Operation ProMix® PD2K Proportioner for Automatic Spray Applications 332564B Electronic positive displacement proportioner for fast-setting two-component materials. Automatic 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.
Contents Related Manuals .................................................. 3 Models................................................................. 4 Warnings ............................................................. 6 Important Isocyanate (ISO) Information .................. 9 General Information ............................................ 10 Advanced Display Module (ADM) ........................ 11 ADM Display................................................ 11 USB Download Procedure ...............
Related Manuals Related Manuals Current manuals are available at www.graco.com. Manual No. Description Manual No.
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 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.
Models Figure 3 Model AC2000 (High Pressure) Identification Label Figure 4 Non-Intrinsically Safe Color Change Control (Accessory) Identification Label Figure 5 Intrinsically Safe Color Change Control (Accessory) Identification Label Figure 6 Pump Expansion Kit (Accessory) Identification Label 332564B 5
Warnings Warnings The following warnings are for the setup, use, grounding, maintenance and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard 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.
Warnings INTRINSIC SAFETY WARNING 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.
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.
Important Isocyanate (ISO) Information Important Isocyanate (ISO) Information Isocyanates (ISO) are catalysts used in two component materials. Isocyanate Conditions Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. NOTICE Partially cured ISO will reduce performance and the life of all wetted parts. Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates.
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. 10 • 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.
Advanced Display Module (ADM) Advanced Display Module (ADM) ADM Display The ADM display shows graphical and text information related to setup and spray operations. For detail on the display and individual screens, see Run Mode Screens, page 58, or Setup Mode Screens, page 66. Keys are used to input numerical data, enter setup screens, navigate within a screen, scroll through screens, and select setup values.
Advanced Display Module (ADM) USB Upload Procedure Use this procedure to install a system configuration file and/or a custom language file. 6. If installing the system configuration settings file, place SETTINGS.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. 7. If installing the custom language file, place DISPTEXT.TXT file into UPLOAD folder. 2.
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.
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.
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.
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.
Pre-Operation Tasks Pre-Operation Tasks Pre-operation Checklist Go through the Pre-Operation Checklist daily, before each use. ✔ Checklist System grounded Verify all grounding connections were made. See Grounding in the Installation manual. Power On 1. Turn the AC Power Switch (P) ON (I = ON, 0 = OFF). 2. The Graco logo will display while the system initializes, followed by the Home screen. . The system status will 3. Press the Start key change from “System Off” to “Startup.
Pre-Operation Tasks Initial System Setup Valve Settings 1. Change optional setup selections to desired parameters, as described in Setup Mode Screens, page 66. 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 72 and Flush Screen, page 73. Flush Before Using Equipment The pump fluid section was tested with lightweight oil, which is left in the fluid passages to protect parts.
Pressure Relief Procedure Pressure Relief Procedure Follow the Pressure Relief Procedure whenever you see this symbol. With Color Change NOTE: The following procedure relieves all fluid and air pressure in the system. 1. Turn off the supply pumps. Open the drain valve on the supply line fluid filter to relieve pressure in the supply lines. Do this for each color. This equipment stays pressurized until pressure is manually relieved.
Operation Using Automatic Display Module (ADM) Operation Using Automatic Display Module (ADM) Prime and Fill the System NOTE: See Run Mode Screens, page 58, 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.
Operation Using Automatic Display Module (ADM) Spraying To spray in a multiple color system, also see Multiple Color Systems, page 87. NOTE: See Run Mode Screens, page 58, for further screen information, if needed. 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.
Operation Using Automatic Display Module (ADM) Purging To purge one color and fill with a new color, see Color Change, page 87. Flush Mixed Material 3. Trigger the spray device to relieve pressure. 4. 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.
Operation Using Automatic Display Module (ADM) Flush the System Color Change System 1. Relieve the pressure. See Pressure Relief Procedure, page 19. 2. Attach regulated solvent supply lines as follows: To avoid fire and explosion, always ground equipment and waste container. To avoid injury from splashing, always flush at lowest possible pressure.
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.
Operation Using a Programmable Logic Controller (PLC) Digital Inputs • Safety Interlock: This normally open contact works 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.
Operation Using a Programmable Logic Controller (PLC) Discrete I/O Connections on EFCM Figure 11 KEY A1 Gun Trigger Input B1 Analog Set Point Input C1 Safety Interlock Input 26 332564B
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. Each kit includes all parts needed to install the CGM, along with Manual 334494, which contains installation instructions applicable to any kit.
Operation Using a Programmable Logic Controller (PLC) Network Communication I/O Data Map 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.
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.
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.
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.
Operation Using a Programmable Logic Controller (PLC) Notes 32 332564B
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 01 40102 Pump 1 Status uint32
Operation Using a Programmable Logic Controller (PLC) 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 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
Operation Using a Programmable Logic Controller (PLC) 23 24 25 26 27 28 40146 40148 40150 40152 40154 40200 Gun 1 Trigger Input Status uint32 Gun 2 Trigger Input Status uint32 Gun 3 Trigger Input Status uint32 Gun 4 Trigger Input Status uint32 Safety Interlock Input Status uint32 Command Acknowledge uint32 NONE 0 = Gun not triggered 1 = Gun triggered NONE 0 = Gun not triggered 1 = Gun triggered NONE 0 = Gun not triggered 1 = Gun triggered NONE 0 = Gun not triggered 1 = Gun triggered NO
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.
Operation Using a Programmable Logic Controller (PLC) INPUT REGISTER 01: Pump Flush Sequence/Prime Material Selection INPUT REGISTER 03: Mix (Pump 1) Control Set Point 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. The Mix Control Set Point register is used to set and adjust the mixing fluid control set point.
Operation Using a Programmable Logic Controller (PLC) INPUT REGISTER 08: Clear Active Alarm INPUT REGISTER 10: Gun 1 Trigger 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.
Operation Using a Programmable Logic Controller (PLC) Notes 332564B 39
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 01 40158 Pump Flush Sequence #/Prime Material # uint32 NONE 1 - 5, 1 - 34 02 40160 Flush/Prime Pump Command uint32 NONE 0 = No OP 1 = Flush Pump 1 2 = Prime Pump 1 3 = Flush
Operation Using a Programmable Logic Controller (PLC) 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
Operation Using a Programmable Logic Controller (PLC) Operation Flow Charts Purge Mode Sequence Purge A System Command Write ‘6’ to Input Register 00 Is system in Standby or Pumps Off? 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.
Operation Using a Programmable Logic Controller (PLC) Inactive Pump Flush and Prime Sequences Write Prime Material # (1-34) to Output Register 01 Write Flush Sequence # (1-5) 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 Is requested pump status* = Standby? (Output Register* = ‘1’) Write Prime Pump Command
Operation Using a Programmable Logic Controller (PLC) Color Change Sequence Write Goto Recipe Number (0,1 - 60) to Input Register 07 Recipe Change System Command Write ‘3’ to Input Register 00 System Mode = Recipe Change (Output Register 00 = ‘2’) NO YES Is system in Standby with no alarm conditions? NO No action taken. Either pumps are currently running or an alarm condition exists. Is Material B changing? YES Purge Material B out gun.
Operation Using a Programmable Logic Controller (PLC) Mixing Sequence Mix System Command Write ‘5’ to Input Register 00 System Mode = Standby: Fill Ready? Stem Mode = Standby: Mix Ready? NO YES NO YES A recipe is loaded in the pumps but not yet filled out to the gun. Mixed material is pumped out to the gun. 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.
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 Register 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.
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 40 and Network Output Data Map (Read Only), page 33.
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 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 Write User ID The Write User ID command allows users to assign a User ID to a Job Log.
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 72, 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.
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 73, 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.
Operation Using a Programmable Logic Controller (PLC) 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 71, 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.
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.
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.
Operation Using a Programmable Logic Controller (PLC) Read Job Info The Read Job Info command is used to access data from any of the most recent 200 job logs. The argument is the chronological index of the job log, where 0 is the most recent job log and 199 is the 200th most recent. The date is returned as four-byte packet with each byte holding a two-digit value for (from MSB to LSB) year, month, day, and day of the week (Monday = 01).
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).
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).
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.
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 14 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 67.
Run Mode Screens Home Screen Key Key Description Details A Date and Time See Advanced Screen 1, page 82, 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 62) • Fill (see Fill Screen, page 63), available only if manual override is enabled on System Screen 5, page 71.
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.
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 ( 332564B Details ) ) ) 61
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 71. The screens show a system in manual override mode.
Run Mode Screens Fill Screen NOTE: This screen is visible only if manual override is enabled on System Screen 5, page 71. 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.
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 71. 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.
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 24 Jobs Screen Figure 25 Errors Screen Events Screen The Events screen displays the 200 most recent Event Codes in a log, with date, time, and description.
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 66. Figure 27 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.
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 58. Color Pumps Enter the number of color pumps in your system. Catalyst Pumps Enter the number of catalyst pumps in your system. Non-Mix Pressure Enter a lower pressure for use when not mixing and spraying (for example during fill or flushing).
Setup Mode Screens System Screen 2 System screen 2 sets the following system operating parameters. 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.
Setup Mode Screens System Screen 3 System screen 3 sets the following system operating parameters. Gun Hose Length Enter the length of the hose from the remote mix manifold to the spray device. Gun Hose Diameter Enter the diameter of the hose from the remote mix manifold to the spray device. The minimum diameter is 1/8 in. (3 mm). Mix At Wall This field is always enabled in Automatic systems.
Setup Mode Screens System Screen 4 System screen 4 sets the following system operating parameters. Enable Uncheck Enable while setting the IP Address, Subnet mask, Gateway, DNS1 or DNS2. When the settings are loaded, check the Enable box to write the new settings to the selected Gateway. Check this box to enable the selected Gateway so that the PLC can communicate with it. DHCP Figure 31 System Screen 4 Gateway ID Select the desired Gateway ID from the dropdown menu.
Setup Mode Screens System Screen 5 System screen 5 sets the following system operating parameters. are controlled through a PC, PLC, or other networked device. Gun Trigger Signal Select the format of the signal indicating whether the spray device is triggered. • Discrete — the signal is sent via a direct, hard-wired connection • Network — the signal is sent via a PC, PLC, or other networked device.
Setup Mode Screens Recipe Screen Figure 33 Valid Recipe Screen Figure 34 Invalid Recipe Screen Recipe Catalyst (B) Valve Enter the desired recipe number (1-60). Enter the desired catalyst valve number (1-4). Recipe 0 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.
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 35 Flush Screen Flush Number Enter the desired flush sequence (1-5). For hard to flush colors, select a longer sequence. 1 is the default, and should be designated for the longest, most thorough flush duration. A Wash Cycle activates the pump with the valves closed, to use pumping motion to thoroughly clean the pump.
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.
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.
Setup Mode Screens Pump Screen 3 Pump screen 3 sets the pressure alarm limits for the pump. When Inlet Pressure in Pump Screen 1, page 74 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 76.
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 68 to set test parameters. See Pump Pressure Check, page 84 for complete test instructions. To initiate the test, press the Pressure Check button for the desired pump.
Setup Mode Screens Calibrate Screen 2 Calibrate Screen 2 initiates a volume test for the selected pump. During the test, the Volume Check screen will appear. The pump and lines must be primed with color or catalyst before doing the Volume Check. See Pump Volume Check, page 85 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 43 Calibrate Screen 2 to end the test.
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 86 for complete instructions. To initiate the calibration, press the Volume Check button. The screen displays the volume dispensed.
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. for 1-2 Press and hold the Reset button seconds to clear the alarm and reset the counter. NOTE: The Pump Stall Test can only be reset by successfully completing the test.
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. Figure 52 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.
Setup Mode Screens Advanced Screen 1 Advanced screen 1 sets the following display parameters. • Swedish • Russian Date Format Select mm/dd/yy, dd/mm/yy, or yy/mm/dd. Date Enter the date, using the format selected. Use two digits for the month, day, and year. Time Enter current time in hours (24 hour clock) and minutes. Seconds are not adjustable. Figure 53 Advanced Screen 1 Language Defines the language of the screen text.
Setup Mode Screens Advanced Screen 2 Advanced screen 2 sets display units (US or metric). Enable USB Downloads/Uploads Select this box to enable USB downloads and uploads. Enabling USB activates the Download Depth field. Download Depth Enter the number of days for which you want to retrieve data. For example, to retrieve data for the previous week, enter 7.
Calibration Checks Calibration Checks Pump Pressure Check NOTE: Enter the transducer calibration data before doing the pressure check. 1. The pump and lines must be primed with color or catalyst before doing the Pressure Check. See Prime and Fill the System, page 20. 2. If the display is on a Run Mode screen, press to access setup screens. Perform the pressure check: • The first time the system is operated.
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. 1. The pump and lines must be primed with color or catalyst before doing the Volume Check. See Prime and Fill the System, page 20. 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 78. 5. Press the soft key to check. 8.
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 20. 2. If the display is on a Run Mode screen, press to access setup screens. 3. Scroll to Calibrate in the menu bar.
Color Change Color Change Multiple Color Systems 1. Command the system to Standby. 2. Enable manual override on System Screen 5, page 71. Color Change Module Kits are available as an accessory. See manual 333282 for complete information. Single Color Systems 1. Follow the procedure under Flush the System, page 23. 2. Load the new color. See Prime and Fill the System, page 20. 3. Command the system to Mix to start spraying. 3. Select the new recipe on the Spray Screen, page 62.
System Errors System Errors System errors alert you of a problem and help prevent off-ratio spraying. There are three types: Advisory, Deviation, and Alarm. An Advisory records an event in the system, and will clear itself after 60 seconds. A Deviation records an error in the system but does not shut down the equipment. The deviation must be acknowledged by the user. If an Alarm occurs, operation stops.
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 65 to view the last 200 errors, with date, time, and description. Purge Errors Code Type Description Problem Cause Solution F7P1 Alarm Air Flow Switch On The air flow switch is indicating unexpected atomizing air flow. Air flow switch is stuck in flow position. Clean or replace switch. Leak downstream in air line or fitting.
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.
System Errors Code Type Description Problem Cause Solution DH0# Alarm No Stall Pump # Pump failed the stall test; did not stall on either the upstroke or the downstroke. Valve failure, seal failure, worn rod or cylinder. Replace inlet and outlet valve and seal for up and down strokes. Replace piston and throat seals. Replace rod and cylinder as necessary. DK0# Alarm Position Pump # Pump was detected to be out of position. EBH# Record Home Complete Pump # Record of pump homing is complete.
System Errors Code Type Description Problem Cause Solution F1F# Alarm Flow Low Fill Pump # There has been no flow or low flow during a pump fill operation. There is a restriction on the outlet side of the pump or color stack. 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.
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.
System Errors Code Type Description Problem Cause Solution 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. This alarm is active only during Mix mode. There is a leak on the B side.
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).
System Errors Code Type Description Problem CAGX Alarm Comm. Error Gateway System does not detect a CGM that was registered as being connected at power up. CDC# Alarm Duplicate Color Change # CDDX Alarm Duplicate Fluid Module 96 Cause Solution 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.
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.
System Errors Code Type Description Problem Cause Solution 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.
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.
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.
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.
Maintenance Maintenance Preventive Maintenance Schedule • Flush at the lowest pressure possible. Check connectors for leaks and tighten as necessary. 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.
Technical Data Technical Data Positive Displacement Proportioner 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.
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.
