial was
changed while the
system was powered
up.
Unplug the Modbus
CGM from the CAN
network and re-plug
it back in so that it
re-registers with the
new address.
The Modbus CGM is
not connected/failed.
Check that the Modbus
CGM is properly
connected to the CAN
network and it's LEDs
indicate it is powered.
CDC#
Alarm
Duplicate Color
Change #
System detects two or
more identical Color
Change Modules.
More than one Color
Change Module with
the same address
is connected in the
system .
Check the system and
remove the extra color
change module.
CDDX
Alarm
Duplicate Fluid
Module
System sees two
or more identical
Enhanced Fluid
Control Modules
EFCM).
More than one EFCM
is connected in the
system.
Check the system
and remove the extra
EFCM.
3A4486B
105
System Errors
USB Errors
Code
Type
Description
Problem
Cause
Solution
EAUX
Advisory
USB Busy
USB drive is inserted,
download is in
progress.
Indicates USB port
is uploading or
downloading data.
Wait for USB Idle.
EBUX
Record
USB Drive
Removed
USB drive was
removed while
downloading or
uploading.
Downloading/uploading data on USB was
interrupted by the USB
device being removed.
Replace the USB
device and begin
process again.
EQU0
Advisory
USB Idle
USB download
completed, drive may
be removed.
Data transfer is
completed to the USB
device.
Remove USB device
from ADM.
EQU1
Record
USB Sys.
Settings
Downloaded
Settings were
downloaded to USB
drive.
User installed USB
device in ADM USB
port.
n/a
EQU2
Record
USB Sys.
Settings
Uploaded
Settings were
uploaded from USB
drive.
User installed USB
device in ADM USB
port.
n/a
EQU3
Record
USB Custom
Lang.
Downloaded
Custom language was
downloaded to USB
drive.
User installed USB
device in ADM USB
port.
n/a
EQU4
Record
USB Custom
Lang.
Uploaded
Custom language was
uploaded from USB
drive.
User installed USB
device in ADM USB
port.
n/a
EQU5
Record
USB Logs
Downloaded
Data logs were
downloaded to USB
drive.
User installed USB
device in ADM USB
port.
n/a
EVUX
Advisory
USB Disabled
USB drive has been
inserted, downloading
is disabled.
Configuration of
system is blocking
data transfer.
Change configuration
to enable USB
download function.
MMUX
Advisory
Maint. USB
Logs Full
USB memory is more
than 90% full.
Configuration
parameter on system
is enabled to generate
this advisory.
Complete download to
ensure no data is lost.
WSUX
Advisory
USB Config.
Err.
USB configuration
file does not match
expected; checked on
startup.
A software update
was not completed
successfully.
Reinstall software.
WXUD
Advisory
USB Download
Err.
An error occurred while
downloading to the
USB drive.
User installed
incompatible USB
device in ADM USB
port.
Repeat process with
compatible USB
device.
WXUU
Advisory
USB Upload
Err.
An error occurred while
uploading from the
USB drive.
User installed
incompatible USB
device in ADM USB
port.
Repeat process with
compatible USB
device.
106
3A4486B
System Errors
Miscellaneous Errors
NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable
component number, which can vary. The unit’s display will show the applicable number as the last digit in the
code. For example, the B9D# code listed in this table will be displayed as B9D1 if the affected component is pump
1, B9D2 for pump 2, and so on.
Code
Type
Description
Problem
Cause
Solution
B9A#
Advisory
Volume
Rollover A
Current Mix
Unit #
Batch counter for
material A rolled over
for Mix Unit #.
The totalizer has
reached maximum
capable value and
started over at zero.
n/a
B9AX
Advisory
Volume
Rollover A
Lifetime
Grand total counter for
material A rolled over.
The totalizer has
reached maximum
capable value and
started over at zero.
n/a
B9B#
Advisory
Volume
Rollover B
Current Mix
Unit #
Batch counter for
material B rolled over
for Mix Unit #.
The totalizer has
reached maximum
capable value and
started over at zero.
n/a
B9BX
Advisory
Volume
Rollover B
Lifetime
Grand total counter for
material B rolled over.
The totalizer has
reached maximum
capable value and
started over at zero.
n/a
B9D#
Advisory
Volume
Rollover Pump
#
Grand total counter for
pump # rolled over.
The totalizer has
reached maximum
capable value and
started over at zero.
n/a
B9S1
B9S2
Advisory
Volume
Rollover
Solvent
Current Mix
Unit #
Batch counter for
solvent rolled over for
Mix Unit 1 (1) or Mix
Unit 2 (2).
The totalizer has
reached maximum
capable value and
started over at zero.
n/a
B9S3
B9S4
Advisory
Volume
Rollover
Solvent
Lifetime
Grand total counter for
solvent rolled over for
Mix Unit 1 (3) or Mix
Unit 2 (4).
The totalizer has
reached maximum
capable value and
started over at zero.
n/a
WX00
Alarm
Software
Errors
An unexpected
software error has
occurred.
Call Graco technical
support.
Calibration Errors
NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable
component number, which can vary. The unit’s display will show the applicable number as the last digit in the
code. For example, the ENT# code listed in this table will be displayed as ENT1 if the affected component is pump
1, ENT2 for pump 2, and so on.
Code
Type
Name
Description
END#
Record
Calibration Pump #
A calibration test was run on the pump.
ENS#
Record
Calibration Solvent Meter #
A calibration test was run on the solvent
meter.
ENT#
Record
Calibration Stall Test Pump #
A stall test was completed successfully on
pump #.
3A4486B
107
System Errors
Maintenance Errors
NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable
component number, which can vary. For example, the MAD# code listed in this table will be displayed as MAD1 if the
affected component is pump 1, MAD2 for pump 2, and so on.
Because some components are assigned a 2–digit number, the last digit of the code is displayed as an alphanumeric
character. The second table below correlates the alphanumeric digit to its component number. For example, code
MEDZ represents outlet valve 30.
Code
Type
Name
Description
MAD#
Advisory
Maint. Outlet Pump #
Maintenance is due on pump.
MAT#
Advisory
Maint. Stall Test Pump
#
Maintenance stall test is due on pump.
MEB#
Advisory
Maint. Valve Catalyst
(B) #
Maintenance is due on catalyst valve.
MED#
Advisory
Maint. Valve Outlet #
Maintenance is due on outlet valve.
MEF#
Advisory
Maint. Valve Inlet #
Maintenance is due on inlet valve.
MEG#
Advisory
Maint. Valve Gun #
Maintenance is due on gun valve.
MEN#
Advisory
Maint. Valve Auxiliary
Maintenance is due on auxiliary valve.
MES#
Advisory
Maint. Valve Solvent #
Maintenance is due on solvent valve.
MFF#
Advisory
Maint. Meter Flow #
Maintenance is due on flow meter.
MFS#
Advisory
Maint. Meter Solvent #
Maintenance stall test is due on solvent meter.
MGH0
Advisory
Maint. Filter Fluid
Maintenance is due on fluid filter.
MGP0
Advisory
Maint. Filter Air
Maintenance is due on air filter.
MJP#
Advisory
Maint. Valve Air
Maintenance is due on air valve.
Alphanumeric Last Digits
Alphanumeric Digit
Component Number
Alphanumeric Digit
Component Number
1
1
G
16
2
2
H
17
3
3
J
18
4
4
K
19
5
5
L
20
6
6
M
21
7
7
N
22
8
8
P
23
9
9
R
24
A
10
T
25
B
11
U
26
C
12
V
27
D
13
W
28
E
14
Y
29
F
15
Z
30
108
3A4486B
Maintenance
Maintenance
Preventive Maintenance Schedule
Flushing
The operating conditions of your particular system
determine how often maintenance is required.
Establish a preventive maintenance schedule by
recording when and what kind of maintenance is
needed, and then determine a regular schedule for
checking your system.
• Flush before changing fluids, before fluid can dry
in the equipment, at the end of the day, before
storing, and before repairing equipment.
• Flush at the lowest pressure possible. Check
connectors for leaks and tighten as necessary.
• Flush with a fluid that is compatible with the fluid
being dispensed and the equipment wetted parts.
Cleaning the ADM
Use any alcohol-based household cleaner, such as
glass cleaner, to clean the ADM.
3A4486B
109
Appendix A: Integration with Allen Bradley PLC
Appendix A: Integration with Allen Bradley PLC
This appendix outlines how to integrate a ProMix PD2K with an Allen Bradley Studio 5000 Programmable Logic
Controller (PLC).
To integrate, the ProMix PD2K must have the Ethernet/IP protocol for PLC CGM (Graco Part number CGMEPO)
installed prior to performing this procedure.
In the PLC software, perform the following steps:
1. Add the new Ethernet module.
2. The Select Module Type screen opens.
a. In the search field, type “generic” .
b. Select ETHERNET-MODULE Generic Ethernet Module.
NOTE: Do not select the Close on Create checkbox.
c.
110
Click the Create button.
3A4486B
Appendix A: Integration with Allen Bradley PLC
3. The New Module screen opens.
Configure the module by defining the fields as follows:
NOTE: The Open Module Properties checkbox must remain selected so that the configuration can be completed
after completing this screen.
a. Name (required): Enter a name for the module (select a name that will have meaning for you when viewed on
the Ethernet directory shown by the figure in step 1).
b. Description (optional): Use any description desired.
c.
IP Address (required): Enter the static IP address of the Graco EtherNet/IP CGM installed in the ProMix PD2K.
d. Input: Assembly Instance (required): Enter “100”, which is a device-specific parameter for the Graco
EtherNet/IP CGM.
e. Input: Size (required): Enter “62”, which is the number of 32–bit registers that are allocated for input variables
in the Graco EtheNet/IP CGM.
f.
Output: Assembly Instance (required): Enter “150”, which is the device-specific parameter for the Graco
EtherNet/IP CGM.
g. Output: Size (required): Enter “30”, which is the number of 32–bit registers that are allocated for output
variables in the Graco EtheNet/IP CGM.
h. Configuration: Assembly Instance (required): Enter “1”.
i.
Configuration: Size (required): Enter “0”.
j.
Click the OK button. The Module Properties Report window will be displayed.
3A4486B
111
Appendix A: Integration with Allen Bradley PLC
4. On the Connection tab:
NOTE: An asterisk appears after the tab heading if unsaved changes are present. Click the Apply button to
save changes without exiting this screen.
a. Enter a Requested Packet Interval (RPI) value.
NOTE: Graco recommends a value of 30 ms or greater.
b. If desired, select the available checkboxes.
c.
Click the OK button to save all changes and exit this screen.
Table 7 Potential Configuration Problems
Error
Description
Connection Request Error — Invalid Input
Application Path
This error, which also triggers an I/O Fault on the PLC, is caused by
an invalid number being entered for the Input: Assembly Instance
parameter. The correct value for this parameter is “100”.
Connection Request Error — Invalid Output
Application Path
This error, which also triggers an I/O Fault on the PLC, is caused by
an invalid number being entered for the Output: Assembly Instance
parameter. The correct value for this parameter is “150”.
Connection Request Error — Invalid Input
Size
This error, which also triggers an I/O Fault on the PLC, is caused by
an invalid number being entered for the Input: Size parameter. The
correct value for this parameter is “62”.
Connection Request Error — Invalid Output
Size
This error, which also triggers an I/O Fault on the PLC, is caused by
an invalid number being entered for the Output: Size parameter. The
correct value for this parameter is “30”.
Module Configuration Rejected — Format
Error
This error, which also triggers an I/O Fault on the PLC, is caused
by an invalid number being entered for the Configuration: Size
parameter. Because there are no configuration registers associated
with the module, the correct value for this parameter is “0”.
112
3A4486B
Technical Data
Technical Data
Positive Displacement
Proportioner
U.S.
Metric
AC1002 and AC3002 Air
Spray Systems
300 psi
2.1 MPa, 21 bar
AC2002 and AC4002
Air-Assisted Spray
Systems
1500 psi
10.5 MPa, 105 bar
100 psi
0.7 MPa, 7.0 bar
85–100 psi
0.6–0.7 MPa, 6.0–7.0 bar)
Maximum fluid working
pressure:
Maximum working air
pressure:
Air supply:
Air filter inlet size:
3/8 npt(f)
Air filtration for air logic
(user-supplied):
5 micron (minimum) filtration required; clean and dry air
Air filtration for atomizing
air (user-supplied):
30 micron (minimum) filtration required; clean and dry air
Mixing ratio range:
0.1:1 — 50:1, ±1%
one or two component:
Fluids handled:
• solvent and waterborne paints
• polyurethanes
• epoxies
• acid catalyzed varnishes
• moisture sensitive isocyanates
Viscosity range of fluid:
20–5000 centipoise
Fluid filtration
(user-supplied):
100 mesh minimum
Maximum fluid flow:
800 cc/minute (depending on material viscosity)
Fluid outlet size:
1/4 npt(m)
External power supply
requirements:
90 - 250 Vac, 50/60 Hz, 7 amps maximum draw
15 amp maximum circuit breaker required
8 to 14 AWG power supply wire gauge
Operating temperature
range:
36 to 122°F
2 to 50°C
Storage temperature
range:
—4 to 158°F
—20 to 70°C
Weight (approximate):
195 lb
88 kg
Sound data:
Less than 75 dB(A)
Wetted parts:
AC1002 and AC2002
AC4002
3A4486B
17–4PH, 303, 304 SST, Tungsten carbide (with nickel binder),
perfluoroelastomer; PTFE, PPS, UHMWPE
316 SST, 17–4PH SST, PEEK,
perfluoroelastomer; PTFE, PPS, UHMWPE
113
Graco Standard Warranty
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 WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY
OF FITNESS FOR A PARTICULAR PURPOSE.
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 MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT,
MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but
not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if
any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim
for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from
Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods
sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents,
notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly
hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente
document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou
intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
To place an order, contact your Graco Distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
For patent information, see www.graco.com/patents.
Original Instructions. This manual contains English. MM 3A4486
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
2016,, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Copyright 2016
www.graco.com
Revision B, January 2018

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