Graco 332564C, ProMix® PD2K Proportioner for Automatic Spray Applications Owner's Manual

Operation
ProMix® PD2K Proportioner for
Automatic Spray Applications
332564C
EN
fast--setting two
two--component materials. Automatic
Electronic positive displacement proportioner for fast
system with Advanced Display Module. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual and in your
installation, repair, and associated component manuals. Save these
instructions.
See page 3 for model part numbers and
approvals information.
PROVEN QUALITY. LEADING TECHNOLOGY.
Contents
Related Manuals .................................................. 3
Models................................................................. 4
Warnings ............................................................. 7
Important Isocyanate (ISO) 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 ................................ 17
Screen Icons ............................................... 17
Pre-Operation Tasks........................................... 18
Pre-operation Checklist ................................ 18
Power On .................................................... 18
Initial System Setup ..................................... 19
Flush Before Using Equipment...................... 19
Valve Settings.............................................. 19
Pressure Relief Procedure .................................. 20
Without Color Change .................................. 20
With Color Change....................................... 20
Operation Using Advanced Display Module
(ADM)................................................... 21
Prime and Fill the System ............................. 21
Spraying...................................................... 22
Purging ....................................................... 23
Shutdown .................................................... 24
Operation Using a Programmable Logic
Controller (PLC) .................................... 25
Network Communications and Discrete
I/O ................................................. 25
Discrete I/O ................................................. 25
Communication Gateway Module (CGM)
Details ........................................... 27
Network Communication I/O Data Map ........... 28
Operation Flow Charts ................................. 43
Network Communication - Dynamic
Command Structure (DCS) ............. 52
PLC Diagnostic Screens............................... 64
Flow Control System .................................... 65
Run Mode Screens ............................................. 66
Opening Screen........................................... 66
Home Screen .............................................. 66
Spray Screen............................................... 70
Fill Screen ................................................... 71
Usage Screen.............................................. 72
Jobs Screen ................................................ 73
2
Errors Screen .............................................. 73
Events Screen ............................................. 73
Setup Mode Screens .......................................... 74
Password Screen......................................... 74
System Screen 1 ......................................... 75
System Screen 2 ......................................... 76
System Screen 3 ......................................... 78
System Screen 4 ......................................... 78
System Screen 5 ......................................... 79
Recipe Screen ............................................. 80
Flush Screen ............................................... 82
Pump Screen 1 ............................................ 83
Pump Screen 2 ............................................ 85
Pump Screen 3 ............................................ 86
Pressure Alarm and Deviation Limits ............. 86
Calibration Screens...................................... 87
Maintenance Screens................................... 90
Advanced Screen 1...................................... 92
Advanced Screen 2...................................... 93
Advanced Screen 3...................................... 93
Advanced Screen 4...................................... 94
Diagnostic Screens ...................................... 95
Calibration Checks.............................................. 96
Pump Pressure Check ................................. 96
Pump Volume Check.................................... 97
Solvent Meter Calibration ............................. 98
Color Change ..................................................... 99
Multiple Color Systems................................. 99
System Errors .................................................. 100
To Clear Error and Restart.......................... 100
Gun Trigger Input Function ......................... 100
Error Codes ............................................... 101
Maintenance .................................................... 114
Preventive Maintenance Schedule .............. 114
Flushing .................................................... 114
Cleaning the ADM...................................... 114
Appendix A: Integration with Allen Bradley
PLC.................................................... 115
Appendix B: Multiple Guns ................................ 118
Spray Screen............................................. 122
Fill Screen ................................................. 122
Potlife Screen ............................................ 123
Recipe 0.................................................... 123
Maintenance Screen 4 ............................... 124
Operation With a PLC ................................ 124
Technical Data ................................................. 125
Graco Standard Warranty...................................... 1
332564C
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
334494
ProMix PD2K CGM Installation
Kits, Instructions — Parts
332339
Dosing Pumps, Instructions —
Parts
332454
Color/Catalyst Dispense Valves,
Instructions — Parts
332564C
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
AC0500
A
100 psi (0.7 MPa, 7.0 bar)
With low–pressure pumps:
300 psi (2.068 MPa,
20.68 bar)
Location of PD2K and
Electrical Control Box
(ECB) Labels
With high–pressure pumps:
1500 psi (10.34 MPa,
103.4 bar)
AC1000
A
100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa,
20.68 bar)
AC2000
A
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa,
103.4 bar)
0359
II 2 G
Figure 1 Model AC1000 (Low Pressure) Identification
Label
Figure 2 24M672 Control Box Identification Label
4
Continued on the next page.
332564C
Models
Figure 3 Model AC2000 (High Pressure)
Identification Label
®
ProMix PD2K / PD1K
Electronic Proportioner
II 2 G
Ex ia IIA T3
FM13 ATEX 0026
IECEx FMG 13.0011
Intrinsically safe
equipment for Class I,
Div 1, Group D, T3
Ta = 2°C to 50°C
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
7
100
MPa
bar
PSI
POWER REQUIREMENTS
VOLTS
AMPS
90-250 ~
7 AMPS MAX
50/60 Hz
Um: 250 V
MAX TEMP 50°C (122°F)
Artwork No. 294280 Rev. D
Read Instruction Manual
.7
Warning: Substitution of components
may impair intrinsic safety.
PART NO.
MFG. YR.
SERIES
SERIAL
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
Figure 4 Model AC0500 Identification Label
Figure 5 Non-Intrinsically Safe Color Change Control (Accessory) Identification Label
Figure 6 Intrinsically Safe Color Change Control
(Accessory) Identification Label
332564C
5
Models
Figure 7 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 8 CGM Identification Label
6
332564C
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance and repair of this equipment. The exclamation
point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risks. When these
symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard
symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help
prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic
drop cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable
fumes are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are antistatic or conductive.
• Stop operation immediately if static sparking occurs or you feel a shock, Do not use equipment until
you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause
electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
332564C
7
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.
8
332564C
Warnings
WARNING
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but
is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and
create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
332564C
9
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 materials containing
isocyanates creates potentially harmful mists,
vapors, and atomized particulates.
Read and understand material manufacturer’s
warnings and material MSDS to know specific
hazards and precautions related to isocyanates.
Prevent inhalation of isocyanate mists, vapors,
and atomized particulates by providing sufficient
ventilation in the work area. If sufficient ventilation
is not available, a supplied-air respirator is required
for everyone in the work area.
To prevent contact with isocyanates, appropriate
personal protective equipment, including
chemically impermeable gloves, boots, aprons,
and goggles, is also required for everyone in the
work area.
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
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.
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.
10
332564C
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.
332564C
• 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 66, or
Setup Mode Screens, page 74.
1. Enable USB downloads. See
Advanced Screen 3, page 93.
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
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.)
7
8
9
9. Open DOWNLOAD folder.
0
.
10. Open LOG FILES folder labeled with the highest
number. The highest number indicates the most
recent data download.
Figure 9 Advanced Display Module
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
332564C
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.
332564C
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.
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
332564C
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.
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
Function
Press to enter screen for editing. Highlights editable data
on a screen. Use Up/Down arrows to move between
data fields on the screen.
Enter Screen
Press to exit screen after editing.
Exit Screen
Press to accept calibration value.
Accept
Press to cancel or reject calibration value.
Cancel
Press to start a pump priming procedure.
Prime Pump
Press to start a line fill procedure.
Line/Fill/Run
Press to start a spray procedure.
Mix
Press to start a purge procedure.
Purge
332564C
15
Advanced Display Module (ADM)
Key
Function
Standby
Press to stop all pumps and put system in Standby.
Stop
Press to start a pump pressure check.
Pressure Check
Press to start a pump volume check.
Volume Check
Press to log the material usage and increment the job
number.
Job Complete
Press to reset the current usage counter.
Counter Reset
Appears on the User ID Keyboard screen. Use to move
cursor to the left.
Move Cursor to Left
Appears on the User ID Keyboard screen. Use to move
cursor to the right.
Move Cursor to Right
Appears on the User ID Keyboard screen. Use to erase
all characters.
Erase All
Appears on the User ID Keyboard screen. Use to erase
one character at a time.
Backspace
Appears on the User ID Keyboard screen. Use to
change case (upper/lower).
Upper Case/Lower Case
16
332564C
Advanced Display Module (ADM)
Navigating the Screens
Screen Icons
There are two sets of screens:
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.
• The Run screens control mixing operations and
display system status and data.
• The Setup screens control system parameters and
advanced features.
Press
on any Run screen to enter the Setup
screens. If the system has a password lock, the
Password screen displays. If the system is not locked
(password is set to 0000), System Screen 1 displays.
Press
on any Setup screen to return to the
Home screen.
Press the Enter soft key
function on any screen.
Press the Exit soft key
Screen Icons
User ID
Job Number
Potlife
Target Ratio
Recipe Number
Flow Rate
Pressure
Volume
to activate the editing
to exit any screen.
Use the other softkeys to select the function adjacent
to them.
Material B
Material A
Material A+B
Solvent
Calendar
Time
Alarm/Advisory
Deviation
332564C
17
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
System grounded
Verify all grounding connections
were made. See Grounding in the
Installation manual.
All connections tight and correct
2. The Graco logo will display while the system
initializes, followed by the Home screen.
. The system status will
3. Press the Start key
change from “System Off” to “Startup.” Once
the pumps are powered and are in the Home
position, the system status will change from
“Startup” to “Standby.”
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 19, 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.
Figure 10 Power Switch
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).
18
332564C
Pre-Operation Tasks
Initial System Setup
Valve Settings
1. Change optional setup selections to
desired parameters, as described in
Setup Mode Screens, page 74.
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 80 and
Flush Screen, page 82.
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.
332564C
Figure 11 Valve Adjustment
19
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.
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 the system 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 in the
system.
3. Flush the remote mix manifold and spray device.
See Flush Mixed Material, page 23.
4. Shut off the solvent supply pump. To relieve
pressure, command the system to Purge and
trigger the spray device. When the pressure is
relieved, command the system to Standby to
avoid getting a Purge Incomplete alarm.
If using an electrostatic gun, shut off the
electrostatics before flushing the gun.
2. Trigger the gun to relieve pressure. From
Maintenance Screen 4 on the ADM, check the
box in the field labeled Gun for each color in the
system, to manually open each color valve.
3. 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
the system will go to Standby.
4. Shut off the solvent supply pump. Set the system
to Recipe 0 to flush solvent from the pumps and
to purge to the spray device. Command the
system to Standby after just a couple of seconds,
to avoid getting a Purge Incomplete alarm.
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. Verify on the ADM Home Screen that neither
pump is showing any pressure.
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.
20
332564C
Operation Using Advanced Display Module (ADM)
Operation Using Advanced Display Module (ADM)
Prime and Fill the System
NOTE: See Run Mode Screens, page 66, for further
screen information, if needed.
NOTE: You must prime the input lines to the pumps
or the inputs to the color change valves before
priming the pump and filling the entire system.
4. If the system is powered down, press
on the
ADM. Make sure that the system is in Standby
mode.
5. Verify that the recipes and the flush sequences
are programmed correctly by checking
the Recipe Screen, page 80 and the
Flush Screen, page 82.
6. Enable the manual override on System Screen 5.
7. Go to the Fill Screen, page 71.
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 23. The equipment
was tested with lightweight oil, which should be
flushed out to avoid contaminating your material.
8. Select the desired color to load. Press the Prime
. The color will load the pump
Pump key
through the color stack and out the outlet stack
dump valve.
NOTE: In a single color system, step 8 can be
skipped..
9. Press the Fill Line key
to run color out to
the remote mix manifold. The pump will run until
you press the Stop key
to stop the pump.
10. Trigger the gun into a grounded reservoir or
purge receptacle until the line is full, then press
the Stop key
.
11. Repeat for all material lines.
332564C
21
Operation Using Advanced Display Module (ADM)
Spraying
To spray in a multiple color system, also see
Multiple Color Systems, page 99.
NOTE: See Run Mode Screens, page 66, for further
screen information, if needed.
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.
1. Command the system to Mix. The system will
load the correct mixed material volume.
NOTE: The system will automatically run a Mix
Fill if the recipe is not currently loaded into the
system. The Mix Fill volume calculation includes
the remote mix manifold volume and the mixed
material hose volume. The mixed material hose
volume is determined by the gun hose length and
diameter entered in System Screen 3, page 78,
and the remote-to-mix hose length and diameter
also entered in System Screen 3, page 78.
22
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.
332564C
Operation Using Advanced Display Module (ADM)
Purging
To purge one color and fill with a new color, see
Color Change, page 99.
Flush the System
Flush Mixed Material
To avoid fire and explosion, always ground
equipment and waste container. To avoid injury
from splashing, always flush at lowest possible
pressure.
There are times when you only want to purge the
remote mix manifold and the spray device, such as:
Follow this procedure before:
• end of potlife
• the first time material is loaded into the equipment
• breaks in spraying that exceed the potlife
• servicing
• overnight shutdown or end of shift
• shutting down equipment for an extended period
of time
• before servicing the remote mix manifold, hose or
gun.
• putting equipment into storage
1. Command the system to Standby.
Single Color System
2. If you are using a high pressure spray device or
an electrostatic gun, shut off the atomizing air.
1. Relieve the pressure. See
Pressure Relief Procedure, page 20.
2. Disconnect the color and catalyst supply lines
from the pump inlet manifolds, and connect
regulated solvent supply lines.
To reduce risk of fire and explosion, if using
an electrostatic gun, shut off the electrostatics
before flushing the gun.
3. Command the system to Purge A or Purge B.
(See Purge Mode Sequence, page 43.) Trigger
the spray device into a grounded metal pail until
the purge sequence is complete. When done
purging, the system automatically switches to
Standby mode, signalling the spray device to
stop spraying.
4. If the system 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.
3. Set the solvent supply pressure regulator at the
lowest pressure possible. Generally a setting
of 25–50 psi (0.18–0.35 MPa, 1.8–3.5 bar) is
sufficient.
4. Enable manual override on
System Screen 5, page 79.
5. On the ADM, go to the Fill screen. Set the
. The system
Material to Color (A). Press
will pump solvent through pump A all the way to
the gun.
6. Hold a metal part of the spray device firmly to a
grounded metal pail. Trigger the spray device
until clean solvent dispenses.
7. On the ADM, go to the Fill screen. Set the
Material to Catalyst (B). Press
. The
system will pump solvent through pump B all the
way to the gun.
8. Relieve the pressure. See
Pressure Relief Procedure, page 20
332564C
23
Operation Using Advanced Display Module (ADM)
Color Change System
1. Relieve the pressure. See
Pressure Relief Procedure, page 20.
2. Attach regulated solvent supply lines as follows:
• Multiple color/single catalyst system: On the
color side, do not disconnect the color supply
line from the inlet manifold of Pump A. Instead,
connect a regulated solvent supply line to the
designated solvent valve on the color valve
manifold. On the catalyst side, disconnect
the catalyst supply line from the inlet manifold
of Pump B, and connect a regulated solvent
supply line.
• Multiple color/multiple catalyst system:
Connect regulated solvent supply lines to
the designated solvent valves on the color
and catalyst valve manifolds. Do not connect
solvent supply lines directly to the inlet
manifolds of the pumps.
3. Set the solvent supply pressure regulator at the
lowest pressure possible. Generally a setting
of 25–50 psi (0.18–0.35 MPa, 1.8–3.5 bar) is
sufficient.
4. On the ADM, go to the Fill screen. Select Color
(A). Enter the color number in the box to the right.
5. Select the Flush Line box.
6. If the solvent is not already loaded, press the
Prime softkey
. The system will prime
solvent into the selected pump and out the outlet
dump valve.
. The system will
7. Press the Fill softkey
flush the selected Color (A) line with the solvent
until the user presses Stop
.
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 20
Shutdown
1. Flush out the mixed material to avoid potlife errors
and fluid setup in the lines. See Purging, page 23.
on the Display Module to turn off
4. Press
power to the pumps.
2. Follow the Pressure Relief Procedure, page 20.
5. Shut off system power (0 position).
3. Close the main air shutoff valve on the air supply
line and on the control box.
24
332564C
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
System Screen 5, page 79). 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 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.
Digital 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
NOTE: This digital input is always enabled.
Do not toggle this input to put the system into
Standby mode.
Trigger: This normally open (maintained)
• Gun Trigger
contact provides a signal to the system to indicate
whether or not a spray device is triggered. This
input provides timing for alarm functions and also
drives the flow control algorithm. If the input is
OPEN the system operates as though the spray
device is off. The input must be maintained
CLOSED to signal that the spray device is
triggered.
NOTE: The Gun Trigger discrete input must be
enabled via Configure Screen 5 on the ADM. If it
is set to ‘Network’ the discrete input is ignored and
the spray device trigger signal is handled via the
network communications.
If enabled, it is imperative that this signal be sent
any time the spray device is triggered. Without the
signal, the flow control features will not work.
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.
Analog Inputs
Point: When enabled, this 4-20mA
Flow Control Set Point
signal input is used to set and adjust the operating
flow control set point. The ProMix PD2K scales the
set point linearly from 0 to the Max Set Point setting
(see System Screen 5, page 79). Examples,
Table 3 and Figure 12 show where discrete I/O
connections are made on the ProMix PD2K.
• 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.
Table 3 PD2K Discrete I/O Connections
• 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.
I/O
Description
EFCM
Connector
Pins
Gun Trigger
Input
6
1,2
Normally Open
Contact
Control Set
Point
7
1,2
4-20 mA Input
Safety
Interlock
Input
7
11,12
Normally Open
Contact
332564C
Type
NOTE: The Flow Control discrete input must be
enabled via Configure Screen 5 on the ADM. If
set to ‘Network’ the discrete input is ignored and
set point adjustment is handled via the network
communications.
25
Operation Using a Programmable Logic Controller (PLC)
4–20 mA Flow Control Set Point Input
Figure 12
O = Output
R = Return
PD2K Discrete Input
PLC (4–20 MA Signal)
Discrete I/O Connections on EFCM
Figure 13
KEY
A1
Gun Trigger Input
B1
Analog Set Point Input
C1
Safety Interlock Input
26
332564C
Operation Using a Programmable Logic Controller (PLC)
Communication Gateway Module (CGM) Details
CGM Overview
The CGM provides a control link between the PD2K
system and a selected fieldbus. This linkage provides
the means for remote monitoring and control by
external automation systems.
CGM Kits
The PD2K system comes with a Modbus TCP
CGM. Other communication protocols are available,
but require both the CGM installation kit and the
appropriate CGM and the CGM. See the tables
below.
332564C
CGM
Installation Kit
Part No.
Field Bus
Manual
24W829
All
334494
CGM Part No.
Fieldbus
Manual
CGMDN0
DeviceNet
312864
CGMEP0
EtherNet/IP
312864
CGMPN0
PROFINET
312864
24W462
Modbus TCP
334183
27
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 74.
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 33.
OUTPUT REGISTER 00: 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 system is not in
operation.
2
Recipe Change
The system is in the process of a color change sequence.
3
Recipe Change: Purge A
The system is purging material A as part of a recipe change.
4
Recipe Change: Purge B
The system is purging material B as part of a recipe change.
5
Recipe Change: Fill
The system is filling the hose from the remote valves to the mix manifold
with material as part of a recipe change.
6
Mix Fill
The system is mixing material at ratio through the mix manifold and
out the gun.
7
Mix
The system is currently mixing/spraying material.
8
Mix Idle
The system has paused mix operation due to the absence of a gun
trigger signal.
9
Purge A
The system is purging material A while in Standby.
10
Purge B
The system is purging material B while in Standby.
11
Standby: Mix Ready
The system has a valid recipe loaded out to the gun.
12
Standby: Fill Ready
The system has a valid recipe loaded in the pumps, but not in the gun.
13
Standby: Mix Not Ready
The system requires that a recipe change operation be completed.
14
Standby: Alarm
The system has an active alarm.
15
Line Filling/Flushing
The system is filling/flushing a color change hose between the outlet
valves and remote valves.
28
332564C
Operation Using a Programmable Logic Controller (PLC)
OUTPUT REGISTERS 01, 02, 03, and 04: Pump
Status
OUTPUT REGISTER 07: Actual Mix Potlife
Remaining
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 02: Flush/Prime
Pump Command, page 36.
The Actual Potlife Remaining register contains
the current amount of time remaining in the active
recipe’s potlife in seconds.
Table 4 Pump States for Output Registers 01–04
OUTPUT REGISTER 08: Active Recipe Number
Number
Pump
State
0
Off
The pump is powered down or
not enabled.
1
Standby
The pump is powered but not
currently active.
2
Busy
The pump is currently in
a recipe change or mixing
operation.
3
4
Description
NOTE: If potlife is disabled for the active recipe or at
initial startup this value will be 0xFFFFFFFF.
The Active Recipe Number register contains the
number of the active recipe (1 – 60).
• This value is 0 if the system was flushed.
Flushing
Priming
The pump is currently flushing
with solvent
The pump is currently priming
with material.
OUTPUT REGISTER 05: Actual Mix Flow
• This value is 61 if the system does not know the
current loaded recipe, if the recipe is invalid, or at
initial startup.
OUTPUT REGISTER 09: Active Recipe Material A
The Active Recipe Material A register contains the
number of the Color (1 – 30) that is associated with
the current recipe.
• This value is 0 if the system was flushed.
• This value is 61 if the current recipe is invalid or at
initial startup.
OUTPUT REGISTER 10: Active Recipe Material B
The Actual Mix Flow register reports back the
instantaneous mixing flow rate in cc/min.
The Active Recipe Material B data register contains
the number of the Catalyst (31 – 34) that is associated
with the current recipe.
NOTE: This register is valid only during a mix
operation.
• This value is 0 if the system was flushed.
OUTPUT REGISTER 06: Actual Mix Ratio
The Actual Mix Ratio register contains the
instantaneous calculated mix ratio.
• The value reported is the ratio antecedent
multiplied by 100. The ratio consequent is
always 1.
Example: Value = 250 >> A mix ratio of 2.5:1
(Material A to Material B)
• If the current recipe ratio is 0:1 (1K recipe) this
value will be 0.
This register is valid only during a mix operation.
332564C
• 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 11: 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.
29
Operation Using a Programmable Logic Controller (PLC)
OUTPUT REGISTER 12: Active Recipe Material B
Flush Sequence
OUTPUT REGISTER 19: Actual Pump 1 Fluid
Pressure
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.
OUTPUT REGISTER 20: Actual Pump 2 Fluid
Pressure
• If the current recipe is invalid this value reflects the
Flush Sequence associated with Material B pump
of recipe 0.
• This value is 0 if the current recipe ratio is 0:1 (1K
recipe).
OUTPUT REGISTER 13: Active Recipe Ratio Set
Point
The Active Recipe Ratio Set Point data register
contains the ratio set point associated with the
current recipe.
• The value reported is the ratio antecedent
multiplied by 100. The ratio consequent is
always 1.
OUTPUT REGISTER 21: Actual Pump 3 Fluid
Pressure
OUTPUT REGISTER 22: Actual Pump 4 Fluid
Pressure
These registers contain the instantaneous fluid
pressure on the outlet of pumps 1–4 in PSI.
OUTPUT REGISTER 23: Gun 1 Trigger Input Status
The Gun 1 Trigger Input Status register contains the
status of the Gun Trigger Discrete Input.
• The value is 0 if the input is OPEN (gun not
triggered).
• The value is 1 if the input is CLOSED (gun
triggered).
Example: Value = 250 >> A mix ratio of 2.5:1
(Material A to Material B)
This data register is valid only for systems configured
to use the discrete input for the Gun Trigger. See
Gun Trigger Signal, page 79.
• This value is 0 if the current recipe ratio is 0:1 (1K
recipe).
OUTPUT REGISTER 24: Gun 2 Trigger Input Status
OUTPUT REGISTER 25: Gun 3 Trigger Input Status
OUTPUT REGISTER 14: Active Recipe Potlife
Timeout Set Point
The Active Recipe Potlife Timeout Set Point register
contains the set point for the potlife time associated
with the current recipe in minutes.
• This value is 0 if the potlife time is disabled for the
current recipe.
OUTPUT REGISTER 15: Actual Pump 1 Flow Rate
OUTPUT REGISTER 16: Actual Pump 2 Flow Rate
OUTPUT REGISTER 26: Active Gun
These registers are only used with Multiple Guns
enabled. See Appendix B: Multiple Guns, page 118.
OUTPUT REGISTER 27: Safety Interlock Input
Status
The Safety Interlock Input Status register contains
the status of the Safety Interlock Discrete Input.
• The value will be 0 if the input is OPEN (Normal).
OUTPUT REGISTER 17: Actual Pump 3 Flow Rate
• The value will be 1 if the input is CLOSED (Safety
Stop).
OUTPUT REGISTER 18: Actual Pump 4 Flow Rate
See Safety Interlock in Digital Inputs, page 25.
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.
30
OUTPUT REGISTERS 28 – 36: DCS Command
Structure
See Dynamic Command Description, page 52.
332564C
Operation Using a Programmable Logic Controller (PLC)
OUTPUT REGISTER 37: Time
OUTPUT REGISTER 38 – 40: Software Version
The Time register contains a count of total seconds
since the Unix Epoch (January 1, 1970).
The Software Version registers contain the “major,”
“minor,” and “build” revisions of the ADM software.
• The actual value reported is not important. This
register should be used for diagnosing status of
communication between the ProMix PD2K and the
networking device.
These registers are NOT currently available with the
Modbus Communications Gateway Module.
This register is NOT currently available with the
Modbus Communications Gateway Module.
332564C
31
Operation Using a Programmable Logic Controller (PLC)
Notes
32
332564C
Operation Using a Programmable Logic Controller (PLC)
Network Output Data Map (Read Only)
Network
Output ID
Modbus
Register
Parameter Name
Data Type
Units
Range
00
40100
Current System Mode
uint32
NONE
1 = Pump Off
2 = Recipe Change
3 = Recipe Change: Purge
A
4 = Recipe Change: Purge
B
5 = Recipe 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
01
40102
Pump 1 Status
uint32
NONE
0 = Off
1 = Standby
2 = Busy
3 = Flushing
4 = Priming
02
40104
Pump 2 Status
uint32
NONE
0 = Off
1 = Standby
2 = Busy
3 = Flushing
4 = Priming
03
40106
Pump 3 Status
uint32
NONE
0 = Off
1 = Standby
2 = Busy
3 = Flushing
4 = Priming
04
40108
Pump 4 Status
uint32
NONE
0 = Off
1 = Standby
2 = Busy
3 = Flushing
4 = Priming
05
40110
Actual Mix Flow
uint32
cc/min
1 - 1600
06
40112
Actual Mix Ratio
uint32
NONE
0 - 5000
332564C
33
Operation Using a Programmable Logic Controller (PLC)
Network
Output ID
Modbus
Register
Parameter Name
Data Type
Units
Range
07
40114
Actual Mix Potlife
Remaining
uint32
sec
0 – 59940
08
40116
Active Recipe Number
uint32
NONE
0 - 61
09
40118
Active Recipe Material
A
uint32
NONE
1 - 30, 61
10
40120
Active Recipe Material
B
uint32
NONE
31 - 34, 61
11
40122
Active Recipe Material
A Flush Sequence
uint32
NONE
1-5
12
40124
Active Recipe Material
B Flush Sequence
uint32
NONE
1-5
13
40126
Active Recipe Ratio
Set Point
uint32
NONE
0 - 5000
14
40128
Active Recipe Potlife
Time Set Point
uint32
min
0 - 999
15
40130
Actual Pump 1 Flow
Rate
uint32
cc/min
0 - 800
16
40132
Actual Pump 2 Flow
Rate
uint32
cc/min
0 - 800
17
40134
Actual Pump 3 Flow
Rate
uint32
cc/min
0 - 800
18
40136
Actual Pump 4 Flow
Rate
uint32
cc/min
0 - 800
19
40138
Actual Pump 1 Fluid
Pressure
uint32
PSI
0 - 1500
20
40140
Actual Pump 2 Fluid
Pressure
uint32
PSI
0 - 1500
21
40142
Actual Pump 3 Fluid
Pressure
uint32
PSI
0 - 1500
22
40144
Actual Pump 4 Fluid
Pressure
uint32
PSI
0 - 1500
23
40146
Gun 1 Trigger Input
Status
uint32
NONE
0 = Gun not triggered
Gun 2 Trigger Input
Status*
uint32
Gun 3 Trigger Input
Status*
uint32
24
25
40148
40150
1 = Gun triggered
NONE
0 = Gun not triggered
1 = Gun triggered
NONE
0 = Gun not triggered
1 = Gun triggered
26
40152
Active Gun*
uint32
NONE
1-3
27
40154
Safety Interlock Input
Status
uint32
NONE
0 = Open
34
1 = Closed
332564C
Operation Using a Programmable Logic Controller (PLC)
Network
Output ID
Modbus
Register
Parameter Name
Data Type
Units
Range
28
40200
Command
Acknowledge
uint32
NONE
0 := NOP
1 = BUSY
2 = ACK
3 = NAK
4 = ERR
29
40202
Command Return 0
uint32
N/A
N/A
30
40204
Command Return 1
uint32
N/A
N/A
31
40206
Command Return 2
uint32
N/A
N/A
32
40208
Command Return 3
uint32
N/A
N/A
33
40210
Command Return 4
uint32
N/A
N/A
34
40212
Command Return 5
uint32
N/A
N/A
35
40214
Command Return 6
uint32
N/A
N/A
36
40216
Command Return 7
uint32
N/A
N/A
37
N/A
Time
uin32
sec
0 – 4,294,967,295
38
N/A
Software Version –
Major
uint32
NONE
0 – 99
39
N/A
Software Version –
Minor
uint32
NONE
0 – 99
40
N/A
Software Version –
Build
uint32
NONE
0 – 999
*
332564C
Only used when Multiple Guns is
enabled.
DCS Register
35
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: 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 system takes no action.
1
Power Pumps
The system powers on or powers off the pumps.
2
Remote Stop
The system stops all current operations and turns off power to the
pumps.
3
Recipe Change
The system initiates a recipe change. (See also Register 7.)
4
Mix Fill
The system fills the mix manifold and gun with material at ratio for
a valid recipe.
5
Mix
The system initiates a mix/spray cycle.
6
Purge A
The system purges only Material A out through the gun.
7
Purge B
The system purges only Material B out through the gun.
8
Standby
The system puts all active pumps into Standby mode.
9
Purge Recipe
The system automatically determines the purge sequence required
based on the loaded recipe.
10
Purge (Inactive)
This command is only valid if Multiple Guns is enabled. The system will
purge an inactive spray device. (See also Register 7.)
36
332564C
Operation Using a Programmable Logic Controller (PLC)
INPUT REGISTER 01: 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 02
below) 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 30 if priming a Color
pump.
• Write a value between 31 and 34 if priming a
Catalyst pump.
• Write a value of 41–43 (instead of 31) if
your system has multiple guns and Catalyst
1 is common to more than one gun. See
Appendix B: Multiple Guns, page 118.
• Write a value of 51–53 (instead of 33) if
your system has multiple guns and Catalyst
3 is common to more than one gun. See
Appendix B: Multiple Guns, page 118.
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.
INPUT REGISTER 02: 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
01) 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 01 – 04).
If an invalid Flush Sequence or invalid material
number is written to the Pump Flush Sequence/Prime
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.
NOTE: If two pumps are currently mixing and an
inactive pump is commanded to flush or prime it will
continue its operation to completion without affecting
the system mode status. When the mixing operation
is complete, the system status will reflect Standby
mode while the flushing/priming pump completes its
operation.
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.
332564C
37
Operation Using a Programmable Logic Controller (PLC)
INPUT REGISTER 03: Mix (Pump 1) Control Set
Point
The Mix Control Set Point register is used to set and
adjust the mixing fluid control set point. It also is used
as the fluid control set point for pump 1 when running
a 1K recipe. It can be changed at any time, and the
system will immediately adjust to the new set point.
• If the system 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 5, page 79.
• If the system is configure for Pressure Control this
value can be set between 0 and the maximum
pump pressure in PSI. See Fluid Control on
System Screen 5, page 79.
NOTE: The Flow Control must be configured to
‘Network’ via System Screen 5 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 25.
INPUT REGISTER 04: Pump 2 Control Set Point
INPUT REGISTER 05: Pump 3 Control Set Point
INPUT REGISTER 06: Pump 4 Control Set Point
These registers are not used.
INPUT REGISTER 07: Go to Recipe Number
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 60 can
be written to this register. However, a recipe must be
enabled via the ADM before it can be loaded. See
Recipe Screen, page 80.
INPUT REGISTER 08: Clear Active Alarm
The Clear Active Alarm register is used to
acknowledge an alarm remotely so that the system
may resume operation. Be sure that the alarm
condition has been alleviated. Write a 1 to this
register to acknowledge the latest active alarm. If
more than one alarm is currently active only the most
recent alarm will be acknowledged. A repeated write
should be performed to clear any remaining active
alarms. See figure 9.
(See System Errors, page 100 for more information
on clearing alarms.)
NOTE: This register is not polled by the ProMix
PD2K. An alarm 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.*
INPUT REGISTER 09: 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.
(See Usage Screen, page 72 for more information on
Job Logs and Job Complete.)
NOTE: This register is not polled by the ProMix
PD2K. A job is logged only when a value of ‘1’
is written to this register. It is recommended the
automation reset this register by writing a 0 to it at all
other times to avoid inadvertently logging a job.*
* It is recommended to wait at least 500 msec for the
PD2K to process before resetting to ‘0’.
NOTE: Writing to this register does not trigger a recipe
change. See Color Change Sequence, page 48.
38
332564C
Operation Using a Programmable Logic Controller (PLC)
INPUT REGISTER 10: Gun 1 Trigger
The Gun 1 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.
Input Register 10
1
0
1
0
Gun Trigge r
Discrete Signal
ProMix PD2K
Gun Trigge r S ta te
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.
Figure 14 Gun Trigger Timing (Network and Discrete
Signals Shown
• Write a value of ‘1’ to signal that the gun is
triggered.
INPUT REGISTER 11: Gun 2 Trigger
• 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 5 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 25. NOTE: Because timing is so
critical for flow control Graco recommends that users
provide a discrete input to minimize latency effects.
INPUT REGISTER 12: Gun 3 Trigger
These registers are only used with Multiple Guns
enabled. See Appendix B: Multiple Guns, page 118.
INPUT REGISTER 13: Gun 4 Trigger
This register is not used.
INPUT REGISTERS 14 – 21: DCS Command
Structure
See Dynamic Command Description, page 52.
332564C
39
Operation Using a Programmable Logic Controller (PLC)
Notes
40
332564C
Operation Using a Programmable Logic Controller (PLC)
Network Input Data Map (Write/Read)
Network
Input ID
Modbus
Register
Parameter Name
Data
Type
Units
Range
00
40156
System Mode Command
uint32
NONE
0 = No
1 = Power Pumps
2 = Remote Stop
3 = Recipe Change
4 = Mix Fill
5 = Mix
6 = Purge A
7 = Purge B
8 = Standby
9 = Recipe Purge
10 = Purge (Inactive)
01
40158
Pump Flush Sequence #/Prime
Material #
uint32
NONE
1 - 5, 1 - 34,
41 - 43*, 51 - 53*
02
40160
Flush/Prime Pump Command
uint32
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 Fill/Flush Line
03
40162
Mix (Pump 1) Control Set Point
uint32
cc/min or
PSI
1 - 1600
04
40164
Pump 2 Control Set Point
uint32
cc/min or
PSI
1 - 1600
05
40166
Pump 3 Control Set Point
uint32
cc/min or
PSI
1 - 1600
06
40168
Pump 4 Control Set Point
uint32
cc/min or
PSI
1 - 1600
07
40170
Go to Recipe Number
uint32
NONE
0, 1 - 60
08
40172
Clear Active Alarm
uint32
NONE
1 = Clear Active Alarm
09
40174
Job Complete
uint32
NONE
1 = Trigger job complete
332564C
41
Operation Using a Programmable Logic Controller (PLC)
Network
Input ID
Modbus
Register
Parameter Name
Data
Type
Units
Range
10
40176
Gun 1 Trigger
uint32
NONE
0 = Gun not triggered
1 = Gun triggered
11
40178
Gun 2 Trigger*
uint32
NONE
0 = Gun not triggered
1 = Gun triggered
12
40180
Gun 3 Trigger*
uint32
NONE
0 = Gun not triggered
1 = Gun triggered
13
40182
Gun 4 Trigger
uint32
NONE
0 = Gun not triggered
1 = Gun triggered
14
40184
Command Argument 0
uint32
NONE
N/A
15
40186
Command Argument 1
uint32
NONE
N/A
16
40188
Command Argument 2
uint32
NONE
N/A
17
40190
Command Argument 3
uint32
NONE
N/A
18
40192
Command Argument 4
uint32
NONE
N/A
19
40194
Command Argument 5
uint32
NONE
N/A
20
40196
Command Argument 6
uint32
NONE
N/A
21
40198
DCS Command
uint32
NONE
See Command Table
These registers are not used.
*
42
DCS Register
Only used with Multiple Guns enabled.
332564C
Operation Using a Programmable Logic Controller (PLC)
Operation Flow Charts
Purge Mode Sequence
Purge A System Command
Write ‘6’ to Input Re gis te r 00
Is system 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.
332564C
43
Operation Using a Programmable Logic Controller (PLC)
Purge Recipe Sequence
Purge Recipe System Command
Write ‘9’ to Input Re gis te r 00
Is system 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.
44
332564C
Operation Using a Programmable Logic Controller (PLC)
Purge (Inactive) Sequence
Write Recipe #
(1 - 60) to Input Register 7
NOTE: This comm a nd is only va lid
for a system with M ultiple Guns
enabled. (see Appe ndix B - Multiple
Guns).
Write Purge (Inactive)
Command
‘10’ to Input Register 00
Is Current System Mode =
Standby ?
(Output Register 00 = 1 1,
12, 13)
NO
No action taken.
NO
No action taken.
YES
Is Recipe # loaded in one of
the spray devices?
YES
System will begin to run Recipe
Purge sequence for appropriate
spray device.
332564C
45
Operation Using a Programmable Logic Controller (PLC)
Inactive Pump Flush and Prime Sequences
Write Flush Sequence #
(1-5) to Output Register 01
Write Prime Material #
(1-34) to Output Register 01
NOTE: Be sure to read to
appropriate Output Register*
for the desired pump status:
Register 01 - Pump 1
Register 02 - Pump 2
Register 03 - Pump 3
Register 04 - Pump 4
Write
Flush Pump Command
(1,3,5,7) to Input Register 02
Write
Prime Pump Command
(2,4,6,8) to Input Register 02
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’)
46
332564C
Operation Using a Programmable Logic Controller (PLC)
Line Fill and Flush Sequences
Write Material #
(1 - 34) to Output Register 01
Write Material #
(1 - 34) to Output Register 01
Write Line Flush Command
‘10’ to Input Register 02
Write Line Fill Command
‘9’ to Input Register 02
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 ?
(Output Register 02 = ‘1 1’)
YES
Current System Mode is set to
Standby: Mix Not Ready .
(Output Register 00 = ‘13’)
332564C
47
Operation Using a Programmable Logic Controller (PLC)
Color Change Sequence
Write Go to Re c ip e Nu m b e r
(0,1 - 60) t o Input Registe r 07
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 .
48
332564C
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: System 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.
332564C
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.
49
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
?
YES
NO
No action taken.
System 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
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, pumps
system is put into
Standby . System Mode =
Standby: Mix Ready
50
332564C
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’)
Clear Active Alarm
Write ‘1’ to Input Re gis te r 08
Is there an active
alarm?
NO
No action taken.
YES
YES
Clear most recent active
alarm.
Remaining alarm(s) still
active.
Is there more than 1
active alarm?
NO
Clear active alarm.
NOTE: If more than 1 active
alarm exists a repeated write
of ‘1’ to Input Register 08 is
required for each.
332564C
51
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 41 and Network Output Data Map (Read Only), page 33.
Use the following sequence for the DCS.
1. Write the appropriate command arguments to INPUT REGISTERS 14 – 20. 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 21.
3. The ProMix PD2K will respond to a valid command by writing a 2 (Acknowledge) to OUTPUT REGISTER 28.
4. The ProMix PD2K will write appropriate return values to OUTPUT REGISTERS 29 – 36.
ProMix PD2K Inputs
(PLC Outputs)
[arg_0]
INPUT REGISTER 14
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 14+ 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 21
[id]
ProMix PD2K Outputs
(PLC Inputs)
OUTPUT REGISTER 28
ACK = 2
OUTPUT REGISTER 29
[rtn_0]
OUTPUT REGISTER 29+ n
[rtn_n]
Figure 15 Dynamic Command Structure Timing
52
332564C
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
4
Write Fluid Control Mode
5
Write Mix Fill Set Point
10
Read User ID
11
Read Recipe
12
Read Flush Sequence
13
Read Fluid Control Mode
14
Read Job Info
15
Read Alarm Info
16
Read Event Info
17
Read Recipe Potlife Time
19
Read Mix Fill Set Point
20
Read Pump Material
21
Read Gun Contents
332564C
53
Operation Using a Programmable Logic Controller (PLC)
Write User ID
The Write User ID command allows users to assign a User ID to a Job Log. See Usage Screen, page 72, 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 the ProMix PD2K.
DCS Register
Parameter Description
Data
Type
Units
Value
Range
DCS
Command
Write User ID
uint32
NONE
1
0 - 21
Argument 0
User ID characters [3:0]
(ASCII)
uint32
NONE
0x6E686F4A = [‘n’,
’h’, ’o’, ’J’]
N/A
Argument 1
User ID characters [7:4]
(ASCII)
uint32
NONE
0x656F4420 = [‘e’,
’o’, ’D’, ’ ‘]
N/A
Argument 2
User ID characters [9:8]
(ASCII)
uint32
NONE
0x0 = [null]
N/A
Acknowledge
Command Acknowledged
uint32
NONE
2 = ACK
0-4
Return 0
User ID characters [3:0]
(ASCII)
uint32
NONE
0x6E686F4A
N/A
Return 1
User ID characters [7:4]
(ASCII)
uint32
NONE
0x656F4420
N/A
Return 2
User ID characters [9:8]
(ASCII)
uint32
NONE
0x0
N/A
54
332564C
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 80, 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.
Example: Configure Recipe 6 for Color = 2, Catalyst = 1, Color Flush Sequence = 2, Catalyst Flush Sequence = 3,
Mix Ratio Set Point = 1.50:1, and Potlife = 10 minutes.
DCS Register
Parameter Description
Data
Type
Units
Value
Range
DCS
Command
Write Recipe
uint32
NONE
2
0 - 21
Argument 0
Recipe Number
uint32
NONE
6
0 - 60
Argument 1
Material A
uint32
NONE
2
0 – 30
Argument 2
Material B
uint32
NONE
31
0, 31 – 34
Argument 3
Material A Flush Sequence
uint32
NONE
2
1-5
Argument 4
Material B Flush Sequence
uint32
NONE
3
1-5
Argument 5
Mix Ratio Set Point
uint32
NONE
150 = 1.50:1
0 - 5000
Argument 6
Potlife Time Set Point
uint32
min
10
0 - 999
Acknowledge
Command Acknowledged
uint32
NONE
2 = ACK
0-4
Return 0
Recipe Number
uint32
NONE
6
0 - 60
Return 1
Material A
uint32
NONE
2
0 – 30
Return 2
Material B
uint32
NONE
31
0, 31 – 34
Return 3
Material A Flush Sequence
uint32
NONE
2
1–5
Return 4
Material B Flush Sequence
uint32
NONE
3
1–5
Return 5
Mix Ratio Set Point
uint32
NONE
150
0 - 5000
Return 6
Potlife Time Set Point
uint32
min
10
0 - 999
Return 7
Recipe Gun Assignment*
uint32
NONE
1
1–3
*
332564C
Only used when Multiple Guns is enabled.
55
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 82, 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
Write Fluid Control Mode
The Write Fluid Control Mode command allows users to remotely change Fluid Control between ‘Flow’ and
‘Pressure’. See System Screen 5, page 79, for more details on Fluid Control mode. The return registers will echo
the arguments received.
NOTE: The Fluid Control mode should be changed only when the system is in Standby or when the pumps are
powered off. Do not change Fluid Control modes during a mix operation.
Example: Change to Flow Control mode.
DCS Register
Parameter Description
Data
Type
Units
Value
Range
DCS
Command
Write Fluid Control Mode
uint32
NONE
4
0 - 21
Argument 0
Fluid Control Mode
uint32
NONE
0 = Flow Mode
0 = Flow
1 = Pressure
Acknowledge
Command Acknowledged
uint32
NONE
2 = ACK
0-4
Return 0
Fluid Control Mode
uint32
NONE
0
0 = Flow
1 = Pressure
56
332564C
Operation Using a Programmable Logic Controller (PLC)
Write Mix Fill Set Point
The Write Mix Fill Set Point command allows for setting an alternate control set point to decrease the time it takes to
fill the line with mixed material. See System Screen 5, page 79, for more details on Mix Fill Set Point. The return
registers will echo the arguments received.
NOTE: The Mix Fill Set Point units depend on the selected Fluid Control Mode of the system. If the Fluid Control
Mode is ‘Flow’, the units will be cc/min. If the Fluid Control Mode is ‘Pressure’, the units will be PSI. If the value is
zero, this set point will be ignored.
Example: Configuring a flow control system to a Mix Fill Set Point of 300 cc/min.
DCS Register
Parameter Description
Data
Type
Units
Value
Range
DCS
Command
Write Mix Fill Set Point
uint32
NONE
5
0 - 21
Argument 0
Mix Fill Set Point
uint32
cc/min
or PSI
300
1 - 1600
(cc/min)
1 - 1500 (PSI)
0 := Disabled
Acknowledge
Command Acknowledged
uint32
NONE
2 = ACK
0-4
Return 0
Mix Fill Set Point
uint32
cc/min
or PSI
300
1 - 1600
(cc/min)
1 - 1500 (PSI)
0 := Disabled
Read User ID
The Read User ID command reads back the current User ID. See Usage Screen, page 72, 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 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 - 21
Acknowledge
Command Acknowledged
uint32
NONE
2 = ACK
0-4
Return 0
User ID characters [3:0]
(ASCII)
uint32
NONE
0x6E686F4A = [‘n’,
’h’, ’o’, ’J’]
N/A
Return 1
User ID characters [7:4]
(ASCII)
uint32
NONE
0x656F4420 = [‘e’,
’o’, ’D’, ’ ‘]
N/A
Return 2
User ID characters [9:8]
(ASCII)
uint32
NONE
0x0 = [null]
N/A
332564C
57
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 Recipe 5 data as it is currently configured with Color = 3, Catalyst = 2 (32), Color Flush Sequence =
1, Catalyst Flush Sequence = 4, Mix Ratio Set Point = 3.25:1, and Potlife = 35 min.
DCS Register
Parameter Description
Data
Type
Units
Value
Range
DCS
Command
Read Recipe
uint32
NONE
11
0 - 21
Argument 0
Recipe #
uint32
NONE
5
0 - 60
Acknowledge
Command Acknowledged
uint32
NONE
2 = ACK
0-4
Return 0
Recipe #
uint32
NONE
5
0 - 60
Return 1
Material A
uint32
NONE
3
0 - 30, 61
Return 2
Material B
uint32
NONE
32
0, 31 - 34, 61
Return 3
Material A Flush Sequence
uint32
NONE
1
1-5
Return 4
Material B Flush Sequence
uint32
NONE
4
1-5
Return 5
Mix Ratio Set Point
uint32
NONE
325
0 - 5000
Return 6
Potlife Time Set Point
uint32
min
35
0 - 999
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
1-5
Gun Purge Time
uint32
NONE
sec
1
Return 1
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
58
332564C
Operation Using a Programmable Logic Controller (PLC)
Read Fluid Control Mode
The Read Fluid Control Mode command is used to read the current Fluid Control mode of the system is currently
operating under. No arguments are required.
Example: Read Fluid Control as currently set to
Pressure mode.
DCS Register
Parameter Description
Data
Type
Units
Value
Range
DCS
Command
Read Fluid Control Mode
uint32
NONE
13
0 - 21
Acknowledge
Command Acknowledged
uint32
NONE
2 = ACK
0-4
Return 0
Fluid Control Mode
uint32
NONE
1 = Pressure
0 = Flow
1 = Pressure
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 72, 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.
DCS Register
Parameter Description
Data Type
Units
Value
Range
DCS
Command
Read Job Info
uint32
NONE
14
0 - 21
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
Recipe #
uint32
NONE
2
0 - 60
Return 4
A+B Volume
uint32
cc
1234
N/A
Return 5
User ID [3:0] (ASCII)
uint32
NONE
0x6E686F4A = [‘n’,
’h’, ’o’, ’J’]
N/A
Return 6
User ID [7:4] (ASCII)
uint32
NONE
0x656F4420 = [‘e’,
’o’, ’D’ ‘ ’]
N/A
Return 7
User ID [9:8] (ASCII)
uint32
NONE
0
N/A
332564C
59
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 100, 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 - 21
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’;
60
332564C
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 - 21
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
Read Recipe Potlife Time
The Read Recipe Potlife Time command returns the remaining potlife time, in minutes, for a selected
recipe if it is currently loaded and mixed. This command is particularly useful if Multiple Guns is enabled.
See Appendix B: Multiple Guns, page 118 .
NOTE: This command will return 0xFFFFFFFF if there is no potlife time associated with the recipe or the timer has
not started.
Example: Read recipe 1 potlife time remaining that is currently “12 minutes”.
DCS Register
Parameter Description
Data
Type
Units
Value
Range
DCS
Command
Read Recipe Potlife Time
uint32
NONE
17
0 - 21
Argument 0
Recipe Number
uint32
NONE
1
1 - 60
Acknowledge
Command Acknowledged
uint32
NONE
2 = ACK
0-4
Return 0
Recipe Number
uint32
NONE
1
1 - 60
Return 1
Potlfe Time Remaining
uint32
min
12
0 - 999
332564C
61
Operation Using a Programmable Logic Controller (PLC)
Read Mix Fill Set Point
The Read Mix Fill Set Point command is used to read the current Mix Fill Set Point. See System Screen 5, page 79,
for more details on Mix Fill Set Point. No arguments are required.
NOTE: The Mix Fill Set Point units depend on the selected Fluid Control Mode of the system. If the Fluid Control
Mode is ‘Flow’, the units will be cc/min. If the Fluid Control Mode is ‘Pressure’, the units will be PSI. If the value is
zero, this set point will be ignored.
Example: Read the Mix Fill Set Point, currently set to 350 cc/min.
DCS Register
Parameter Description
Data
Type
Units
Value
Range
DCS
Command
Read Mix Fill Set Point
uint32
NONE
19
0 - 21
Acknowledge
Command Acknowledged
uint32
NONE
2 = ACK
0-4
Return 0
Mix Fill Set Point
uint32
cc/min
or PSI
350
1 - 1600
(cc/min)
1 - 1500 (PSI)
0 := Disabled
Read Pump Material
The Read Pump Material command returns the material number of the color or catalyst that is currently loaded in
a user-specified pump.
NOTE: This command will return ‘0’ if the pump is filled with solvent, or ‘61’ if the material is unknown.
Example: Read what material is loaded in pump 1, which is currently color 2.
DCS Register
Parameter Description
Data
Type
Units
Value
Range
DCS
Command
Read Pump Material
uint32
NONE
20
0 - 21
Argument 0
Pump Number
uint32
NONE
1
1-4
Acknowledge
Command Acknowledged
uint32
NONE
2 = ACK
0-4
Return 0
Pump Number
uint32
NONE
1
1-4
Return 1
Material Number
uint32
NONE
2
0 - 34, 61
62
332564C
Operation Using a Programmable Logic Controller (PLC)
Read Gun Contents
The Read Gun Contents command returns the recipe number of the mixed material that is currently loaded in a
user-specified gun. This command is used if Multiple Guns are enabled. See Appendix B: Multiple Guns, page 118 .
NOTE: This command will return ‘0’ if the gun is filled with solvent, or ‘61’ if the material is unknown.
Example: Read what material is loaded in gun 1, which is currently recipe 2.
DCS Register
Parameter Description
Data
Type
Units
Value
Range
DCS
Command
Read Gun Contents
uint32
NONE
21
0 - 21
Argument 0
Gun Number
uint32
NONE
1
1-3
Acknowledge
Command Acknowledged
uint32
NONE
2 = ACK
0-4
Return 0
Gun Number
uint32
NONE
1
1-3
Return 1
Recipe Number
uint32
NONE
2
0 - 61
332564C
63
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 1–4
These screens show all PD2K Network Outputs with
their associated register ID, Modbus TCP address,
current value, and any relevant state information.
Figure 17 PLC Diagnostic Screen 5
PLC Diagnostic Screens 7
Figure 16 PLC Diagnostic Screen 1
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.
PLC Diagnostic Screens 5–6
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 18 PLC Diagnostic Screen 7
64
332564C
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
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 5, page 79, 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.
332564C
Gun On/Off Prediction
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% higher than the desired pressure for longer than
10msec, then the system predicts that the gun trigger
has been released. If the actual pressure drops
below the desired pressure longer than 10msec, then
the system predicts that the gun has been triggered.
The gun on/off prediction is used in the flow control
algorithm to prevent the fluid pressure from becoming
too high or too low due to a system disturbance. For
example, if a gun off prediction occurs while the gun
trigger input is high, the system will begin to control
to the pressure value last stored in the pressure table
for the current flow set point.
System Startup and Defaults
The pressure table is stored in volatile memory, so
the table values will be lost 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).
65
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 19 Opening Screen
Home Screen
The Home screen displays the current status of the
system. The following table details the information
shown.
To view pump flow rates and pressures
(as shown), select “Diagnostic Mode” on
System Screen 1, page 75.
Figure 20 Home Screen, in Mix Mode with
Diagnostics On
66
332564C
Run Mode Screens
Home Screen Key
Key
Description
Details
A
Date and Time
See Advanced Screen 1, page 92, 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 70)
• Fill (see Fill Screen, page 71), available only if manual override is
enabled on System Screen 5, page 79.
• Usage (see Usage Screen, page 72)
• Jobs (see Jobs Screen, page 73)
• Errors (see Errors Screen, page 73)
• Events (see Events Screen, page 73)
C
Status Bar
System Status: Displays the current mode of operation:
• Pump Off
• Change Recipe
• Standby
• Idle
• Startup
• Prime Pump
• Mix
• Calibrate
• Fill
• Stall Test
• Purge
• Maintenance Test
• Shutdown
D
332564C
Error Status
Displays any active error code.
67
Run Mode Screens
Key
Description
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
Details
• Clear = power off
• Yellow = standby
• Green = active
S
Solvent Flow Rate
Shows solvent flow rate, if a solvent meter is attached.
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)
68
332564C
Run Mode Screens
Key
Description
U
Active Recipe (
)
V
Current Ratio (
)
W
Potlife Time Remaining (
X
Total Volume for the Current
Job ( )
Y
Current Flow Rate (
Z
Current Pressure (
332564C
Details
)
)
)
69
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 5, page 79. The screens show a
system in manual override mode.
The Spray screen includes the following information:
• Active Recipe (can be changed on this screen)
• Target Ratio
• Actual Ratio
• Target Pressure (if Pressure Mode is selected on
System Screen 5) or Target Flow (if Flow Mode is
selected). Target pressure or flow can be changed
on this screen).
Figure 21 Spray Screen, in Standby Mode
• Actual Pressure
• Actual Flow
• Potlife Remaining
• Gun Animation
In addition, the Spray screen includes three soft keys:
Press to put the system in
Standby.
Press to spray mixed material.
Figure 22 Spray Screen, in Mix Mode
Press to purge the gun.
Figure 23 Spray Screen, in Idle Mode
70
332564C
Run Mode Screens
Fill Screen
NOTE: This screen is visible only if manual override
is enabled on System Screen 5, page 79.
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.
To prime the pumps and fill the lines, first read
Prime and Fill the System, page 21.
1. Press the Edit softkey
for editing.
Figure 24 Fill Screen, Color (A) Selected
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.
4. Press the Fill softkey
. The system will
attempt to fill the Color (A) lines until the user
presses Stop
container.
Figure 25 Fill Screen, Solvent Selected
. Trigger the gun into a waste
5. Repeat for Catalyst (B).
332564C
71
Run Mode Screens
Usage Screen
The first Usage screen displays the current job usage
and grand total usage of component A, B, A+B,
and solvent (S). Edits may be made only if manual
override is enabled on System Screen 5, page 79.
The second Usage screen displays the total volume
pumped for all available materials.
1. Press the Edit softkey
for editing.
to open the screen
2. To enter or change the User ID ( ), select the
field to open the User ID Keyboard screen,
and enter the desired name (10 characters
maximum).
Figure 27 User ID Keyboard Screen
3. To log the current job, press the Job Complete
softkey
. This will clear the current usage
fields and increment to the next job number.
The Grand Totals cannot be cleared. See the
Jobs Screen, page 73, to review past jobs.
4. Press the Edit softkey
to close the screen.
Figure 28 Usage Log
Figure 26 Usage Screen
72
332564C
Run Mode Screens
Jobs Screen
Errors Screen
The Jobs screen displays the 200 most recent job
numbers, recipes, and A+B volumes in a log, with
date, time, and User ID.
The Errors screen displays the 200 most recent Error
Codes in a log, with date, time, and description.
Figure 30 Errors Screen
Figure 29 Jobs Screen
Events Screen
The Events screen displays the 200 most recent
Event Codes in a log, with date, time, and description.
Figure 31 Events Screen
332564C
73
Setup Mode Screens
Setup Mode Screens
Press
screens.
on any Run screen to enter the Setup
Password Screen
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 74.
Figure 32 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 92.
74
332564C
Setup Mode Screens
System Screen 1
System screen 1 includes the following fields which
define your system.
Diagnostic Mode
Select this box to display flow rate and pressure for
each pump on the Home Screen, page 66.
Color Pumps
Enter the number of color pumps in your system.
Catalyst Pumps
Enter the number of catalyst pumps in your system.
Non--Mix Pressure
Non
Figure 33 System Screen 1, During Standby
Enter a lower pressure for use when not mixing and
spraying (for example during fill or flushing).
NOTE: Low pressure systems may be set 100 psi
(0.7 MPa, 7 bar) lower than target pressure; high
pressure systems may be set 300 psi (2.1 MPa, 21
bar) lower than target pressure.
Solvent Meter
Select this box if your system uses a solvent meter.
The Solvent K-Factor field will then become active.
Solvent K-Factor
Enter the solvent meter K-Factor.
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75
Setup Mode Screens
System Screen 2
System screen 2 sets the following system operating
parameters.
Maximum Leak Rate
Enter the maximum allowable leak rate for a pump
stall test.
Mix Idle Timeout
Figure 34 System Screen 2, in Standby Mode
Mix Pressure Tolerance
The pressure of one component must be within
a percentage (±) of the pressure of the other
component during spray or mix. Set the desired
Mix Pressure Tolerance in this field. Two different
set points are available for systems that are mixing
recipes with different viscosities and might require
very different tolerance bands. The assignment of
which set point is used is set on the Recipe screen.
The default is 25%. See Recipe Screen, page 80.
Stall Test Pressure
The Gun Trigger Input signals that the device is
triggered. If you are not using a gun trigger signal,
the system does not know if the spray device is
spraying. If a pump failed you could spray pure resin
or catalyst without knowing. This should be caught
by the Mix No Flow Timeout; the default is 5 seconds.
The Mix Idle Timeout will trigger Idle mode, which
will run a pump stall test to check for leaks, then put
the pumps in Standby (holding their current position)
after the designated period of time. Enter the desired
Mix Idle Timeout in this field.
See Digital Inputs, page 25.
Mix No Flow Timeout
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 25.
Set the minimum stall test pressure. The setting
should be approximately 50 psi (0.35 MPa, 3.5 bar)
higher than the highest inlet pressure.
NOTE: If the material supply pressure at the pump
inlet is greater than 90% of the Stall Test Pressure, the
system will generate an alarm and will not complete
the stall test. See Calibrate Screen 1, page 87.
Pump Stall Test
Set the duration for the pump stall test. See
Calibrate Screen 1, page 87.
76
332564C
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.
It is recommended that, once the system is fully
installed and ready to use, the user load a recipe and
then spray the mixed material. While spraying, note
the outlet pressures of both the A and B pumps (per
the ADM’s main screen or the PLC) and spray long
enough to ensure the pressures have stabilized to
a nominal value. The difference between the outlet
pressures of the A and B pumps is an established
baseline for the Mix Pressure Tolerance set point.
The Mix Pressure Tolerance set point allows the
B-side pump outlet pressure to vary a specified
percentage away from the A-side pump outlet (spray)
pressure. For example: In the following figure, if the
spray pressure (A-side pump outlet pressure) is 100
332564C
psi, and the Mix Pressure Tolerance is set to 25%,
the B-side outlet pressure is allowed to float between
75 and 125 psi (100 psi ± 25%) without generating
an alarm.
140
120
100
A
80
B
60
40
20
0
Figure 35 The acceptable B-side pump outlet
pressure range for a system with a target spray
pressure (A) of 100 psi and a Mix Pressure Tolerance
of 25%.
It is recommended that you keep the Mix Pressure
Tolerance set point as low as possible to alert the
user of anything affecting the mix ratio accuracy.
However, if your system is generating several
differential pressure alarms, or will be mixing a wide
variety of materials at different mix ratios, you may
need to increase the Mix Pressure Tolerance.
77
Setup Mode Screens
System Screen 3
System Screen 4
System screen 3 sets the following system operating
parameters.
System screen 4 sets the following system operating
parameters.
Figure 36 System Screen 3
Figure 37 System Screen 4
Multiple Guns
Check this box to enable the option to use more than
a single spray device (with a maximum of three). See
Appendix B: Multiple Guns, page 118.
Gun Hose Length
Gateway ID
Select the desired Gateway ID from the dropdown
menu.
Enable
Enter the length of the hose from the remote mix
manifold to the spray device.
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.
Gun Hose Diameter
Check this box to enable the selected Gateway so
that the PLC can communicate with it.
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
This field is always enabled in Automatic systems.
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.
Hose Length and Diameter
TCP/IP
Enter the length and diameter of the hose from the
remote color stack to the remote mix manifold, for
both A and B hoses.
78
Use the remaining fields to set the IP address, subnet
mask, Gateway, DNS1, and DNS2.
332564C
Setup Mode Screens
System Screen 5
System screen 5 sets the following system operating
parameters.
The value will be a flow rate if Fluid Control is set
to ‘Flow’, or a pressure if Fluid control is set to
‘Pressure’.
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.
Flow Control (Setpoint Signal)
Figure 38 System Screen 5
Fluid Control
Select the format of the signal that indicates system
flow rate or pressure.
Select the desired operating mode (pressure or flow),
using the pull-down menu.
• Discrete — the signal is sent via a direct,
hard-wired connection. This selection will make
the Max Rate field active.
• In Pressure Mode, the motor will adjust the pump
speed to maintain the fluid pressure set by an
external control device.
• Network — the signal is sent via a PC, PLC, or
other networked device.
• In Flow Mode, the motor will maintain a constant
speed to maintain the target flow rate set by an
external control device.
• Recipe — flow rate or pressure is set according to
user-entered value on each recipe screen.
Low Flow Tolerance
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.
Mix Fill Set Point
Set a higher flow rate or pressure for use while mix
filling to decrease the time needed to fill the hose and
spray device. Once the spray device is filled, the
system will use the target set point as set by the PLC.
The default value is ‘0’. When set to ‘0’, the system
ignores the Mix Fill Set Point and instead uses the
target set point as set by the PLC.
332564C
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.
79
Setup Mode Screens
Recipe Screen
Figure 39 Valid Recipe Screen
Figure 40 Invalid Recipe Screen
Recipe
Flush Sequence
Enter the desired recipe number (1-60).
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 82. 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.
Recipe 0
Use Recipe 0 to flush the system.
• If a recipe (1–60) is loaded: Select Recipe 0 to flush
the previously active pumps and purge the gun.
• If Recipe 0 or 61 is loaded: Select Recipe 0 to
flush all pumps and purge the gun.
Enabled
Selecting “Enabled” makes the selected recipe
accessible from the Spray screen on the ADM or to
the PLC.
Note: Recipe 0 is always enabled.
Color (A) Valve
Mix Ratio
Enter the desired mix ratio (0 to 50.0):1.
Potlife Time
Enter the potlife time (0 to 999 minutes). Entering
0 disables this function.
Enter the desired color valve number (1-30).
Mix Pressure Tolerance
NOTE: If you enter a number which is not valid in
your system configuration, the field will be highlighted
and the recipe becomes invalid. For example, if your
configuration has 8 color valves and you enter 30,
the field will appear as shown below.
Select the Mix Pressure Tolerance set point to
use while mixing for each recipe. The set point is
shown next to the selection box. (See Mix Pressure
Tolerance on System Screen 2, page 76.)
Catalyst (B) Valve
Enter the desired catalyst valve number (1-4).
NOTE: If you enter a number which is not valid in
your system configuration, the field will be highlighted
and the recipe is invalid. For example, if your
configuration has 1 catalyst valve and you enter 4,
the field will be highlighted and the recipe is invalid.
80
332564C
Setup Mode Screens
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 41 Dual Solvent 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
➜
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Mixed
Material
Second
Fill Material (if applicable)
First Fill
Material
(If applicable)
Purge 3
Solvent
Purge 2
Solvent
Purge 1
Solvent
Mixed
Material
➜
81
Setup Mode Screens
Flush Screen
Initial Flush
Enter the initial flush volume (0 to 9999 cc).
Final Flush
Enter the final flush volume (0 to 9999 cc).
Wash Cycles
Figure 42 Flush Screen
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.
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.
Strokes per Wash Cycle
Enter the desired pump strokes per wash cycle (0
to 99). Default is 1.
Gun Purge Time
Enter the spray device purge time (0 to 999 seconds).
82
332564C
Setup Mode Screens
Pump Screen 1
NOTE: Your system may include 2, 3, or 4 pumps.
Information for each pump is accessible under a
separate tab in the menu bar at the top of the screen.
Select the tab for the desired pump. Each pump has
three screens. Only the screens for Pump 1 are
shown here, but the same fields appear on all.
Pump screen 1 includes the following fields which
define the pump.
Select Color Change
Select this box if your system uses color change.
Materials
Enter the number of materials used in your system.
Each color change module controls 8 colors.
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
Figure 43 Pump Screen 1
The module displays the number of colors available
in your system. This field is not editable.
Pump Size
Select 35cc or 70cc, as appropriate.
Inlet Pressure
Select one of the following:
• Disabled
• Monitor, to track inlet pressure
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83
Setup Mode Screens
Remote Valve Map
Valve Map
Select an alternate valve map for the IS color change
modules. This is useful for a system that has more
than one color pump but relatively few color change
materials. The alternate maps allow for consolidating
two color pumps (Alternate 1) or three color pumps
(Alternate 2) onto a single IS color change module.
See the Color Change and Remote Mix Manifold Kits
manual (333282) for valve maps.
Select an alternate valve map for a system with two
catalyst pumps that requires one pump to change
among three catalysts (Module 5) and only a single
catalyst on Pump 4 (Module 6 if color change is still
used for this pump). See the Color Change and
Remote Mix Manifold Kits manual (333282) for valve
maps.
Figure 45 Pump Screen 1 Catalyst
Figure 44 Pump Screen 1 Color
NOTE: This selection is only available on Pump
Screen 1 for color pumps.
84
NOTE: This selection is only available on Pump
Screen 1 for catalyst pumps.
332564C
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.
Figure 46 Pump Screen 2, Default Settings Enabled
• Inlet Offset Factor: This field is only used if Inlet
Pressure in Pump Screen 1, page 83 is set to
Monitor; it is grayed out if set to Disabled. The
valid range is -01.20 to +01.20 mV/V.
• Inlet Sensitivity Factor: This field is only used if
Inlet Pressure in Pump Screen 1, page 83 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 47 Pump Screen 2, Default Settings Disabled
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85
Setup Mode Screens
Pump Screen 3
Pressure Alarm and Deviation Limits
Pump screen 3 sets the pressure alarm limits for the
pump.
Inlet fields are only active if Inlet Pressure
in Pump Screen 1, page 83 is set to Monitor; they
are grayed out if set to Disabled. Outlet fields are
active at all times.
When Inlet Pressure in Pump Screen 1, page 83 is
set to Disabled, the inlet limit fields are grayed
out and only the outlet limit fields are active. See
Pressure Alarm and Deviation Limits, page 86.
• 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 48 Pump Screen 3, Pressure Monitoring
Disabled
When Inlet Pressure in Pump Screen 1, page 83 is
set to Monitor, all fields are active. See
Pressure Alarm and Deviation Limits, page 86.
Figure 49 Pump Screen 3, Pressure Monitoring
Enabled
86
332564C
Setup Mode Screens
Calibration Screens
Calibrate Screen 1
Calibrate Screen 1 initiates a pump pressure check
(stall test) for the selected pump. During the test, the
Stall Test screen will appear.
The pump and lines must be primed with color
or catalyst before doing the stall test. See
System Screen 2, page 76 to set test parameters.
See Pump Pressure Check, page 96 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.
Figure 50 Calibrate Screen 1
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 51 Stall Test Screen
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87
Setup Mode Screens
Calibrate Screen 2
Calibrate Screen 2 initiates a volume test for the
selected pump. During the test, the Volume Check
screen will appear.
The pump and lines must be primed with color
or catalyst before doing the Volume Check. See
Pump Volume Check, page 97 for complete test
instructions.
To initiate the test, press the Volume Check
button for the desired pump.
The screen displays the volume dispensed. Press
Figure 52 Calibrate Screen 2
to end the test.
Press and hold the Reset button
seconds to reset the volume counter.
for 1-2
Figure 53 Volume Check Screen
88
332564C
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 98 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
Figure 55 Enter Measured Volume of Solvent
Volume field, or press
to end the test.
After the Measured Volume is entered, the Accept
Calibration window will appear. Press
to accept
the calibration. Press
to cancel the calibration
and retain the previous K-factor.
Press and hold the Reset button
seconds to reset the volume counter.
for 1-2
Figure 56 Accept Calibration
Figure 54 Calibrate Screen 3
332564C
89
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 57 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 59 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 58 Maintenance Screen 2, Current Status
90
332564C
Setup Mode Screens
Maintenance Screen 4
Maintenance screen 4 displays cycle counts for a
selected color, catalyst, or solvent valve.
Press and hold the Reset button
seconds to reset the counter.
for 1-2
If the system is in Standby, valves can be opened
or closed by selecting or deselecting the box for the
corresponding valve. Leaving this screen will close
all manually-driven valves.
Figure 61 Maintenance Screen 4, Solvent Valve
Resets
NOTE: In Fig. 48, the number to the right of “Solvent”
is the pump number, not the material number.
Figure 60 Maintenance Screen 4, Color Valve Resets
332564C
91
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.
Figure 62 Advanced Screen 1
Language
Defines the language of the screen text. Select:
• English (default)
• Spanish
• French
Password
The password is only used to enter Setup mode.
The default is 0000, which means no password is
required to enter Setup. If a password is desired,
enter a number from 0001 to 9999.
NOTE: Be sure to write down the password and keep
it in a secure location.
Screen Saver
• German
• Japanese
• Chinese
Select the desired screen timeout in minutes (00-99).
5 is the default. Select zero (0) to disable the screen
saver.
• Korean
• Dutch
• Italian
• Portuguese
Silent Mode
Select Silent Mode to disable the alarm buzzer and
audible feedback.
• Swedish
• Russian
92
332564C
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 63 Advanced Screen 2
Figure 64 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.
332564C
93
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 65 Advanced Screen 4
94
332564C
Setup Mode Screens
Diagnostic Screens
Diagnostic Screen 1
Diagnostic Screen 2
Figure 66 Diagnostic Screen 1
Figure 67 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 68 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.
332564C
95
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 21.
2. If the display is on a Run Mode screen, press
to access setup screens.
Perform the pressure check:
• The first time the system is operated.
• Whenever new materials are used in the system,
especially if the materials have viscosities that
differ significantly.
• At least once per month as part of regular
maintenance.
• Whenever a pump is serviced or replaced.
During each pressure test, the dose valve will close
during an up stroke and a down stroke (in either
order). This test is to verify that the valves are
seating properly and not leaking. If leaking occurs,
the system will alarm after the test for that particular
pump direction.
NOTE: Do not trigger the spray device during the
pressure check.
96
3. Scroll to Calibrate to display
Calibrate Screen 1, page 87.
button for the
4. Press the Pressure Check
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 2, page 76. 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.
332564C
Calibration Checks
Pump Volume Check
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.
1. The pump and lines must be primed with color or
catalyst before doing the Volume Check. See
Prime and Fill the System, page 21.
2. If the display is on a Run Mode screen, press
to access setup screens.
3. Scroll to Calibrate in the menu bar.
4. Scroll to Calibrate Screen 2, page 88.
5. Press the soft key
to check.
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.
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.
332564C
97
Calibration Checks
Solvent Meter Calibration
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.
1. The meter and lines must be primed with
solvent before doing the calibration. See
Prime and Fill the System, page 21.
2. If the display is on a Run Mode screen, press
to access setup screens.
3. Scroll to Calibrate in the menu bar.
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.
4. Scroll to Calibrate Screen 3, page 89.
5. Press the soft key
to initiate the calibration.
11. Press
to accept the calibration. Press
to cancel the calibration and retain the previous
K-factor.
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.
98
332564C
Color Change
Color Change
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 80.
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 5, page 79.
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..
3. Select the new recipe on the
Spray Screen, page 70. This will change
colors in the pump and initiate a gun purge.
332564C
99
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’.
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’.
To Clear Error and Restart
NOTE: When a deviation or alarm occurs, be
sure to determine the error code before resetting
it. If you forget which code occurred, go to the
Errors Screen, page 73, to view the last 200 errors,
with date and time stamps.
If an alarm has occurred, correct the cause before
resuming operation.
To acknowledge a deviation or clear an alarm, press
• Alarm buzzer sounds (unless in silent mode).
on the Advanced Display Module. Users also
may acknowledge and clear errors via a network
device. INPUT REGISTER 08: Clear Active Alarm in
ProMix PD2K Network Inputs, page 36.
• Alarm popup screen shows the active alarm code
(see Error Codes, page 101).
Gun Trigger Input Function
If any of the system error types occur:
• Status bar on the Advanced Display Module shows
the active alarm code.
• Alarm is saved in the date/time stamped log.
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.
The Gun Trigger Input signals the controller when
the gun is triggered. The gun icon on the Advanced
Display Module shows spray when the Gun Trigger
Input is activated.
If a pump fails, pure resin or catalyst could spray
indefinitely if the unit does not detect the condition
and intervene, which is why the Gun Trigger Input
is so important.
If the unit detects through the Gun Trigger Input
signal that the gun is triggered, yet one or both of the
pumps are not running, a Flow Not Detected Alarm
(F8D1) occurs after 10 seconds (default) and the
system goes into Standby.
100
332564C
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 73 to view the last 200 errors, with date, time, and description.
Purge Errors
Code
Type
Description
Problem
Cause
Solution
ETE0
Record
Purge Not
Complete
The system was unable
to complete a purge
sequence.
An indication that the
system either could
not complete or was
interrupted before
completing a gun purge.
No action required.
SPD1
Alarm
Gun Purge
Incomplete
The system timed out
without reaching the
user-specified volume of
solvent for a purge.
Solvent flow switch not
working.
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
Alarm
Flow
The solvent flow switch
Detected
is indicating unexpected
Solvent Gun solvent flow.
F7S2
QPD1
QP##
332564C
Alarm
Flow
Detected
Solvent Mix
Alarm,
then
Deviation
Potlife
Expired
Deviation
Potlife
Expired
Recipe ##
Problem
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.
The solvent flow switches One or both solvent flow
indicate that both are
switches are stuck in flow
flowing solvent at the
position.
same time.
There is a leak through
one or both of the solvent
cutoff valves.
Potlife time has expired
before the system has
moved the required
amount of material
(potlife volume) through
the mixed material line.
Potlife time has expired
before the system has
moved the required
amount of material
(potlife volume) through
the mixed material line in
an inactive gun loaded
with recipe ##. *This only
applies to systems with
multiple guns.
Purge process was not
completed.
Clean or replace the
switch(es).
Check for leaks and
repair valve(s).
Make sure purge process
is completed.
Solvent supply shut off or Verify solvent supply is
empty.
available and on, supply
valves are open.
An inactive gun has
mixed material for recipe
## loaded and has
not dispensed enough
material in the required
amount of time.
Purge the inactive gun.
101
System Errors
Code
Type
Description
Problem
Cause
Solution
SND1
Alarm
Mix Fill
Incomplete
The system timed out
before the mix fill cycle
loaded the gun with
mixed material.
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.
102
332564C
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.
332564C
103
System Errors
Code
Type
Description
Problem
DK0#
Alarm
Position
Pump #
Pump was detected to
be out of position.
EBH#
Record
Home
Complete
Pump #
Record of pump homing
is complete.
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.
Cause
Solution
Re-enable pump power
to reset pump. Make
sure inlet supply
pressure is not too
high.
An indication on the
display that the pump
completed the home
function
No action required.
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.
F1D#
Alarm
Flow Low Mix The pump was unable to
Pump #
maintain it's target flow
rate.
F1F#
Alarm
Flow Low Fill
Pump #
F1S#
104
Alarm
Flow Low
Purge Pump
#
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.
There is a restriction
in the hose or gun that
is preventing the pump
from dispensing at it's
target rate.
Check that the gun
is triggered and for
restrictions in the hose.
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.
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.
Make sure there are
no restrictions in the
system. Increase
non-mix pressure if
necessary to create flow
during the purge function.
332564C
System Errors
Code
Type
Description
Problem
Cause
Solution
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.
F8D1
Alarm
Flow Not
Detected
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.
332564C
105
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
Solution
F6F#
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.
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.
106
332564C
System Errors
Code
Type
Description
Problem
Cause
Solution
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.
QADX
Alarm
Differential
Pressure A
Over B
Low differential pressure. There is a leak on the B
This alarm is active only side.
during Mix mode.
QBDX
332564C
Alarm
Differential
Pressure B
Over A
High differential
pressure. This alarm
is active only during Mix
mode.
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.
There is a leak on the A
side.
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.
107
System Errors
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
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
EMIX
Advisory
Pump Off
The pumps are not
powered and are unable
to move.
Pump power was turned
off or an error occurred.
Start pumps by pressing
pump start key on
Advanced Display
module.
ES00
Advisory
Factory
Defaults
Record of defaults being
loaded.
WSN1
Alarm
Config Error
Color
A color defined for the
system is not assigned
to any gun. *This only
applies to systems with
multiple guns.
One or more colors
is missing a valid gun
assignment.
Ensure all colors for all
color pumps have a gun
assigned to them on
Pump Screen 4.
WSN2
Alarm
Config Error
Catalyst
A catalyst defined for the
system has an invalid
gun assignment. *This
only applies to systems
with multiple guns.
One or more catalyst
is missing a valid gun
assignment.
Ensure all catalysts for
all catalyst pumps have a
gun assigned to them on
Pump Screen 4.
Too many catalyst gun
assignments exist.
The total number of
catalyst gun assignments
for the system may not
exceed four.
108
n/a
332564C
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.
332564C
109
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.
110
332564C
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
B9A0
Advisory
Volume
Rollover A
Current
Batch counter for
material A rolled over.
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
B9B0
Advisory
Volume
Rollover B
Current
Batch counter for
material B rolled over.
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
B9S0
Advisory
Volume
Rollover
Solvent
Current
Batch counter for
solvent rolled over.
The totalizer has
reached maximum
capable value and
started over at zero.
n/a
B9SX
Advisory
Volume
Rollover
Solvent
Lifetime
Grand total counter for
solvent rolled over.
The totalizer has
reached maximum
capable value and
started over at zero.
n/a
WX00
Alarm
Software
Errors
An unexpected
software error has
occurred.
332564C
Call Graco technical
support.
111
System Errors
Calibration Errors
NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable
component number, which can vary. The unit’s display will show the applicable number as the last digit in the
code. For example, the ENT# code listed in this table will be displayed as ENT1 if the affected component is pump
1, ENT2 for pump 2, and so on.
Code
Type
Name
Description
END#
Record
Calibration Pump #
A calibration test was run on the pump.
ENS0
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 #.
112
332564C
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.
MES#
Advisory
Maint. Valve Solvent #
Maintenance is due on solvent valve.
MFF#
Advisory
Maint. Meter Flow #
Maintenance is due on flow meter.
MFS0
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.
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
332564C
113
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.
114
332564C
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.
Click the Create button.
332564C
115
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 “41”, 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 “22”, 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”.
116
i.
Configuration: Size (required): Enter “0”.
j.
Click the OK button. The Module Properties Report window will be displayed.
332564C
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 “41”.
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 “22”.
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”.
332564C
117
Appendix B: Multiple Guns
Appendix B: Multiple Guns
A ProMix PD2K Automatic system normally operates
with a single remote mix manifold and spray device
(see Fig 69), but may be configured to used multiple
(up to three maximum) remote mix manifolds and
spray devices (see Fig 70). Having multiple spray
devices has the advantage of very fast color changes;
the system could have a recipe loaded in each spray
device and could then switch between them almost
instantly. The PD2K will also track potlife time for
multiple mixed recipes.
Figure 69 Fluid lines for a typical PD2K Automatic
system.
118
332564C
Appendix B: Multiple Guns
Figure 70 Fluid lines for a PD2K Automatic system
with multiple guns.
332564C
119
Appendix B: Multiple Guns
The Multiple Guns operation mode may be enabled
on System Screen 3 by checking the box and then
subsequently entering the number of spray devices
for the system in the Number field.
Figure 73 Pump Screen 4 Catalyst
Figure 71 System Screen 3 Multiple Guns
Each color in the system must be assigned to a single
spray device. Assignment of the color to a spray
device is done on the Pump Screen 4 by entering the
spray device number next to the color number.
Figure 74 Pump Screen 4 Catalyst Common
Recipes can only be set up to use a color and catalyst
that are assigned to the same spray device. If the
color and catalyst spray device assignments do not
match, the recipe will be invalidated and disabled.
See Recipe Screen, page 80 for more information
on invalid recipes.
Figure 72 Pump Screen 4 Color
Catalysts may be assigned to a single spray device,
shared among multiple spray devices (common),
or a mix of both. Only one catalyst per pump may
be configured as Common, and because each
assignment requires a remote valve, the total number
(including each common assignment) cannot exceed
four. To configure a catalyst as common to multiple
spray devices, check the Common box and select all
appropriate spray devices.
When common catalysts are used, the system will
automatically allocate each spray device assignment
to a unique remote catalyst valve (1–4), shown in the
following table.
On the left, locate the row that has;
1. the number of catalyst pumps,
2. the catalyst valve map selection (see
Pump Screen 1, page 83), and
3. the appropriate common catalyst configuration
for your system.
Follow along the resulting row to the right to find the
system’s remote catalyst valve allocation.
120
332564C
Appendix B: Multiple Guns
Table 8 Remote Catalyst Valve allocation for system using Common catalyst
Catalyst
Pumps
Valve
Map
Selection
Pump 2:
Common
Catalyst
Pump 4:
Common
Catalyst
Remote
Catalyst
Valve 1
Remote
Catalyst
Valve 2
Remote
Catalyst
Valve 3
Remote
Catalyst
Valve 4
1
Standard
None
N/A
Catalyst 1
Catalyst 2
Catalyst 3
Catalyst 4
1
Standard
Common to
Guns 1 & 2
N/A
Catalyst 1
(Gun 1)
Catalyst 1
(Gun 2)
Catalyst 2
Catalyst 3
1
Standard
Common to
Guns 1 & 3
N/A
Catalyst 1
(Gun 1)
Catalyst 1
(Gun 3)
Catalyst 2
Catalyst 3
1
Standard
Common to
Guns 2 & 3
N/A
Catalyst 1
(Gun 2)
Catalyst 1
(Gun 3)
Catalyst 2
Catalyst 3
1
Standard
Common to
Guns 1–3
N/A
Catalyst 1
(Gun 1)
Catalyst 1
(Gun 2)
Catalyst1
(Gun3)
Catalyst 2
2
Standard
None
-
Catalyst 1
Catalyst 2
-
-
2
Standard
Common to
Guns 1 & 2
-
Catalyst 1
(Gun 1)
Catalyst 1
(Gun 2)
-
-
2
Standard
Common to
Guns 1 & 3
-
Catalyst 1
(Gun 1)
-
-
2
Standard
Common to
Guns 2 & 3
-
Catalyst 1
(Gun 3)
-
-
2
Standard
-
None
-
-
Catalyst 3
Catalyst 4
2
Standard
-
Common to
Guns 1 & 2
-
-
Catalyst 3
(Gun 1)
Catalyst 3
(Gun 2)
2
Standard
-
Common to
Guns 1 & 3
-
-
Catalyst 3
(Gun 1)
Catalyst 3
(Gun 3)
2
Standard
-
Common to
Guns 2 & 3
-
-
Catalyst 3
(Gun 2)
Catalyst 3
(Gun 3)
2
Alternate
None
N/A
Catalyst 1
Catalyst 2
Catalyst 3
Catalyst 4
2
Alternate
Common to
Guns 1 & 2
N/A
Catalyst 1
(Gun 1)
Catalyst 1
(Gun 2)
Catalyst 2
Catalyst 4
2
Alternate
Common to
Guns 1 & 3
N/A
Catalyst 1
(Gun 1)
Catalyst 1
(Gun 3)
Catalyst 2
Catalyst 4
2
Alternate
Common to
Guns 2 & 3
N/A
Catalyst 1
(Gun 2)
Catalyst 1
(Gun 3)
Catalyst 2
Catalyst 4
2
Alternate
Common to
Guns 1–3
N/A
Catalyst 1
(Gun 1)
Catalyst 1
(Gun 2)
Catalyst 1
(Gun 3)
Catalyst 4
With Multiple Guns enabled, the system requires two additional remote solvent valves for each spray device. Because
of this, the total number of colors is reduced to 26 and the valve map for the IS color change modules are configured
differently. Refer to Color Change and Remote Mix Kit manual (333282) for more detail.
332564C
121
Appendix B: Multiple Guns
Spray Screen
Fill Screen
The Spray screen provides the same information and
operating capabilities as with a single spray device
(see Spray Screen, page 70). In addition, the Spray
screen shows the contents of each spray device,
and allows the user to purge a spray device that is
not currently active. (The active spray device is that
which is, or was, most recently spraying or loading
mixed material, and is highlighted on the left side
of the screen.) If manual override is enabled, and
the system is in Standby, the user may select Purge
and enter the recipe number to be flushed from an
inactive gun. This provides the ability to purge a
spray device that is currently inactive but loaded with
mixed material that has an expired potlife.
The Fill screen operates the same as with a single
spray device (see Fill Screen, page 71).
NOTE: When filling a line, it is important to know
and trigger the appropriate spray device to which
the material is assigned to avoid over-pressuring the
system.
When filling a line with a catalyst that is common, the
user will also need to select one of the spray devices.
The system will open the appropriate valves and fill
material out the selected spray device.
Figure 76 Fill Screen Common Catalyst
Figure 75 Spray Screen Purge
NOTE: Only a recipe that is loaded in one of the spray
devices may be selected to be purged. This prevents
inadvertent purging of a desired loaded recipe.
122
332564C
Appendix B: Multiple Guns
Potlife Screen
Recipe 0
With Multiple Guns enabled, an additional Run Mode
screen is now accessible. This screen will show all
recipes that are currently loaded in a spray device
that have a non-zero potlife, and the amount of time
remaining in the potlife.
If a user wishes to always skip purging the B-side
of a particular spray device, or to avoid nuisance
purging alarms when no catalyst solvent is plumbed
to a particular spray device manifold, it may be
disabled on Recipe Screen 0. Select the 1K option
for the appropriate Gun number to indicate only
single-component recipes are run through that
manifold. (Default value is 2K).
NOTE: 1K should only be selected for manifolds
that do not have a B-side solvent plumbed to the
manifold. If a combination of one-component and
two-component recipes are run through a manifold,
the system will automatically determine whether the
B-side needs to be purged or can be skipped.
Figure 77 Potlife Screen
Figure 78 Recipe 0 Multiple Guns
332564C
123
Appendix B: Multiple Guns
Maintenance Screen 4
Operation With a PLC
Color change valves may be manually overridden
from Maintenance Screen 4 the same as with a single
spray device (see Maintenance Screen 4, page 91).
All spray devices defined for the system are required
to have provided for them a unique gun trigger
signal. The following table shows where discrete I/O
connections are made for the three available gun
trigger inputs on the EFCM.
For a catalyst configured as common, the user will
have to identify which remote valve to cycle by
selecting the appropriate gun.
Figure 79 Maintenance Screen 4 Common Catalyst
Because each spray device has its own unique
remote solvent valves, when overriding a remote
solvent valve the user will similarly have to identify
the appropriated spray device.
NOTE: For remote solvent valves, the pump number
only identifies whether the valve is for the color
solvent valve (color pump number) of for the catalyst
solvent valve (catalyst pump number).
Figure 80 Maintenance Screen 4 Solvent
124
I/O Description
EFCM
Connector
Pins
Type
Gun
Trigger
Input 1
6
1, 2
Normally
Open
Contact
Gun
Trigger
Input 2
6
3, 4
Normally
Open
Contact
Gun
Trigger
Input 3
6
5, 6
Normally
Open
Contact
If the Gun Trigger is configured to ‘Network’,
Input Registers 10, 11, and 12 are
used. Review Discrete I/O, page 25 and
ProMix PD2K Network Inputs, page 36.
Output Register 26 is used to indicate which gun is
currently the ‘active’ spray device.
When command a line fill/flush for a common catalyst
from the PLC using Input Registers 01 and 02,
the appropriat spray device must be identified and
triggered to avoid over-pressurizing the system.
To accomplish this, the common catalysts have
a special material number designation. If filling
with a common catalyst on pump 2, instead of
using material 31 the user will enter 41, 42, and
43 for spray device 1, 2, and 3, respectively.
See ProMix PD2K Network Inputs, page 36, and
Line Fill and Flush Sequences, page 47, for details.
If one of the inactive spray devices is loaded with
material and the potlife expires, it may be disired
to purge the material immediately, but not change
over materials in the pumps. The Purge (Inactive)
system command will allow the user to momentarily
cease spraying the active gun and purge and inactive
gun, then immediately return to spraying with the
previously active gun. The user must enter the recip
of the inactive gun in Output Register 07 first and
then command the system with Output Register 10
(see Purge (Inactive) Sequence, page 45).
332564C
Technical Data
Technical Data
U.S.
Metric
AC1000 Air Spray Systems
300 psi
2.1 MPa, 21 bar
AC2000 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)
Positive Displacement
Proportioner
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:
Fluids handled:
0.1:1 — 50:1, ±1%
one or two component:
• 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:
External power supply
requirements:
1/4 npt(m)
90 - 250 Vac, 50/60 Hz, 7 amps maximum draw
15 amp maximum circuit breaker required
8 to 14 AWG power supply wire gauge
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:
17–4PH, 303, 304 SST, Tungsten carbide (with nickel binder),
perfluoroelastomer; PTFE, PPS, UHMWPE
332564C
125
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 332564
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
2014,, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Copyright 2014
www.graco.com
Revision C, May 2016

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