Graco 332564B - User Manual

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 warni...

Important Isocyanate (ISO) Information Important Isocyanate (ISO) Information Isocyanates (ISO) are catalysts used in two component materials. Isocyanate Conditions Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates.Read and u...

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. • To protect the screens from paints and solvents, clea...

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...

Advanced Display Module (ADM) USB Upload Procedure Use this procedure to install a system configuration file and/or a custom language file.1. If necessary, follow the USB Download Procedure, to automatically generate the proper folder structure on the USB flash drive. 2. Insert the USB flash drive into t...

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 Startup/Shutdown Key and Indicator Press to startup or shutdow...

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 finger...

Pre-Operation Tasks Pre-Operation Tasks Pre-operation Checklist Go through the Pre-Operation Checklist daily, before each use. ✔ ChecklistSystem groundedVerify all grounding connections were made. See Grounding in the Installation manual.All connections tight and correctVerify all electrical, fluid, ...

Pre-Operation Tasks Initial System Setup 1. Change optional setup selections to desired parameters, as described in Setup Mode Screens, page 66 . 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 w...

Pressure Relief Procedure Pressure Relief Procedure Follow the Pressure Relief Procedure whenever you see this symbol. This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, ...

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 pr...

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 volum...

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 There are times when you only want to purge the remote mix manifold and the spray device, such as:• end of potlife• breaks in spraying that exceed the ...

Operation Using Automatic Display Module (ADM) Flush the System To avoid fire and explosion, always ground equipment and waste container. To avoid injury from splashing, always flush at lowest possible pressure. Follow this procedure before:• the first time material is loaded into the equipment• servic...

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 ...

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 operatin...

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.NOTE: The fol...

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, measure...

Operation Using a Programmable Logic Controller (PLC) Notes 32 332564B

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 remo...

Operation Using a Programmable Logic Controller (PLC) Operation Flow Charts Purge Mode Sequence YES YES YES YES NO NO NO NO Purge A System Command Write ‘6’ to Input Register 00 Is system in Standby or Pumps Off? Is solvent flow switch 1 ON? Purge time expired? System Mode = Standby: Mix Not Ready (...

Operation Using a Programmable Logic Controller (PLC) Inactive Pump Flush and Prime Sequences YES YES YES YES YES NO NO NO NO NO Write Flush Sequence # (1-5) to Output Register 01 Write Flush Pump Command (1,3,5,7) to Input Register 02 Write Prime Pump Command (2,4,6,8) to Input Register 02 Is reque...

Operation Using a Programmable Logic Controller (PLC) Color Change Sequence YES YES YES NO NO NO NO YES NO YES YES Write Goto Recipe Number (0,1 - 60) to Input Register 07 Recipe Change System Command Write ‘3’ to Input Register 00 Is system in Standby with no alarm conditions? Is purge complete and...

Operation Using a Programmable Logic Controller (PLC) Mixing Sequence YES YES NO NO YES NO NO YES Mix System Command Write ‘5’ to Input Register 00 System Mode = Standby: Fill Ready ? A recipe is loaded in the pumps but not yet filled out to the gun. Mixed material is pumped out to the gun. No actio...

Operation Using a Programmable Logic Controller (PLC) Alarm Clearing Sequence NO Clear Active Alarm Write ‘1’ to Input Register 08 NOTE: If an alarm condition is active the System Mode will eitherbe Pump Off or Standby: Alarm . (Output Register 00 = ‘1’ or ‘14’) No action taken. 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 ...

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 ...

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 ...

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. Exam...

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 a...

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 =...

Operation Using a Programmable Logic Controller (PLC) Read Fluid Control Mode The Read Fluid Control Mode command is used to read the current Fluid Control mode of the system is currently operating under. No arguments are required. Example: Read Fluid Control as currently set to Pressure mode. DCS R...

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 200 th most recent. The date is ret...

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 200 th most recent...

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 200 th most recen...

Operation Using a Programmable Logic Controller (PLC) Flow Control System Overview 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 contr...

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 disp...

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 overri...

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 t...

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 availa...

Run Mode Screens Jobs 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. Figure 24 Jobs Screen Errors Screen The Errors screen displays the 200 most recent Error Codes in a log, with date, time, and description. Figure 25...

Setup Mode Screens Setup Mode Screens Press on any Run screen to enter the Setup screens.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 . Password Screen Figur...

Setup Mode Screens System Screen 1 System screen 1 includes the following fields which define your system. Figure 28 System Screen 1, During Standby 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 ...

Setup Mode Screens System Screen 2 System screen 2 sets the following system operating parameters. Figure 29 System Screen 2, in Standby Mode Mix Pressure Tolerance The pressure of one component must be within a percentage (±) of the pressure of the other component during spray or mix. Set the desir...

Setup Mode Screens System Screen 3 System screen 3 sets the following system operating parameters. Figure 30 System Screen 3 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...

Setup Mode Screens System Screen 4 System screen 4 sets the following system operating parameters. Figure 31 System Screen 4 Gateway ID Select the desired Gateway ID from the dropdown menu. Enable Uncheck Enable while setting the IP Address, Subnet mask, Gateway, DNS1 or DNS2. When the settings are ...

Setup Mode Screens System Screen 5 System screen 5 sets the following system operating parameters. Figure 32 System Screen 5 Fluid Control Select the desired operating mode (pressure or flow), using the pull-down menu.• In Pressure Mode, the motor will adjust the pump speed to maintain the fluid press...

Setup Mode Screens Recipe Screen Figure 33 Valid Recipe Screen Recipe Enter the desired recipe number (1-60). Recipe 0 Use Recipe 0 to flush the system.• If a recipe (1–60) is loaded: Select Recipe 0 to flush the previously active pumps and purge the gun. • If Recipe 0 or 61 is loaded: Select Recipe 0...

Setup Mode Screens Flush Screen 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. Gun Purge Time Enter the spray device purge time (0 t...

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 th...

Setup Mode Screens Pump Screen 2 Pump screen 2 sets the pressure transducer settings for the pump. Figure 37 Pump Screen 2, Default Settings Enabled Figure 38 Pump Screen 2, Default Settings Disabled Default Settings Selected When the “Use Default Settings” box is selected, default settings are used...

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 . Figure 39 P...

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 ...

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 instru...

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...

Setup Mode Screens Maintenance Screens Maintenance Screen 1 Use this screen to set maintenance intervals. Set to 0 to disable the alarm.NOTE: The Pump Stall Test cannot be disabled. You must enter a value other than 0. Figure 48 Maintenance Screen 1, Interval Settings Maintenance Screen 2 Maintenanc...

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 for 1-2 seconds to reset the counter.If the system is in Standby, valves can be opened or closed by selecting or deselecting the box fo...

Setup Mode Screens Advanced Screen 1 Advanced screen 1 sets the following display parameters. Figure 53 Advanced Screen 1 Language Defines the language of the screen text. Select:• English (default)• Spanish• French• German• Japanese• Chinese• Korean• Dutch• Italian• Portuguese • Swedish• Russian Dat...

Setup Mode Screens Advanced Screen 2 Advanced screen 2 sets display units (US or metric). Figure 54 Advanced Screen 2 Display Units Select the desired display units:• Grand Total Volume (US gallon or liter)• Pressure (psi, bar, or MPa)• Length (ft or m) Advanced Screen 3 Advanced screen 3 enables US...

Calibration Checks Calibration Checks Pump Pressure Check NOTE: Enter the transducer calibration data before doing the pressure check. Perform the pressure check:• The first time the system is operated.• Whenever new materials are used in the system, especially if the materials have viscosities that ...

Calibration Checks Pump Volume Check 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 Calib...

Calibration Checks Solvent Meter 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 Calibra...

Color Change Color Change 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...

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 ...

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 Air flow s...

Maintenance Maintenance Preventive Maintenance Schedule 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 chec...

Technical Data Technical Data Positive Displacement Proportioner U.S. Metric Maximum fluid working pressure: AC1000 Air Spray Systems 300 psi 2.1 MPa, 21 bar AC2000 Air-Assisted Spray Systems 1500 psi 10.5 MPa, 105 bar Maximum working air pressure: 100 psi 0.7 MPa, 7.0 bar Air supply: 85–100 psi 0.6–...

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 warr...