Graco ProMix PD2K Instruction Manual

Operation
ProMix® ProMix®
ProMix®PD2K PD2K PD2KDual Dual DualFluid Fluid FluidPanel Panel Panel
Electric Electric
ElectricProportioner Proportioner Proportionerfor for forAutomatic Automatic Automatic
Spray Spray
SprayApplications Applications Applications3A4486D
EN
Electronic Electronic
Electronicpositive positive positivedisplacement displacement displacementproportioner proportioner proportionerfor for fortwo two two- - -component component componentmaterials. materials. materials.Automatic Automatic Automaticsystem system systemwith with with
Advanced Advanced
AdvancedDisplay Display DisplayModule. Module. Module.For For Forprofessional professional professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
ReadallwarningsandinstructionsinthismanualandinyourPD2K
installation,repair,andassociatedcomponentmanuals.Savethese
instructions.
Seepage4formodelpartnumbersand
approvalsinformation.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
RelatedManuals..................................................3
Models.................................................................4
Warnings.............................................................6
ImportantIsocyanate(ISO)Information..................9
ImportantAcidCatalystInformation.....................10
GeneralInformation............................................11
AdvancedDisplayModule(ADM)........................12
ADMDisplay................................................12
USBDownloadProcedure............................12
USBUploadProcedure................................13
ADMKeysandIndicators.............................14
SoftKeyIcons.............................................15
NavigatingtheScreens................................16
ScreenIcons...............................................16
Pre-OperationTasks...........................................17
Pre-operationChecklist................................17
PowerOn....................................................17
InitialSystemSetup.....................................18
FlushBeforeUsingEquipment......................18
ValveSettings..............................................18
PressureReliefProcedure..................................19
WithoutColorChange..................................19
WithColorChange.......................................19
OperationUsingAdvancedDisplayModule
(ADM)...................................................20
PrimeandFilltheSystem.............................20
Pre-FillthePump.........................................20
Spraying......................................................20
Purging.......................................................21
Shutdown....................................................22
OperationUsingaProgrammableLogic
Controller(PLC)....................................23
NetworkCommunicationsandDiscrete
I/O.................................................23
DiscreteI/O.................................................23
CommunicationGatewayModule(CGM)
Details...........................................26
NetworkCommunicationI/ODataMap...........27
OperationFlowCharts.................................42
NetworkCommunication-Dynamic
CommandStructure(DCS).............50
PLCDiagnosticScreens...............................59
FlowControlSystem....................................60
RunModeScreens.............................................61
OpeningScreen...........................................61
HomeScreen..............................................61
SprayScreen...............................................64
FillScreen...................................................65
UsageScreen..............................................66
JobsScreen................................................67
ErrorsScreen..............................................67
EventsScreen.............................................67
SetupModeScreens..........................................68
PasswordScreen.........................................68
SystemScreen1.........................................68
SystemScreen2.........................................69
SystemScreen3.........................................70
SystemScreen4.........................................71
SolventPush...............................................72
SystemScreen5.........................................74
GatewayScreen..........................................75
RecipeScreen.............................................76
FlushScreen...............................................79
Air/SolventChop..........................................80
PumpScreen1............................................81
CustomValveMapping................................82
PumpScreen2............................................86
PumpScreen3............................................87
CalibrationScreens......................................88
MaintenanceScreens...................................90
AdvancedScreen1......................................92
AdvancedScreen2......................................93
AdvancedScreen3......................................93
AdvancedScreen4......................................94
DiagnosticScreens......................................95
CalibrationChecks..............................................96
PumpPressureCheck.................................96
PumpVolumeCheck....................................97
SolventMeterCalibration.............................97
ColorChange.....................................................98
MultipleColorSystems.................................98
SystemErrors....................................................99
On-ScreenHelp...........................................99
ToClearErrorandRestart..........................100
GunTriggerInputFunction.........................100
ErrorCodes...............................................101
Maintenance....................................................111
PreventiveMaintenanceSchedule..............111
Flushing....................................................111
CleaningtheADM......................................111
AppendixA:IntegrationwithAllenBradley
PLC....................................................112
TechnicalData.................................................115
23A4486D

RelatedManuals
Related Related
RelatedManuals Manuals Manuals
Currentmanualsareavailableatwww.graco.com.
Manual Manual
ManualNo. No. No.Description Description Description
332709ProMixPD2KProportionerfor
AutomaticSprayApplications,
Repair—Parts
332458ProMixPD2KProportionerfor
AutomaticSprayApplications,
Installation
332339DosingPumps,Instructions—
Parts
332454Color/CatalystDispenseValves,
Instructions—Parts
Manual Manual
ManualNo. No. No.Description Description Description
333282ColorChangeandRemoteMix
ManifoldKits,Instructions—Parts
332456PumpExpansionKits,Instructions
—Parts
334183ModbusTCPGatewayModule,
Instructions—Parts
334494ProMixPD2KCGMInstallation
Kits,Instructions—Parts
3A4486D3

Models
Models Models
Models
SeeFigs.1–6forcomponentidenti󰘰cationlabels,includingapprovalinformationandcerti󰘰cation.
Part Part
PartNo. No. No.Series Series
SeriesMaximum Maximum
MaximumAir Air AirWorking Working Working
Pressure Pressure
Pressure
Maximum Maximum
MaximumFluid Fluid FluidWorking Working Working
Pressure Pressure
Pressure
Location Location
Locationof of ofPD2K PD2K PD2Kand and and
Electrical Electrical
ElectricalControl Control ControlBox Box Box
(ECB) (ECB)
(ECB)Labels Labels Labels
AC1002
AC3002
Acid-based
Material
A100psi(0.7MPa,7.0bar)300psi(2.068MPa,
20.68bar)
AC2002
AC4002
Acid-based
Material
A100psi(0.7MPa,7.0bar)1500psi(10.34MPa,
103.4bar)
2575 2575
2575
II2G
Figure1ModelAC1002&AC3002(LowPressure)
Identi󰘰cationLabel
Figure226A188ControlBoxIdenti󰘰cationLabel Continuedonthenextpage.
43A4486D

Models
Figure3ModelAC2002&AC4002(HighPressure)
Identi󰘰cationLabel
Figure4Non-IntrinsicallySafeColorChangeControl(Accessory)Identi󰘰cationLabel
Figure5IntrinsicallySafeColorChangeControl
(Accessory)Identi󰘰cationLabel
Figure6PumpExpansionKit(Accessory)Identi󰘰cationLabel
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
Figure7CGMIdenti󰘰cationLabel
3A4486D5

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.Theexclamation
pointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰crisks.Whenthese
symbolsappearinthebodyofthismanual,referbacktotheseWarnings.Product-speci󰘰chazardsymbolsand
warningsnotcoveredinthissectionmayappearthroughoutthebodyofthismanualwhereapplicable.
WARNING WARNING
WARNINGFIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanigniteorexplode.Paintor
solvent󰘱owingthroughtheequipmentcancausestaticsparking.Tohelpprevent󰘰reandexplosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,andplastic
dropcloths(potentialstaticsparking).
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Neversprayor󰘱ushsolventathighpressure.
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Useonlygroundedhoses.
•Holdgun󰘰rmlytosideofgroundedpailwhentriggeringintopail.Donotusepaillinersunlessthey
areanti-staticorconductive.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock.Donotuseequipmentuntil
youidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
ELECTRIC ELECTRIC
ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Thisequipmentmustbegrounded.Impropergrounding,setup,orusageofthesystemcancause
electricshock.
•Turnoffanddisconnectpoweratmainswitchbeforedisconnectinganycablesandbeforeservicing
orinstallingequipment.
•Connectonlytogroundedpowersource.
•Allelectricalwiringmustbedonebyaquali󰘰edelectricianandcomplywithalllocalcodesand
regulations.
63A4486D

Warnings
WARNING WARNING
WARNINGINTRINSIC INTRINSIC
INTRINSICSAFETY SAFETY SAFETY
Intrinsicallysafeequipmentthatisinstalledimproperlyorconnectedtonon-intrinsicallysafe
equipmentwillcreateahazardousconditionandcancause󰘰re,explosion,orelectricshock.Follow
localregulationsandthefollowingsafetyrequirements.
•Besureyourinstallationcomplieswithnational,state,andlocalcodesfortheinstallationof
electricalapparatusinaClassI,GroupD,Division1(NorthAmerica)orClassI,Zones1and2
(Europe)HazardousLocation,includingallofthelocalsafety󰘰recodes(forexample,NFPA33,
NEC500and516,OSHA1910.107,etc.).
•Tohelpprevent󰘰reandexplosion:
•Donotinstallequipmentapprovedonlyforanon-hazardouslocationinahazardouslocation.
SeemodelIDlabelfortheintrinsicsafetyratingofyourmodel.
•Donotsubstitutesystemcomponentsasthismayimpairintrinsicsafety.
•EquipmentthatcomesincontactwiththeintrinsicallysafeterminalsmustberatedforIntrinsic
Safety.ThisincludesDCvoltagemeters,ohmmeters,cables,andconnections.Removetheunit
fromthehazardousareawhentroubleshooting.
SKIN SKIN
SKININJECTION INJECTION INJECTIONHAZARD HAZARD HAZARD
High-pressure󰘱uidfromdispensingdevice,hoseleaks,orrupturedcomponentswillpierceskin.
Thismaylooklikejustacut,butitisaseriousinjurythatcanresultinamputation.Get Get
Getimmediate immediate immediate
surgical surgical
surgicaltreatment. treatment. treatment.
•Donotpointdispensingdeviceatanyoneoratanypartofthebody.
•Donotputyourhandoverthe󰘱uidoutlet.
•Donotstoporde󰘱ectleakswithyourhand,body,glove,orrag.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopdispensingandbeforecleaning,checking,or
servicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.
MOVING MOVING
MOVINGPARTS PARTS PARTSHAZARD HAZARD HAZARD
Movingpartscanpinch,cutoramputate󰘰ngersandotherbodyparts.
•Keepclearofmovingparts.
•Donotoperateequipmentwithprotectiveguardsorcoversremoved.
•Pressurizedequipmentcanstartwithoutwarning.Beforechecking,moving,orservicingequipment,
followthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedureanddisconnectallpowersources.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMES
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,inhaled,or
swallowed.
•ReadMSDSstoknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicableguidelines.
•Alwayswearchemicallyimpermeablegloveswhenspraying,dispensing,orcleaningequipment.
3A4486D7

Warnings
WARNING WARNING
WARNINGPERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Alwayswearappropriatepersonalprotectiveequipmentandcoverallskinwhenspraying,servicing
equipment,orwhenintheworkarea.Protectiveequipmenthelpspreventseriousinjury,including
long-termexposure;inhalationoftoxicfumes,mistsorvapors;allergicreaction;burns;eyeinjuryand
hearingloss.Thisprotectiveequipmentincludesbutisnotlimitedto:
•Aproperly󰘰ttingrespirator,whichmayincludeasupplied-airrespirator,chemicallyimpermeable
gloves,protectiveclothingandfootcoveringsasrecommendedbythe󰘱uidmanufacturerandlocal
regulatoryauthority.
•Protectiveeyewearandhearingprotection.
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestratedsystem
component.SeeTechnical Technical
TechnicalData Data Datainallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
TechnicalData Data Datainall
equipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcompleteinformation
aboutyourmaterial,requestMSDSfromdistributororretailer.
•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovalsand
createsafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
83A4486D

ImportantIsocyanate(ISO)Information
Important Important
ImportantIsocyanate Isocyanate Isocyanate(ISO) (ISO) (ISO)Information Information Information
Isocyanates(ISO)arecatalystsusedintwo
componentmaterials.
Isocyanate Isocyanate
IsocyanateConditions Conditions Conditions
Sprayingordispensing󰘱uidsthatcontain
isocyanatescreatespotentiallyharmfulmists,
vapors,andatomizedparticulates
•Readandunderstandthe󰘱uidmanufacturer’s
warningsandSafetyDataSheet(SDS)toknow
speci󰘰chazardsandprecautionsrelatedto
isocyanates.
•Useofisocyanatesinvolvespotentially
hazardousprocedures.Donotspraywiththe
equipmentunlessyouaretrained,quali󰘰ed,
andhavereadandunderstoodtheinformation
inthismanualsandinthe󰘱uidmanufacturer’s
applicationinstructionsandSDS.
•Useofincorrectlymaintainedormis-adjusted
equipmentmayresultinimproperlycured
material.Equipmentmustbecarefully
maintainedandadjustedaccordingto
instructionsinthemanual.
•Topreventinhalationofisocynatemists,vapors,
andatomizedparticulates,everyoneinthe
workareamustwearappropriaterespiratory
protection.Alwayswearaproperly󰘰tting
respirator,whichmayincludeasupplied-air
respirator.Ventilatetheworkareaaccordingto
instructionsinthe󰘱uidmanufacturer’sSDS.
•Avoidallskincontactwithiscocyanates.
Everyoneintheworkareamustwearchemically
impermeablegloves,protectiveclothingand
footcoveringsasrecommendedbythe󰘱uid
manufacturerandlocalregulatoryauthority.
Followall󰘱uidmanufacturerrecommendations,
includingthoseregardinghandlingof
contaminatedclothing.Afterspraying,wash
handsandfacebeforeeatingordrinking.
Keep Keep
KeepComponents Components ComponentsA A Aand and andB B BSeparate Separate Separate
Cross-contaminationcanresultincured
materialin󰘱uidlineswhichcouldcauseserious
injuryordamageequipment.Toprevent
cross-contamination:
•Never Never
NeverinterchangecomponentAandcomponent
Bwettedparts.
•Neverusesolventononesideifithasbeen
contaminatedfromtheotherside.
Moisture Moisture
MoistureSensitivity Sensitivity Sensitivityof of ofIsocyanates Isocyanates Isocyanates
Exposuretomoisture(suchashumidity)willcause
ISOtopartiallycure;formingsmall,hard,abrasive
crystals,whichbecomesuspendedinthe󰘱uid.
Eventuallya󰘰lmwillformonthesurfaceandtheISO
willbegintogel,increasinginviscosity.
NOTICE NOTICE
NOTICE
PartiallycuredISOwillreduceperformanceand
thelifeofallwettedparts.
•Alwaysuseasealedcontainerwithadesiccant
dryerinthevent,oranitrogenatmosphere.
Never Never
NeverstoreISOinanopencontainer.
•KeeptheISOpumpwetcuporreservoir(if
installed)󰘰lledwithappropriatelubricant.The
lubricantcreatesabarrierbetweentheISOand
theatmosphere.
•Useonlymoisture-proofhosescompatiblewith
ISO.
•Neverusereclaimedsolvents,whichmay
containmoisture.Alwayskeepsolvent
containersclosedwhennotinuse.
•Alwayslubricatethreadedpartswithan
appropriatelubricantwhenreassembling.
NOTE: NOTE:
NOTE:Theamountof󰘰lmformationandrateof
crystallizationvariesdependingontheblendofISO,
thehumidity,andthetemperature.
Changing Changing
ChangingMaterials Materials Materials
NOTICE NOTICE
NOTICE
Changingthematerialtypesusedinyour
equipmentrequiresspecialattentiontoavoid
equipmentdamageanddowntime.
•Whenchangingmaterials,󰘱ushtheequipment
multipletimestoensureitisthoroughlyclean.
•Alwayscleanthe󰘱uidinletstrainersafter
󰘱ushing.
•Checkwithyourmaterialmanufacturerfor
chemicalcompatibility.
•Whenchangingbetweenepoxiesandurethanes
orpolyureas,disassembleandcleanall󰘱uid
componentsandchangehoses.Epoxiesoften
haveaminesontheB(hardener)side.Polyureas
oftenhaveaminesontheA(resin)side.
3A4486D9

ImportantAcidCatalystInformation
Important Important
ImportantAcid Acid AcidCatalyst Catalyst CatalystInformation Information Information
ThePD2KAC4002Proportionerisdesignedforacidcatalysts(“acid”)currentlyusedintwo-component,
wood-󰘰nishingmaterials.Currentacidsinuse(withpHlevelsaslowas1)aremorecorrosivethanearlieracids.
Morecorrosion-resistantwettedmaterialsofconstructionarerequired,andmustbeusedwithoutsubstitution,to
withstandtheincreasedcorrosivepropertiesoftheseacids.
Acid Acid
AcidCatalyst Catalyst CatalystConditions Conditions Conditions
Acidis󰘱ammable,andsprayingordispensingacidcreatespotentiallyharmfulmists,vapors,andatomized
particulates.Tohelpprevent󰘰reandexplosionandseriousinjury:
•Readandunderstandtheacidmanufacturer’swarningsandSafetyDataSheet(SDS)toknowspeci󰘰chazards
andprecautionsrelatedtotheacid.
•Useonlygenuine,manufacturer’srecommendedacid-compatiblepartsinthecatalystsystem(hoses,󰘰ttings,
etc).Areactionmayoccurbetweenanysubstitutedpartsandtheacid.
•Topreventinhalationofacidmists,vapors,andatomizedparticulates,everyoneintheworkareamustwear
appropriaterespiratoryprotection.Alwayswearaproperly󰘰ttingrespirator,whichmayincludeasupplied-air
respirator.Ventilatetheworkareaaccordingtoinstructionsintheacidmanufacturer’sSDS.
•Avoidallskincontactwithacid.Everyoneintheworkareamustwearchemicallyimpermeablegloves,protective
clothing,footcoverings,aprons,andfaceshieldsasrecommendedbytheacidmanufacturerandlocalregulatory
authority.Followallacidmanufacturerrecommendations,includingthoseregardinghandlingofcontaminated
clothing.Washhandsandfacebeforeeatingordrinking.
•Regularlyinspectequipmentforpotentialleaksandremovespillspromptlyandcompletelytoavoiddirectcontact
orinhalationoftheacidanditsvapors.
•Keepacidawayfromheat,sparks,andopen󰘱ames.Donotsmokeintheworkarea.Eliminateallignition
sources.
•Storeacidintheoriginalcontainerinacool,dry,andwell-ventilatedareaawayfromdirectsunlightand
awayfromotherchemicalsinaccordancewithacidmanufacturer’srecommendations.Toavoidcorrosionof
containers,donotstoreacidinsubstitutecontainers.Resealtheoriginalcontainertopreventvaporsfrom
contaminatingthestoragespaceandsurroundingfacility.
Moisture Moisture
MoistureSensitivity Sensitivity Sensitivityof of ofAcid Acid AcidCatalysts Catalysts Catalysts
Acidcatalystscanbesensitivetoatmospheric
moistureandothercontaminants.Itisrecommended
thecatalystpumpandvalvesealareasexposedto
atmosphereare󰘱oodedwithISOoil,TSL,orother
compatiblematerialtopreventacidbuild-upand
prematuresealdamageandfailure.
NOTICE NOTICE
NOTICE
Acidbuild-upwilldamagethevalvesealsand
reducetheperformanceandlifeofthecatalyst
pump.Topreventexposingacidtomoisture:
•Alwaysuseasealedcontainerwithadesiccant
dryerinthevent,oranitrogenatmosphere.
Neverstoreacidsinanopencontainer.
•Keepthecatalystpumpandthevalveseals󰘰lled
withtheappropriatelubricant.Thelubricant
createsabarrierbetweentheacidandthe
atmosphere.
•Useonlymoisture-proofhosescompatiblewith
acids.
•Alwayslubricatethreadedpartswithan
appropriatelubricantwhenreassembling.
103A4486D

GeneralInformation
General General
GeneralInformation Information Information
•Referencenumbersandlettersinparentheses
inthetextrefertonumbersandlettersinthe
illustrations.
•Besureallaccessoriesareadequatelysizedand
pressure-ratedtomeetsystemrequirements.
•Toprotectthescreensfrompaintsandsolvents,
clear-plasticprotectiveshields(10perpack)are
available.OrderPartNo.197902fortheAdvanced
DisplayModule.Cleanthescreenswithadrycloth
ifnecessary.
3A4486D11

AdvancedDisplayModule(ADM)
Advanced Advanced
AdvancedDisplay Display DisplayModule Module Module(ADM) (ADM) (ADM)
ADM ADM
ADMDisplay Display Display
TheADMdisplayshowsgraphicalandtext
informationrelatedtosetupandsprayoperations.
Fordetailonthedisplayandindividual
screens,seeRunModeScreens,page61,or
SetupModeScreens,page68.
Keysareusedtoinputnumericaldata,entersetup
screens,navigatewithinascreen,scrollthrough
screens,andselectsetupvalues.
NOTICE NOTICE
NOTICE
Topreventdamagetothesoftkeybuttons,donot
pressthebuttonswithsharpobjectssuchaspens,
plasticcards,or󰘰ngernails.
123
456
789
0.
Figure8AdvancedDisplayModule
USB USB
USBDownload Download DownloadProcedure Procedure Procedure
UsetheUSBportontheADMtodownloadorupload
data.
1.EnableUSBdownloads.See
AdvancedScreen3,page93.
2.RemovethecoverfromtheUSBportonthe
bottomoftheADM.InserttheUSBdrive.
3.Duringthedownload,USBBUSYappearsonthe
screen.
4.Whenthedownloadiscomplete,USBIDLE
appearsonthescreen.TheUSBdrivemaythen
beremoved.
NOTE: NOTE:
NOTE:Ifthedownloadoperationtakeslonger
than60seconds,themessagedisappears.To
determineiftheUSBisbusyoridle,checkthe
ErrorStatusbaronthescreen.Ifidle,remove
theUSB.
5.InserttheUSB󰘱ashdriveintotheUSBportof
thecomputer.
6.TheUSB󰘱ashdrivewindowautomaticallyopens.
Ifitdoesnot,opentheUSB󰘱ashdrivefrom
withinWindows®Explorer.
7.OpenGracofolder.
8.Opensystemfolder.Ifdownloadingdatafrom
morethanonesystem,therewillbemorethan
onefolder.Eachfolderislabeledwiththe
correspondingserialnumberoftheADM.(The
serialnumberisonthebackoftheADM.)
9.OpenDOWNLOADfolder.
10.OpenLOGFILESfolderlabeledwiththehighest
number.Thehighestnumberindicatesthemost
recentdatadownload.
11.Openlog󰘰le.Log󰘰lesopeninMicrosoft®
Excel®bydefaultiftheprogramisinstalled.
Theyalsocanbeopenedinanytexteditorof
Microsoft®Word.
NOTE: NOTE:
NOTE:AllUSBlogsaresavedinUnicode
(UTF-16)format.Ifopeningthelog󰘰lein
MicrosoftWord,selectUnicodeencoding.
12.AlwaysreinstalltheUSBcoverafterremoving
theUSB,tokeepthedrivefreeofdirtanddust.
123A4486D

AdvancedDisplayModule(ADM)
USB USB
USBUpload Upload UploadProcedure Procedure Procedure
Usethisproceduretoinstallasystemcon󰘰guration
󰘰leand/oracustomlanguage󰘰le.
1.Ifnecessary,followtheUSB USB
USBDownload Download Download
Procedure, Procedure,
Procedure,toautomaticallygeneratetheproper
folderstructureontheUSB󰘱ashdrive.
2.InserttheUSB󰘱ashdriveintotheUSBportof
thecomputer.
3.TheUSB󰘱ashdrivewindowautomaticallyopens.
Ifitdoesnot,opentheUSB󰘱ashdrivefrom
withinWindowsExplorer.
4.OpentheGracofolder.
5.Openthesystemfolder.Ifworkingwithmore
thanonesystem,therewillbemorethanone
folderwithintheGracofolder.Eachfolderis
labeledwiththecorrespondingserialnumberof
theADM.(Theserialnumberisonthebackof
themodule.)
6.Ifinstallingthesystemcon󰘰gurationsettings󰘰le,
placeSETTINGS.TXT󰘰leintoUPLOADfolder.
7.Ifinstallingthecustomlanguage󰘰le,place
DISPTEXT.TXT󰘰leintoUPLOADfolder.
8.RemovetheUSB󰘱ashdrivefromthecomputer.
9.InstalltheUSB󰘱ashdriveintotheUSBportof
theProMixPD2KsystemUSBport.
10.Duringtheupload,USBBUSYdisplaysonthe
screen.
11.RemovetheUSB󰘱ashdrivefromtheUSBport.
NOTE: NOTE:
NOTE:Ifthecustomlanguage󰘰lewasinstalled,
userscannowselectthenewlanguagefromthe
Languagedrop-downmenuintheAdvancedSetup
Screen1.
NOTE: NOTE:
NOTE:Ifthesystemcon󰘰gurationsettings󰘰lewas
installed,itisrecommendedtoremovethe󰘰lefrom
theUPLOADfolderontheUSB󰘱ashdrive.Thiswill
preventinadvertentlyoverwritinganyfuturesetup
changes.
3A4486D13

AdvancedDisplayModule(ADM)
ADM ADM
ADMKeys Keys Keysand and andIndicators Indicators Indicators
NOTICE NOTICE
NOTICE
Topreventdamagetothesoftkeybuttons,donot
pressthebuttonswithsharpobjectssuchaspens,
plasticcards,or󰘰ngernails.
Table Table
Table1 1 1: : :ADM ADM ADMKeys Keys Keysand and andIndicators Indicators Indicators
Key Key
KeyFunction Function Function
Startup/Shutdown Startup/Shutdown
Startup/Shutdown
Key Key
Keyand and andIndicator Indicator Indicator
Presstostartuporshutdownthepump/motor.
•Solidgreenindicatesthatpowerisappliedtothemotor.
•Solidyellowindicatesthatpowertothemotorisoff.
•BlinkinggreenoryellowindicatesthatthesystemisinSetupmode.
Stop Stop
Stop
Presstoimmediatelystopthesystemandremovemotorpower.
Soft Soft
SoftKeys Keys Keys
Presstoselectthespeci󰘰cscreenoroperationshownonthedisplaydirectlynexttoeachkey.
ThetopleftsoftkeyistheEditkey,whichallowsaccesstoanysettable󰘰eldsonascreen.
Navigation Navigation
NavigationKeys Keys Keys
•
Left/RightArrows: Usetomovefromscreentoscreen.
• Up/DownArrows: Usetomoveamong󰘰eldsonascreen,itemsonadropdownmenu,or
multiplescreenswithinafunction.AlsousedtotogglebetweenMixUnitsonHomeScreen.
Numeric Numeric
NumericKeypad Keypad KeypadUsetoinputvalues.SeeADMDisplay,page12.
Cancel Cancel
Cancel
Usetocanceladataentry󰘰eld.
Setup Setup
Setup
PresstoenterorexitSetupmode.
Enter Enter
Enter
Presstochoosea󰘰eldtoupdate,tomakeaselection,tosaveaselectionorvalue,to
enterascreen,ortoacknowledgeanevent.
143A4486D

AdvancedDisplayModule(ADM)
Soft Soft
SoftKey Key KeyIcons Icons Icons
ThefollowingiconsappearintheADMdisplay,
directlytotheleftorrightofthesoftkeywhich
activatesthatoperation.
NOTICE NOTICE
NOTICE
Topreventdamagetothesoftkeybuttons,donot
pressthebuttonswithsharpobjectssuchaspens,
plasticcards,or󰘰ngernails.
Table Table
Table2 2 2: : :Soft Soft SoftKey Key KeyFunctions Functions Functions
Key Key
KeyFunction Function Function
EnterScreen
Presstoenterscreen
forediting.Highlights
editabledataona
screen.UseUp/Down
arrowstomovebetween
data󰘰eldsonthescreen.
ExitScreen
Presstoexitscreenafter
editing.
Accept
Presstoaccept
calibrationvalue.
Cancel
Presstocancelorreject
calibrationvalue.
Toggle
Presstoswitchbetween
MixUnitsontheSpray
andFillscreens.
PrimePump
Presstostartapump
primingprocedure.
Pre-FillPump
Presstomarkpump
as󰘰lled.(Onlyfor
applicablepumps.)
Line/Fill/Run
Presstostartaline󰘰ll
procedure.
Mix
Presstostartaspray
procedure.
Purge
Presstostartapurge
procedure.
Key Key
KeyFunction Function Function
SolventPurge
Presstoengagesolvent
pushsequence,when
applicable.
Standby
Stop
Presstostopallpumps
andputsystemin
Standby.
RecipeLink
Presstolinkrecipedata
foraspeci󰘰crecipeon
bothMixUnits.
PressureCheck
Presstostartapump
pressurecheck.
VolumeCheck
Presstostartapump
volumecheck.
PressureRelief
Appearsonthe
Maintenancescreen
torelievepumppressure
outthecolorchange
dumpvalve.
JobComplete
Presstologthematerial
usageandincrementthe
jobnumber,forMixUnit
#1orMixUnit#2.
CounterReset
Presstoresetthecurrent
usagecounter.
MoveCursortoLeft
AppearsontheUserID
Keyboardscreen.Useto
movecursortotheleft.
MoveCursortoRight
AppearsontheUserID
Keyboardscreen.Useto
movecursortotheright.
EraseAll
AppearsontheUserID
Keyboardscreen.Useto
eraseallcharacters.
3A4486D15

AdvancedDisplayModule(ADM)
Key Key
KeyFunction Function Function
Backspace
AppearsontheUserID
Keyboardscreen.Useto
eraseonecharacterata
time.
UpperCase/Lower
Case
AppearsontheUser
IDKeyboardscreen.
Usetochangecase
(upper/lower).
Info
Presstogetmore
informationonactive
systemerror.
Troubleshooting
Presstosee
troubleshooting
informationforsystem
error.
QRCode
PresstoseeQRCode
forsystemerror.
Navigating Navigating
Navigatingthe the theScreens Screens Screens
Therearetwosetsofscreens:
•TheRunscreenscontrolmixingoperationsand
displaysystemstatusanddata.
•TheSetupscreenscontrolsystemparametersand
advancedfeatures.
Press onanyRunscreentoentertheSetup
screens.Ifthesystemhasapasswordlock,the
Passwordscreendisplays.Ifthesystemisnotlocked
(passwordissetto0000),SystemScreen1displays.
PressonanySetupscreentoreturntothe
Homescreen.
PresstheEntersoftkey toactivatetheediting
functiononanyscreen.
PresstheExitsoftkeytoexitanyscreen.
Usetheothersoftkeystoselectthefunctionadjacent
tothem.
Screen Screen
ScreenIcons Icons Icons
Asyoumovethroughthescreens,youwillnotice
thaticonsareusedfrequentlytosimplifyglobal
communication.Thefollowingdescriptionsexplain
whateachiconrepresents.
Screen Screen
ScreenIcons Icons Icons
UserID
JobNumber
Potlife TargetRatio
RecipeNumber FlowRate
Pressure Volume
MaterialA
MaterialB
MaterialA+B
Solvent
Calendar Time
Alarm/Advisory
Deviation
MixUnit
163A4486D

Pre-OperationTasks
Pre Pre
Pre- - -Operation Operation OperationTasks Tasks Tasks
Pre Pre
Pre- - -operation operation operationChecklist Checklist Checklist
GothroughthePre-OperationChecklistdaily,before
eachuse.
✔ ✔
✔Checklist Checklist
Checklist
System System
Systemgrounded grounded grounded
Verifyallgroundingconnections
weremade.SeeGrounding Grounding
Groundinginthe
Installationmanual.
All All
Allconnections connections connectionstight tight tightand and andcorrect correct correct
Verifyallelectrical,󰘱uid,air,and
systemconnectionsaretightand
installedaccordingtotheInstallation
manual.
Fluid Fluid
Fluidsupply supply supplycontainers containers containers󰘰lled 󰘰lled 󰘰lled
CheckcomponentAandBand
solventsupplycontainers.
Dose Dose
Dosevalves valves valvesset set set
Checkthatdosevalvesareset
1–1/4turnsopen.Startwith
thesettingsrecommendedin
ValveSettings,page18,thenadjust
asneeded.
Fluid Fluid
Fluidsupply supply supplyvalves valves valvesopen open openand and and
pressure pressure
pressureset set set
TherecommendedcomponentAand
B󰘱uidsupplypressuresare1/2to2/3
ofthetargetspraypressure.
NOTE: NOTE:
NOTE:Lowpressuresystemsmay
besetwithinarangeof±100psi(0.7
MPa,7bar);highpressuresystems
maybesetwithinarangeof±300psi
(2.1MPa,21bar).Iftheinletpressure
ishigherthantheoutletpressure,
ratioaccuracymaybeaffected.
Solenoid Solenoid
Solenoidpressure pressure pressureset set set
85-100psiinletairsupply(0.6-0.7
MPa,6-7bar).
Power Power
PowerOn On On
1.TurntheACPowerSwitch(P)ON(I=ON,
0=OFF).
2.TheGracologowilldisplaywhilethesystem
initializes,followedbytheHomescreen.
3.PresstheStartkey
todisplaythePump
Powerpop-upscreen.
Thesoftkeyoptionsallowforpoweringaspeci󰘰c
MixUnit,orbothatthesametime.Thesystem
statuswillchangefrom“SystemOff”to“Startup.”
Oncethepumpsarepoweredandareinthe
Homeposition,thesystemstatuswillchange
from“Startup”to“Standby.”
Figure9PowerSwitch
3A4486D17

Pre-OperationTasks
Initial Initial
InitialSystem System SystemSetup Setup Setup
1.Changeoptionalsetupselectionsto
desiredparameters,asdescribedin
SetupModeScreens,page68.
2.Setrecipeand󰘱ushinformationas
describedinRecipeScreen,page76,
andFlushScreen,page79.
Flush Flush
FlushBefore Before BeforeUsing Using UsingEquipment Equipment Equipment
Thepump󰘱uidsectionwastestedwithlightweight
oil,whichisleftinthe󰘱uidpassagestoprotectparts.
Toavoidcontaminatingyour󰘱uidwithoil,󰘱ushthe
equipmentwithacompatiblesolventbeforeusing
theequipment.
Valve Valve
ValveSettings Settings Settings
Dosevalvesandpurgevalvesarefactorysetwiththe
hexnut(E)1-1/4turnsoutfromfullyclosed.
Figure10ValveAdjustment
183A4486D

PressureReliefProcedure
Pressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedure
FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedure
wheneveryouseethissymbol.
Thisequipmentstayspressurizeduntilpressure
ismanuallyrelieved.Tohelppreventserious
injuryfrompressurized󰘱uid,suchasskininjection,
splashing󰘱uidandmovingparts,followthe
Pressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopspraying
andbeforecleaning,checking,orservicingthe
equipment.
Without Without
WithoutColor Color ColorChange Change Change
NOTE: NOTE:
NOTE:Thefollowingprocedurerelievesall󰘱uidand
airpressureinthesystem.Useyourcontrolinterface
toissuethenecessarycommandstoyoursystem.
1.Turnoffthesupplypumps.Openthedrainvalve
onthesupplyline󰘱uid󰘰ltertorelievepressure
inthesupplyline.
2.CommandMixUnit#1toStandby.From
MaintenanceScreen4ontheADM,checkthe
boxinthe󰘰eldlabeledGunforthecoloror
catalystinthepump.Triggerthespraydeviceto
relievepressure.Repeatforeachpump.
3.Flushtheremotemixmanifoldandspraydevice.
SeeFlushMixedMaterial,page21.
4.Shutoffthesolventsupplypump.Torelieve
pressure,commandMixUnit#1toPurgeand
triggerthespraydevice.Whenthepressureis
relieved,commandMixUnit#1toStandbyto
avoidgettingaPurgeIncompletealarm.
5.Ifpressureremainsinthesolventlinebetween
thesolventsupplypumpandthesolventvalve:
•VERYSLOWLYloosena󰘰ttingtorelieve
pressuregradually.
•Loosenthe󰘰ttingcompletely.
6.RepeatforMixUnit#2
With With
WithColor Color ColorChange Change Change
NOTE: NOTE:
NOTE:Thefollowingprocedurerelievesall󰘱uidand
airpressureinthesystem.
1.Turnoffthesupplypumps.Openthedrainvalve
onthesupplyline󰘱uid󰘰ltertorelievepressurein
thesupplylines.Dothisforeachcolor.
2.
Tohelpprevent󰘰reandexplosion,shutoff
electrostaticsbefore󰘱ushing.
Ifusinganelectrostaticgun,shutoffthe
electrostaticsbefore󰘱ushingthegun.
3.Triggertheguntorelievepressure.From
MaintenanceScreen5ontheADM,checkthebox
inthe󰘰eldlabeledGunforeachcolorusedwith
MixUnit#1,tomanuallyopeneachcolorvalve.
4.SetthesystemtoRecipe0to󰘱ushthepumps
andtopurgetothespraydevice.Holdthegun
triggeropenafterthesolventvalveshutsoffto
relieveallpressure.When󰘱ushingiscomplete
MixUnit#1willgotoStandby.
5.Shutoffthesolventsupplypump.SetMixUnit
#1toRecipe0to󰘱ushsolventfromthepumps
andtopurgetothespraydevice.CommandMix
Unit#1toStandbyafterjustacoupleofseconds,
toavoidgettingaPurgeIncompletealarm.
6.Ifpressureremainsinthesolventlinebetween
thesolventsupplypumpandthesolventvalve:
•VERYSLOWLYloosena󰘰ttingtorelieve
pressuregradually.
•Loosenthe󰘰ttingcompletely.
7.VerifyontheADMHomeScreenthatneither
pump1nor2isshowinganypressure.
8.RepeatforMixUnit#2andpumps3and4.
3A4486D19

OperationUsingAdvancedDisplayModule(ADM)
Operation Operation
OperationUsing Using UsingAdvanced Advanced AdvancedDisplay Display DisplayModule Module Module(ADM) (ADM) (ADM)
Prime Prime
Primeand and andFill Fill Fillthe the theSystem System System
NOTE: NOTE:
NOTE:SeeRunModeScreens,page61,forfurther
screeninformation,ifneeded.
NOTE: NOTE:
NOTE:Youmustprimetheinputlinestothepumps
ortheinputstothecolorchangevalvesbefore
primingthepumpand󰘰llingtheentiresystem.
1.Ifusinganelectrostaticgun,shutoffthe
electrostaticsbefore󰘰llingthelines.
2.Adjustthemainairpressure.Toensureproper
operation,setthemainairpressureascloseto
100psi(0.7MPa,7.0bar)aspossible.Donot
uselessthan85psi(0.6MPa,6.0bar).
3.Ifthisisthe󰘰rsttimestartingupthesystem,orif
linesmaycontainair,purgeasinstructedunder
FlushtheSystem,page21.Theequipment
wastestedwithlightweightoil,whichshouldbe
󰘱ushedouttoavoidcontaminatingyourmaterial.
4.If If
Ifthe the thesystem system systemis is ispowered powered powereddown, down, down,press
ontheADMtobringupthePumpPowerpop-up
screenand,usingthesoftkeys,turnonpowerto
aspeci󰘰cMixUnitorboth.Makesurethatthe
systemisinStandbymode.
5.Verifythattherecipesandthe󰘱ushsequences
areprogrammedcorrectlybychecking
theRecipeScreen,page76,andthe
FlushScreen,page79.
6.EnablethemanualoverrideonSystemScreen1.
7.GototheFillScreen,page65.
8.Selectthedesiredcolortoload.PressthePrime
Pumpkey .Thecolorwillloadthepump
throughthecolorstackandouttheoutletstack
dumpvalve.
NOTE: NOTE:
NOTE:Inasinglecolorsystem,step8canbe
skipped..
9.PresstheFillLinekey
toruncoloroutto
theremotemixmanifold.Thepumpwillrununtil
youpresstheStopkeytostopthepump.
10.Triggerthegunintoagroundedreservoiror
purgereceptacleuntilthelineisfull,thenpress
theStopkey.
11.Repeatforallmateriallines.
Pre Pre
Pre- - -Fill Fill Fillthe the thePump Pump Pump
NOTE: NOTE:
NOTE:Thisoptionisonlyavailableforpumpsthat
havecolorchangevalvesandonlyasinglematerial.
Ifapumpis󰘰lledwithamaterialwhenthesystem
ispowereddown,thiswillallowtheusertochange
thepump’scontents,without󰘱ushingthepump,the
nexttimepowerisrestored.
1.Enablethemanualoverrideon
SystemScreen1,page68.
2.GototheFillScreen,page65.
3.PressthePre-FillPumpkey .Thepump
willchangefrommaterial61tothepropercolor
orcatalyst.
Spraying Spraying
Spraying
Tosprayinamultiplecolorsystem,alsosee
MultipleColorSystems,page98.
NOTE: NOTE:
NOTE:SeeRunModeScreens,page61,forfurther
screeninformation,ifneeded.
1.CommandaMixUnittoMix.Thesystemwill
loadthecorrectmixedmaterialvolume.
NOTE: NOTE:
NOTE:TheMixUnitwillautomaticallyrunaMix
Filliftherecipeisnotcurrentlyloadedintothe
system.TheMixFillvolumecalculationincludes
theremotemixmanifoldvolumeandthemixed
materialhosevolume.Themixedmaterialhose
volumeisdeterminedbythegunhoselengthand
diameterenteredinSystemScreen3,page70,
andtheremote-to-mixhoselengthanddiameter
alsoenteredinSystemScreen3,page70.
2.Adjustthe󰘱owratebychangingthetarget
pressure(inPressureMode)orthetarget󰘱ow
rate(inFlowMode)ontheSprayScreenor
throughthePLC.The󰘱uid󰘱owrateshownonthe
Sprayscreenisthecombinedtotalofcomponent
AandBoutofthespraydevice.
3.Turnonatomizingairtothespraydevice.Check
thespraypatternasinstructedinyourspray
devicemanual.
NOTICE NOTICE
NOTICE
Donotallowa󰘱uidsupplytanktorunempty.
Thiscandamagethepumpsandleadtothe
proportioningof󰘱uidandairthatmeetstheratio
andtolerancesettingsoftheequipment.Thiscan
furtherresultinsprayinguncatalyzedorpoorly
catalyzedmaterial.
203A4486D