Graco ProMix PD2K Operation Download

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Setup Mode Screens

Pump

Pump Screen

Screen

Screen 3

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

When Inlet

Inlet

Inlet Pressure

Pressure

Pressure in

Pump Screen 1, page 81

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 87

Figure 65 Pump Screen 3, Pressure Monitoring
Disabled

When Inlet

Inlet

Inlet Pressure

Pressure

Pressure in

Pump Screen 1, page 81

set to Monitor, all fields are active. See

Pressure Alarm and Deviation Limits, page 87

Figure 66 Pump Screen 3, Pressure Monitoring
Enabled

Pressure

Pressure Alarm

Alarm

Alarm and

and

and Deviation

Deviation

Deviation Limits

Limits

Inlet fields are only active if Inlet

Inlet

Inlet Pressure

Pressure

Pump Screen 1, page 81

is set to Monitor; they

are grayed out if set to Disabled. Outlet fields are
active at all times.

• Alarm and Deviation ranges are 0-300 psi for

low pressure systems, and 0-1500 psi for high
pressure systems.

• Setting to 0 will disable the alarm. The Inlet Alarm

High and Outlet Alarm High cannot

cannot

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:

NOTE: Outlet Alarm Low is only enabled for systems
using Flow Control.

3A4486D

Summary of Contents for ProMix PD2K

Page 1: ... for two two two component component component materials materials materials Automatic Automatic Automatic system system system with with with Advanced Advanced Advanced Display Display Display Module Module Module For For For professional professional professional use use use only only only Important Important Important Safety Safety Safety Instructions Instructions Instructions Read all warnings...

Page 2: ...twork Communication Dynamic Command Structure DCS 50 PLC Diagnostic Screens 59 Flow Control System 60 Run Mode Screens 61 Opening Screen 61 Home Screen 61 Spray Screen 64 Fill Screen 65 Usage Screen 66 Jobs Screen 67 Errors Screen 67 Events Screen 67 Setup Mode Screens 68 Password Screen 68 System Screen 1 68 System Screen 2 69 System Screen 3 70 System Screen 4 71 Solvent Push 72 System Screen 5 ...

Page 3: ...oMix PD2K Proportioner for Automatic Spray Applications Installation 332339 Dosing Pumps Instructions Parts 332454 Color Catalyst Dispense Valves Instructions Parts Manual Manual Manual No No No Description Description Description 333282 Color Change and Remote Mix Manifold Kits Instructions Parts 332456 Pump Expansion Kits Instructions Parts 334183 Modbus TCP Gateway Module Instructions Parts 334...

Page 4: ...e Pressure Pressure Location Location Location of of of PD2K PD2K PD2K and and and Electrical Electrical Electrical Control Control Control Box Box Box ECB ECB ECB Labels Labels Labels AC1002 AC3002 Acid based Material A 100 psi 0 7 MPa 7 0 bar 300 psi 2 068 MPa 20 68 bar AC2002 AC4002 Acid based Material A 100 psi 0 7 MPa 7 0 bar 1500 psi 10 34 MPa 103 4 bar 2575 2575 2575 II 2 G Figure 1 Model A...

Page 5: ...ntrinsically Safe Color Change Control Accessory Identification Label Figure 6 Pump Expansion Kit Accessory Identification Label PART NO DATE SERIES SERIAL NO 12 30 VDC 4 AMP MAX Type 1 ENCL U S Patent Pending 4003764 Conforms to UL STD 508 Certified to CAN CSA STD C22 2 No 14 RECOGNIZED COMPONENT Artwork No 293656 Rev D Figure 7 CGM Identification Label 3A4486D 5 ...

Page 6: ...king Ground all equipment in the work area See Grounding Grounding Grounding instructions Never spray or flush solvent at high pressure Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pai...

Page 7: ...ke just a cut but it is a serious injury that can result in amputation Get Get Get immediate immediate immediate surgical surgical surgical treatment treatment 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 Pressure Pressure Relief Relief Relie...

Page 8: ... See Technical Technical Technical Data Data Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Technical Technical Data Data 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...

Page 9: ... cured material in fluid lines which could cause serious injury or damage equipment To prevent cross contamination Never Never Never interchange component A and component B wetted parts Never use solvent on one side if it has been contaminated from the other side Moisture Moisture Moisture Sensitivity Sensitivity Sensitivity of of of Isocyanates Isocyanates Isocyanates Exposure to moisture such as...

Page 10: ...d local regulatory authority Follow all acid manufacturer recommendations including those regarding handling of contaminated clothing Wash hands and face before eating or drinking Regularly inspect equipment for potential leaks and remove spills promptly and completely to avoid direct contact or inhalation of the acid and its vapors Keep acid away from heat sparks and open flames Do not smoke in t...

Page 11: ...mbers and letters in the illustrations Be sure all accessories are adequately sized and pressure rated to meet system requirements To protect the screens from paints and solvents clear plastic protective shields 10 per pack are available Order Part No 197902 for the Advanced Display Module Clean the screens with a dry cloth if necessary 3A4486D 11 ...

Page 12: ...complete USB IDLE appears on the screen The USB drive may then be removed NOTE NOTE 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 op...

Page 13: ... with the corresponding serial number of the ADM The serial number is on the back of the module 6 If installing the system configuration settings file place SETTINGS TXT file into UPLOAD folder 7 If installing the custom language file place DISPTEXT TXT file into UPLOAD folder 8 Remove the USB flash drive from the computer 9 Install the USB flash drive into the USB port of the ProMix PD2K system U...

Page 14: ...Stop Stop Stop Press to immediately stop the system and remove motor power Soft Soft Soft Keys Keys Keys 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 Navigation Navigation Navigation Keys Keys Keys Left Right Arrows Use to move from screen to screen Up Dow...

Page 15: ... Fill Pump Press to mark pump as filled Only for applicable pumps Line Fill Run Press to start a line fill procedure Mix Press to start a spray procedure Purge Press to start a purge procedure Key Key Key Function Function Function Solvent Purge Press to engage solvent push sequence when applicable Standby Stop Press to stop all pumps and put system in Standby Recipe Link Press to link recipe data...

Page 16: ...ures 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 to activate the editing function on any screen Press the Exit soft key to exit any screen Use the other softkeys to select t...

Page 17: ...18 then adjust as needed Fluid Fluid Fluid supply supply supply valves valves valves open open open and and and pressure pressure pressure set set set The recommended component A and B fluid supply pressures are 1 2 to 2 3 of the target spray pressure NOTE NOTE 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 ...

Page 18: ...h Flush Flush Before Before Before Using Using Using Equipment Equipment 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 Valve Valve Valve Settings Settings Settings Dose valves and purge valves are factory set wit...

Page 19: ...e alarm 5 If pressure remains in the solvent line between the solvent supply pump and the solvent valve VERY SLOWLY loosen a fitting to relieve pressure gradually Loosen the fitting completely 6 Repeat for Mix Unit 2 With With With Color Color Color Change Change Change NOTE NOTE NOTE The following procedure relieves all fluid and air pressure in the system 1 Turn off the supply pumps Open the dra...

Page 20: ...igger 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 Pre Pre Pre Fill Fill Fill the the the Pump Pump Pump NOTE NOTE NOTE This option is only available for pumps that have color change valves and only a single material If a pump is filled with a material when the system is powered down this will allow the user t...

Page 21: ...ust purge sequence times so only one cycle is required NOTE NOTE NOTE The remote mix manifold and gun remain full of solvent after purging Flush Flush Flush the the the System System System To avoid fire and explosion always ground equipment and waste container To avoid static sparking and injury from splashing always flush at the lowest possible pressure Follow this procedure before the first tim...

Page 22: ...he lowest pressure possible Generally a setting of 25 50 psi 0 18 0 35 MPa 1 8 3 5 bar is sufficient 4 On the ADM go to the Fill screen for Mix Unit 1 Select Color A Enter the color number in the box to the right 5 Select the Flush Line box 6 If the solvent is not already loaded press the Prime softkey The Mix Unit will prime solvent into the selected pump and out the outlet dump valve 7 Press the...

Page 23: ...eck box on System Screen 1 enables a user to operate the system before the automation PLC is available Manual Override can be used to run all functions of the system if a proper gun trigger signal is provided It is not intended to be the main mode of control Graco recommends that Manual Override be disabled during normal operation to avoid driving the system in a way that conflicts with the automa...

Page 24: ...ce 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 Analog Analog Analog Inputs Inputs Inputs Flow Flow Flow Control Control Control Set Set Set Point Point Point 1 1 1 and and and 2 2 2 When enabled these 4 20 mA signal inputs are used to s...

Page 25: ...crete Discrete Discrete I O I O I O Connections Connections Connections on on on EFCM EFCM EFCM Figure 12 KEY KEY KEY A1 Gun Trigger Input 1 A2 Gun Trigger Input 2 B1 Analog Set Point Input 1 B2 Analog Set Point Input 2 C1 Safety Interlock Input 3A4486D 25 ...

Page 26: ...protocols are listed in the tables NOTE NOTE NOTE The CGM Installation kit is also required for DeviceNet EtherNet IP and Modbus TCP protocols PROFINET protocol calls for two CGM modules with the PD2K Dual Panel application The PROFINET kit consolidates all installation hardware as well as the two CGM modules into a single part number CGM CGM CGM Installation Installation Installation Kit Kit Kit ...

Page 27: ... Recipe Change The Mix Unit is in the process of a color change sequence 3 Recipe Change Purge A The Mix Unit is purging material A as part of a recipe change 4 Recipe Change Purge B The Mix Unit is purging material B as part of a recipe change 5 Recipe Change Fill The Mix Unit is filling the hose from the remote valves to the mix manifold with material as part of a recipe change 6 Mix Fill The Mi...

Page 28: ...t Input Status Status Status The Gun Trigger Input Status registers contain the status of the Gun Trigger Discrete Inputs The value is 0 if the input is OPEN gun not triggered The value is 1 if the input is CLOSED gun triggered This data register is valid only for systems configured to use the discrete inputs for the Gun Triggers See Gun Trigger Signal page 71 OUTPUT OUTPUT OUTPUT REGISTERS REGIST...

Page 29: ... register contains the number of the Color 1 32 that is associated with the current recipe This value is 0 if the Mix Unit was flushed This value is 61 if the current recipe is invalid or at initial startup OUTPUT OUTPUT OUTPUT REGISTER REGISTER REGISTER 16 16 16 and and and 42 42 42 Active Active Active Recipe Recipe Recipe Material Material Material B B B The Active Recipe Material B data regist...

Page 30: ...b in cc OUTPUT OUTPUT OUTPUT REGISTER REGISTER REGISTER 23 23 23 and and and 49 49 49 Job Job Job B B B Sprayed Sprayed Sprayed Volume Volume Volume The Job B Sprayed Volume register provides a real time volume of color sprayed during the current job in cc OUTPUT OUTPUT OUTPUT REGISTER REGISTER REGISTER 24 24 24 and and and 50 50 50 Job Job Job Solvent Solvent Solvent Volume Volume Volume The Job ...

Page 31: ...y 13 Standby Mix Not Ready 14 Standby Alarm 15 Line Filling Flushing 16 Pump Prime Flush 17 Maintenance Calibration 0000 41000 Current System Mode uint32 NONE 18 Mix Solvent Push 0 No Events 0001 41002 Event Flag uint32 NONE 1 New Event 0002 41004 Actual Mix Flow Pressure uint32 cc min PSI 1 1600 0003 41006 Actual Mix Ratio uint32 NONE 0 5000 0004 41008 Actual Mix Potlife Remaining uint32 sec 0 59...

Page 32: ...Active Recipe Material A Flush Sequence uint32 NONE 1 5 0018 41036 Active Recipe Material B Flush Sequence uint32 NONE 1 5 0019 41038 Active Recipe Ratio Set Point uint32 NONE 0 5000 0020 41040 Active Recipe Potlife Time Set Point uint32 min 0 999 0021 41042 Job Number uint32 NONE 0 9999 0022 41044 Job A Sprayed Volume unit32 cc 0 999999999 0023 41046 Job B Sprayed Volume unit32 cc 0 999999999 002...

Page 33: ...2 NONE 4 Priming 0034 42016 Pump 3 Material uint32 NONE 0 40 61 0035 42018 Pump 4 Material uint32 NONE 0 40 61 0036 42020 Actual Pump 3 Flow Rate uint32 cc min 0 800 0037 42022 Actual Pump 4 Flow Rate uint32 cc min 0 800 0038 42024 Actual Pump 3Fluid Pressure uint32 PSI 0 1500 0039 42026 Actual Pump 4 Fluid Pressure uint32 PSI 0 1500 0040 42028 Active Recipe Number uint32 NONE 0 30 61 0041 42030 A...

Page 34: ... Interlock Input Status unit32 NONE 1 Closed 0052 43000 Command Return 1 unit32 NONE N A 0053 43002 Command Return 2 unit32 NONE N A 0054 43004 Command Return 3 unit32 NONE N A 0055 43006 Command Return 4 unit32 NONE N A 0056 43008 Command Return 5 unit32 NONE N A 0057 43010 Command Return 6 unit32 NONE N A 0058 43012 Command Return 7 unit32 NONE N A 0059 43014 Command Return 8 unit32 NONE N A 006...

Page 35: ... 4 Mix Fill The Mix Unit fills the mix manifold and gun with material at ratio for a valid recipe 5 Mix The Mix Unit initiates a mix spray cycle 6 Purge A The Mix Unit purges only Material A out through the gun 7 Purge B The Mix Unit purges only Material B out through the gun 8 Standby The Mix Unit puts both active pumps into Standby mode 9 Recipe Purge The Mix Unit automatically determines the pu...

Page 36: ... See Analog Inputs page 24 INPUT INPUT INPUT REGISTER REGISTER REGISTER 04 04 04 and and and 14 14 14 Mix Mix Mix Fill Fill Fill Set Set Set Point Point Point The Mix Fill Set Point register is used to set an alternate control set point during the mix fill process see Mix Fill Set Point on System Screen 2 page 69 If the Mix Unit is configured for Flow Control this value can be set between 5 and 16...

Page 37: ...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...

Page 38: ...f it is set to Discrete this register is ignored and gun trigger is handled via the discrete input See Digital Inputs page 24 NOTE NOTE NOTE Because timing is so critical for flow control Graco recommends that users provide a discrete input to minimize latency effects Input Register 08 Gun Trigger Discrete Signal 1 0 1 0 ProMix PD2K Mix Unit 1 Gun Trigger State Figure 13 Gun 1 Trigger Timing Netwo...

Page 39: ...102 Clear Active Alarm Deviation uint32 NONE 1 Clear Active Alm Dev 0002 41104 Goto Recipe Number uint32 NONE 0 1 30 0003 41106 Mix Control Set Point uint32 cc min PSI 1 1600 0004 41108 Mix Fill Set Point unit32 cc min or PSI 1 1600 0005 41110 Pump Flush Sequence Prime Material unit32 NONE 1 5 1 40 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 ...

Page 40: ...Set Point unit32 cc min or PSI 1 1600 0015 42110 Pump Flush Sequence Prime Material unit32 NONE 1 5 1 40 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 0016 42112 Flush Prime Pump Command unit32 NONE 11 Stop Line Fill Flush 0017 42114 Job Complete unit32 NONE 1 Trigger job complete 0 Gun not ...

Page 41: ...ster Register Parameter Parameter Parameter Name Name Name Data Data Data Type Type Type Units Units Units Range Range Range 0026 43112 Command Argument 7 unit32 NONE N A 0027 43114 Command Argument 8 unit32 NONE N A 0028 43116 Command Argument 9 unit32 NONE N A 0029 43118 Command ID unit32 NONE See Command Table DCS Registers 3A4486D 41 ...

Page 42: ...ps Of f Is solvent flow switch 1 ON Purge time expired System Mode Standby Mix Not Ready Output Register 00 13 System closes color solvent valve at remote stack Purge no flow timeout expired No solvent flow detected Generate alarm 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...

Page 43: ...lly skip Purge B if it is not necessary i e working with one component recipes Is Mix Unit 1 in Standby or Pumps Of f Is solvent flow switch 2 ON Purge no flow timeout expired Purge time expired NO NO No solvent flow detected Generate alarm NO YES YES 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...

Page 44: ...p Status Flushing Output Register 3 Pump is primed using assigned material Pump Status Priming Output Register 4 Pump is either Off or Busy Output Register 0 or 2 Busy refers to a pump that is currently involved in a mixing operation No action taken NOTE Be sure to read to appropriate Output Register for the desired pump status Register 06 Pump 1 Register 07 Pump 2 Is requested pump status Standby...

Page 45: ...5 Write Line Fill Command 9 to Input Register 06 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 Is Current System Mode Standby Output Register 00 1 1 12 13 YES Is corresponding pump primed with selected material NOTE System must be in Standby to flush or fill a hose line since it will run material fro...

Page 46: ... System Command Write 3 to Input Register 00 Is system in Standb y with no alarm conditions Is purge com plete and are p umps primed Is material filled out to mix manifold Fill material out to mix manifold Syst em Mode Recipe Change Fi ll Output Register 00 5 No action taken Either pu mps are currently running or an alarm condition exists Syst em Mode Recipe Change Output Register 00 2 Purge Mater...

Page 47: ...nd Write 1 to Input Register 00 Output Register 00 14 Standby Alarm YES Output Register 00 13 Standby Mix Not Ready YES Output Register 00 11 Standby Mix Ready YES Output Register 00 1 Pump Off NOTE Mix Unit 1 will automatically run t hrough necessary recipe ch ange steps based on it s current state If Goto Reci pe Number has not ch anged it does not have to be rewritten here NOTE System will auto...

Page 48: ...re no existing alarm conditions A recipe is loaded 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 gun trigger signal for longer than Mix Idle timeout System Mode Mix Idle Output Register 00 8 Gun is filled Mix Unit 1 is put into Standby System Mode Standby Mix Ready Output Register 00 1 1 NO System Mode Standby Fi...

Page 49: ...Register 00 1 or 14 and the Event Flag will be set Output Register 01 1 No action taken Clear most recent active alarm or deviation Remaining alarm s or deviation s still active Event Flag set Output Register 01 1 Is there an active alarm or deviation Is there more than 1 active alarm or deviation YES YES NO NOTE If more than 1 active alarm or deviation exists a repeated write of 1 to Input Regist...

Page 50: ...INPUT REGISTERS 20 28 These commands may be written sequentially or sent all at once 2 Once all arguments have been passed write the command ID to INPUT REGISTER 29 3 The ProMix PD2K will respond to a valid command by writing a 2 Acknowledge to OUTPUT REGISTER 61 4 The ProMix PD2K will write appropriate return values to OUTPUT REGISTERS 52 60 INPUT REGISTER 20 ProMix PD2K Inputs PLC Outputs ProMix...

Page 51: ...cters The return registers will echo the arguments received NOTE NOTE NOTE The User ID character string must be terminated with a null character Example Write a User ID of John Doe to Mix Unit 1 of the ProMix PD2K DCS DCS DCS Register Register Register Parameter Parameter Parameter Description Description Description Data Data Data Type Type Type Units Units Units Value Value Value Range Range Ran...

Page 52: ... Type Units Units Units Value Value Value Range Range Range DCS Command Write Recipe uint32 NONE 2 0 16 Argument 0 Mix Unit unint32 NONE 1 1 2 Argument 1 Recipe uint32 NONE 6 0 30 Argument 2 Material A uint32 NONE 2 0 32 Argument 3 Material B uint32 NONE 33 0 33 40 Argument 4 Material A Flush Sequence uint32 NONE 2 1 5 Argument 5 Material B Flush Sequence uint32 NONE 3 1 5 Argument 6 Mix Ratio Set...

Page 53: ...cription Data Data Data Type Type Type Units Units Units Value Value Value Range Range 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 Str...

Page 54: ...t32 NONE 6 0 21 Argument 0 Mix Unit uint32 NONE 1 1 2 0 Not Ready No OP Argument 1 Material Ready Status uint32 NONE 1 1 Material Ready Acknowledge Command Acknowledged uint32 NONE 2 ACK 0 4 Return 0 Mix Unit uint21 NONE 1 1 2 0 Not Ready No OP Return 1 Material Ready Status uint32 NONE 1 1 Material Ready Read Read Read User User User ID ID ID The Read User ID command reads back the current User I...

Page 55: ...5 Return 5 Material B Flush Sequence uint32 NONE 4 1 5 Return 6 Mix Ratio Set Point uint32 NONE 325 0 5000 Return 7 Potlife Time Set Point uint32 min 35 0 999 Return 8 Mix Pressure Tolerance uint32 30 10 90 Read Read Read Flush Flush Flush Sequence Sequence Sequence The Read Flush Sequence command returns all configured parameters for a desired flush sequence The number of the flush sequence to be...

Page 56: ...Screen page 66 for more details on Job Log Example Read back the most recent job log job 25 which ran recipe 2 for a total of 1234 cc s of material under User ID John Doe The job was logged on Thursday May 29 2014 at 11 22 14 AM with Mix Unit 1 DCS DCS DCS Register Register Register Parameter Parameter Parameter Description Description Description Data Data Data Type Type Type Units Units Units Va...

Page 57: ...oding 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 DCS DCS Register Register Register Parameter Parameter Parameter Description Description Description Data Data Data Type Type Type Units Units Units Value Value Value Range Range Range DCS Command Read Alarm Info uint32 NONE 15 0 16 Argume...

Page 58: ...ata Type Type Type Units Units Units Value Value Value Range Range Range DCS Command Read Event Info uint32 NONE 16 0 16 Argument 0 Event Number uint32 NONE 4 0 199 Acknowledge Command Acknowledged uint32 NONE 2 ACK 0 4 Return 0 Event Date uint32 YY MM DD DW 0x0E060302 14 06 03 02 N A Return 1 Event Time uint32 xx HH MM SS 0x080B0B 08 11 11 N A Return 2 Event Code Char 3 0 uint32 NONE 0x30304345 0...

Page 59: ...creens show all PD2K Network Inputs with their associated register ID Modbus TCP address last value written and any relevant state information NOTE NOTE NOTE If a Network Input has not been written it will show a value of 4294967295 0xFFFFFFFF and state as invalid Figure 16 PLC Diagnostic Screen 8 PLC PLC PLC Diagnostic Diagnostic Diagnostic Screens Screens Screens 11 11 11 This screen encapsulate...

Page 60: ...e 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 Pressure Pressure Pressure Control Control Control When the gun trigger signal is removed the system automatically switches to pressure control mode to avoid over pressurizing the flu...

Page 61: ...system The following table details the information shown Only one of the two Mix Units is shown as active on the Home screen regardless of the Mix Unit s status The active Mix Unit s pumps will appear highlighted The other Mix Unit s pumps will be muted with an arrow icon indicating the user must toggle mix units by pressing the Up Down Arrow key To view pump flow rates and pressures as shown sele...

Page 62: ...6 Jobs see Jobs Screen page 67 Errors see Errors Screen page 67 Events see Events Screen page 67 System Status Displays the current mode of operation C Status Bar Pump Off Standby Startup Mix Dispense in 1K Mode Mix Fill Purge Shutdown Change Recipe Idle Prime Pump Calibrate Stall Test Maintenance Test D Error Status Displays any active error code E Pump Animation and Diagnostic Information F Pump...

Page 63: ...ay Device Animation Mix Fill Mix With Gun Triggered Recipe Standby Purge Solvent Standby Mix With Gun Not Triggered U Active Recipe V Current Ratio Not shown in 1K Mode W Potlife Time Remaining X Total Volume for the Current Job Y Current Flow Rate Z Current Pressure Applies specifically to the active Mix Unit on the display To toggle between Mix Units use the Up Down arrows on the Navigation keyp...

Page 64: ...de Target Pressure if Pressure Mode is selected on System Screen 4 or Target Flow if Flow Mode is selected Target pressure or flow can be changed on this screen Actual Pressure Actual Flow Potlife Remaining Gun Animation In addition the Spray screen includes four soft keys Press to put the system in Standby Press to spray mixed material Press to purge the gun Press to switch between Mix Units When...

Page 65: ...pen the screen for editing 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 Trigger the gun into a waste container 5 Repeat for Catalyst B F...

Page 66: ...t shown 1 Press the Edit softkey to open the screen for editing 2 To enter or change the User ID select the field to open the User ID Keyboard screen and enter the desired name 10 characters maximum 3 To log the current job for the appropriate Mix Unit press the corresponding Job Complete softkey or This will clear the current usage fields and increment to the next job number The Grand Totals cann...

Page 67: ...r system errors to assist with troubleshooting To access this information for a system error that has occurred first press to enter edit mode the first error will be highlighted Using the Up and Down arrow keys navigate to the desired error code press again see System Errors page 99 for more information on the troubleshooting information screens Figure 33 Errors Screen Figure 34 Errors Screen Edit...

Page 68: ...ect password clears the field Reenter the correct password To assign a password see Advanced Screen 1 page 92 System System System Screen Screen Screen 1 1 1 System screen 1 includes the following fields which define your system Figure 37 System Screen 1 During Standby Diagnostic Diagnostic Diagnostic Mode Mode Mode Select this box to display flow rate and pressure for each pump on the Home Screen...

Page 69: ...at 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 ho...

Page 70: ...e remote mix manifold to the spray device The minimum diameter is 1 8 in 3 mm Mix Mix Mix At At At Wall Wall Wall Deselect this box only if your system is not using a remote mix manifold Hose Hose Hose Length Length Length and and and Diameter Diameter Diameter Enter the length and diameter of the hose from the remote color stack to the remote mix manifold for both A and B hoses Mix Mix Mix at at ...

Page 71: ... on each recipe screen Max Max Max Set Set Set Point Point Point Set the scaling factor for the 4 20 mA discrete Flow Control Signal see Analog Inputs page 24 Low Low Low Flow Flow Flow Tolerance Tolerance Tolerance 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 fie...

Page 72: ...t push feature is available as an option for certain system configurations See Custom Valve Mapping page 82 The Fluid Fluid Fluid Control Control Control must be set to Flow Flow Flow Mode Mode Mode see System Screen 4 page 71 The resin pump must use the Custom Custom Custom Valve Valve Valve Mapping Mapping Mapping option of Single Single Single Outlet Outlet Outlet Color Color Color Change Chang...

Page 73: ... pushed past the mix manifold and into the mix hose if needed To prevent atomizing solvent it may only be dispensed to a percent of the mix hose volume The default value is 0 which will not dispense solvent beyond the mix manifold The mix hose volume is set by the Gun Hose Length and Gun Hose Diameter see System Screen 3 page 70 If using an electrostatic gun to reduce the risk of fire and explosio...

Page 74: ...dening on the pump rods The Auto Park Pumps timer will automatically park all pumps and turn off pump power The default value of 0 minutes turns off this feature NOTE NOTE NOTE The timer only runs while the system is in Standby and all guns are purged to prevent volumes from going off ratio Mix Mix Mix Balance Balance Balance Interval Interval Interval Not Not Not used used used in in in 1K 1K 1K ...

Page 75: ...nable 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 DHCP 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 ...

Page 76: ...1 Recipes Screen Figure 47 Linked 2 Recipes Screen Recipe Recipe Recipe Enter the desired recipe number 1 30 Recipe Recipe Recipe 0 0 0 Use Recipe 0 to flush the system If If If a a a recipe recipe recipe 1 30 1 30 1 30 is is is loaded loaded loaded Select Recipe 0 to flush the previously active pumps and purge the gun If If If Recipe Recipe Recipe 0 0 0 or or or 61 61 61 is is is loaded loaded lo...

Page 77: ...Time Time Time Enter the potlife time 0 to 999 minutes Entering 0 disables this function Target Target Target Pressure Flow Pressure Flow Pressure Flow Enter the desired target spray pressure or flow rate depending on whether the Mix Unit is configured for Pressure Control or Flow Control see Fluid Control on System Screen 4 This is the pressure or flow rate the pumps will maintain while mixing Th...

Page 78: ...ssure 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 Dual Dual Dual Solvent Solvent ...

Page 79: ...ge 82 for more information NOTE NOTE NOTE Air solvent chop requires additional hardware for the air purge valve See manual 333282 for kit numbers and installation details Initial Initial Initial Flush Flush Flush Enter the initial flush volume 0 to 9999 cc Wash Wash Wash Cycles Cycles Cycles A Wash Cycle activates the pump with the valves closed to use pumping motion to thoroughly clean the pump E...

Page 80: ...h of time for the first purge phase which dispenses only the material selected Air Air Air Chop Chop Chop Set the air chop duty cycle for the chop phase Solvent Solvent Solvent Chop Chop Chop Set the solvent chop duty cycle for the chop phase Total Total Total Chop Chop Chop Set the length of time for the chop phase The system will switch between air and solvent pulses according to the duty cycles...

Page 81: ...ols 8 colors Hose Hose Hose Length Length 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 Hose Hose Diameter Diameter Diameter Enter the diameter of the supply and output hoses Available Available Available Colors Colors Colors The module displays the number of colors available in your system This field is n...

Page 82: ...E NOTE NOTE For systems that select Single it is expected the user knows when a particular material is plumbed and filled to the inlet stack before performing a color change The PD2K system does not know what material is connected up stream of the inlet valve stack Pump Pump Pump Air Air Air Purge Purge Purge Select Enable to add an air purge valve to the pump inlet stack to allow for an air solve...

Page 83: ...h dispense color but one is solvent based and one is water based Pump 2 dispenses a catalyst With the auxiliary valves in place for both pumps only one will flow through the A side of the remote mix manifold and the other is completely isolated by the auxiliary valve Figure 56 Example Application of the Auxiliary Valve Clear Clear Clear Valve Valve Valve Map Map Map Check this box to clear all val...

Page 84: ...Some remote stack valves may be shared by more than one pump They will show up on the valve list for all pumps to which they apply All color change valves require a valid location be assigned for the system to be able to operate properly There are two columns that determine the solenoid location The left column is the color change module number This number must be between 1 and 8 and should reflec...

Page 85: ...pump will run at a steady speed for the set number of strokes full length travel in one direction while alternating between air and solvent for the desired duty cycles One pump stroke takes approximately 2 seconds during this phase NOTE NOTE NOTE Air solvent chop requires additional hardware for the air purge valve See manual 333282 for kit numbers and installation details Figure 61 Flush Screen w...

Page 86: ...ault Settings box is not selected the following calibration values must be entered Invalid values will be over ridden and the system will automatically select the default settings Inlet Offset Factor This field is only used if Inlet Inlet Inlet Pressure Pressure Pressure in Pump Screen 1 page 81 is set to Monitor it is grayed out if set to Disabled The valid range is 01 20 to 01 20 mV V Inlet Sens...

Page 87: ...p Screen 3 Pressure Monitoring Enabled Pressure Pressure Pressure Alarm Alarm Alarm and and and Deviation Deviation Deviation Limits Limits Limits Inlet fields are only active if Inlet Inlet Inlet Pressure Pressure Pressure in Pump Screen 1 page 81 is set to Monitor they are grayed out if set to Disabled Outlet fields are active at all times Alarm and Deviation ranges are 0 300 psi for low pressur...

Page 88: ... 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 NOTE NOTE 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 67 Calibrate Screen 1 Figure 68 Stall Test Screen Calibrate Cali...

Page 89: ... initiate the calibration press the Volume Check button The screen displays the volume dispensed Enter the amount of solvent dispensed in the Measured Volume field or press to end the test After the Measured Volume is entered the Accept Calibration window will appear Press to accept the calibration Press to cancel the calibration and retain the previous K factor Press and hold the Reset button for...

Page 90: ...he solvent meter fluid filter and air filter Press and hold the Reset button for 1 2 seconds to clear the alarm and reset the counter Figure 75 Maintenance Screen 2 Current Status Solvent Solvent Solvent Meter Meter Meter If two solvent meters are used enter the desired solvent meter number Maintenance Maintenance Maintenance Screen Screen Screen 3 3 3 Maintenance screen 3 shows the current interv...

Page 91: ...Relief Select the Autodump checkbox to enable the automated pressure relief functionality The automatic pressure relief will perform the same function as the manual pressure relief but will trigger on its own once the pump s outlet pressure rises above the set Pressure Limit The system will only perform a pressure dump when the pump is in Standby or Off NOTE It is recommended to set the Pressure L...

Page 92: ...its for the month day and year Time Time Time Enter current time in hours 24 hour clock and minutes Seconds are not adjustable Password Password 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 NOTE NOTE Be sure to write down the password and keep it in a secu...

Page 93: ... Screen 3 Enable Enable Enable USB USB USB Downloads Uploads Downloads Uploads Downloads Uploads Select this box to enable USB downloads and uploads Enabling USB activates the Download Depth field Download Download Download Depth Depth 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 Log Log 90 90 90 Full Full Full Ad...

Page 94: ...ns Advanced Advanced Advanced Screen Screen Screen 4 4 4 Advanced screen 4 displays the software part numbers and versions for the system components This is not an editable screen Figure 83 Advanced Screen 4 94 3A4486D ...

Page 95: ... 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 Diagnostic Diagnostic Screens Screens Screens 3 10 3 10 3 10 Figure 86 Diagnostic Screen 1 Diagnostic screens...

Page 96: ... test for that particular pump direction NOTE NOTE NOTE Do not trigger the spray device during 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 3 Scroll to Calibrate to display Calibrate Screen 1 page 88 4 Press the Pressure Check...

Page 97: ...bration Calibration 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 4 Scroll to Calibrate Screen 3 page 89 5 Press the soft key to initiate the calibration NOTE NOTE NOTE For maximum accuracy use a gravimetric mass method ...

Page 98: ...rge 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 76 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 comp...

Page 99: ...een which displays the 200 most recent events with date time and description NOTE NOTE NOTE Most system errors apply only to a specific Mix Unit and therefore only show up on the appropriate menu bar and Event Flag PLC register when that Mix Unit is active All alarms will generate a pop up on the ADM regardless of the active Mix Unit On On On Screen Screen Screen Help Help Help When a system alarm...

Page 100: ... device see INPUT REGISTER 01 and 11 Clear Active Alarm Deviation page 35 Gun Gun Gun Trigger Trigger Trigger Input Input Input Function Function Function 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 do...

Page 101: ...on Description Description Problem Problem Problem Cause Cause Cause Solution Solution Solution Solvent flow switch is stuck in flow position Clean or replace switch F7S1 F7S2 Alarm Flow Detected Solvent Gun The solvent flow switch is indicating unexpected solvent flow for Mix Unit 1 or Mix Unit 2 There is a leak through the solvent cutoff valve Check for leaks and repair valve One or both solvent...

Page 102: ... the pump or line Make sure the pump and down stream color line are loaded with material DE0 Alarm Leak Detected Pump This is a manual stall test failure when the pump cannot build pressure to the target Stall Test Pressure Will fault after 30 seconds 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 fitting...

Page 103: ...pecified amount of time Pump stroke length is shortened by mechanical system tolerance Verify correct assembly of linear actuator and pump piston rods See pump manual Pump dose valves did not actuate Visually inspect valves to ensure they are operating properly verify they have air pressure above 85 psi 0 6 MPa 6 0 bar EF1 Alarm Timeout Shutdown Pump Pump tried but was not able to move to the park...

Page 104: ...een no flow or low flow during a pump purge operation Restriction in the outlet side of the pump or color stack resulting in the solvent flow being too low Make sure there are no restrictions in the system Increase non mix pressure if necessary to create flow during the purge function F7D Alarm Flow Detected Pump The pump flow exceeded 20 cc min flow coming into Idle mode There is a leak in the sy...

Page 105: ...ser 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 great...

Page 106: ...Problem Problem Cause Cause Cause Solution Solution Solution EB00 Rec ord Stop Button Pressed Record of a stop button press Indicates system stop key on ADM was pressed n a EBC Rec ord PLC Power Command for Mix Unit Record of pumps powered off by PLC command The PLC command was used to shut down pump power No action required EBI Rec ord Power Button Pressed Mix Unit Record of pumps powered off by ...

Page 107: ...nterconnected 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 The Mo...

Page 108: ...B 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...

Page 109: ...started over at zero n a B9D Advisory Volume Rollover Pump Grand total counter for pump rolled over The totalizer has reached maximum capable value and started over at zero n a B9S1 B9S2 Advisory Volume Rollover Solvent Current Mix Unit Batch counter for solvent rolled over for Mix Unit 1 1 or Mix Unit 2 2 The totalizer has reached maximum capable value and started over at zero n a B9S3 B9S4 Advis...

Page 110: ...sory Maint Valve Outlet Maintenance is due on outlet valve MEF Advisory Maint Valve Inlet Maintenance is due on inlet valve MEG Advisory Maint Valve Gun Maintenance is due on gun valve MEN Advisory Maint Valve Auxiliary Maintenance is due on auxiliary valve MES Advisory Maint Valve Solvent Maintenance is due on solvent valve MFF Advisory Maint Meter Flow Maintenance is due on flow meter MFS Adviso...

Page 111: ...n determine a regular schedule for checking your system Flushing Flushing Flushing 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 wette...

Page 112: ...ontroller 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 Select Select Module Module Module Type Type Type screen opens a In the search field type generic b Select ETHERNET MODULE Generic Ethernet Module NO...

Page 113: ...erNet IP CGM installed in the ProMix PD2K d Input Assembly Instance required Enter 100 which is a device specific parameter for the Graco EtherNet IP CGM e Input Size required Enter 62 which is the number of 32 bit registers that are allocated for input variables in the Graco EtheNet IP CGM f Output Assembly Instance required Enter 150 which is the device specific parameter for the Graco EtherNet ...

Page 114: ...ction 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 Output Output Assembly Assembly Assembly Instance Instance 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...

Page 115: ...and dry air Mixing ratio range 0 1 1 50 1 1 Fluids handled 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 1 4 npt m External power supply requi...

Page 116: ... WARRANTY WARRANTY WARRANTY AND AND AND DISCLAIMS DISCLAIMS DISCLAIMS ALL ALL ALL IMPLIED IMPLIED IMPLIED WARRANTIES WARRANTIES WARRANTIES OF OF OF MERCHANTABILITY MERCHANTABILITY MERCHANTABILITY AND AND AND FITNESS FITNESS FITNESS FOR FOR FOR A A A PARTICULAR PARTICULAR PARTICULAR PURPOSE PURPOSE PURPOSE IN IN IN CONNECTION CONNECTION CONNECTION WITH WITH WITH ACCESSORIES ACCESSORIES ACCESSORIES ...

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Graco ProMix PD2K, Operation

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