Graco ProMix PD3K Plus Instruction Manual

Operation
ProMix® ProMix®
ProMix®PD3K+ PD3K+ PD3K+Proportioner Proportioner Proportionerfor for for
Automatic Automatic
AutomaticSpray Spray SprayApplications Applications Applications3A6287E
EN
Electronic Electronic
Electronicpositive positive positivedisplacement displacement displacementproportioner proportioner proportionerfor for forup up upto to to4 4 4- - -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
Readallwarningsandinstructionsinthismanualandinyour
InstallationandRepair/Partsmanuals.Savetheseinstructions.
Seepage3formodelpartnumbersand
approvalsinformation.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
RelatedManuals..................................................3
Models.................................................................4
Warnings.............................................................7
ImportantIsocyanate(ISO)Information................10
GeneralInformation............................................12
AdvancedDisplayModule(ADM)........................13
ADMDisplay................................................13
USBDownloadProcedure............................13
USBUploadProcedure................................14
ADMKeysandIndicators.............................15
SoftKeyIcons.............................................16
NavigatingtheScreens................................17
ScreenIcons...............................................17
Pre-OperationTasks...........................................18
Pre-operationChecklist................................18
PowerOn....................................................18
InitialSystemSetup.....................................18
FlushBeforeUsingEquipment......................19
ValveSettings..............................................19
PressureReliefProcedure..................................20
WithoutColorChange..................................20
WithColorChange.......................................20
OperationUsingAdvancedDisplayModule
(ADM)...................................................21
PrimeandFilltheSystem.............................21
Pre-FillthePump.........................................21
Spraying......................................................21
Purging.......................................................22
Shutdown....................................................23
OperationUsingaProgrammableLogic
Controller(PLC)....................................24
NetworkCommunicationsandDiscrete
I/O.................................................24
DiscreteI/O.................................................24
CommunicationGatewayModule(CGM)
Details...........................................26
NetworkCommunicationI/ODataMap...........27
OperationFlowCharts.................................39
NetworkCommunication-Dynamic
CommandStructure(DCS).............47
PLCDiagnosticScreens...............................57
FlowControlSystem....................................58
RunModeScreens.............................................59
OpeningScreen...........................................59
HomeScreen..............................................59
SprayScreen...............................................62
FillScreen...................................................63
PotlifeScreen..............................................64
UsageScreen..............................................65
JobsScreen................................................66
ErrorsScreen..............................................66
EventsScreen.............................................66
SetupModeScreens..........................................67
PasswordScreen.........................................67
SystemScreen1.........................................67
SystemScreen2.........................................68
SystemScreen3.........................................71
SystemScreen4.........................................72
SystemScreen5.........................................73
SystemScreen6.........................................73
SystemScreen7.........................................74
GatewayScreen..........................................75
RecipeScreen1..........................................76
RecipeScreen2..........................................77
RecipeScreen3..........................................78
FlushScreen...............................................79
PurgeScreen..............................................80
Air/SolventChop..........................................80
PumpScreen1............................................81
PumpScreen2............................................82
PumpScreen3............................................83
PumpScreen-MaterialAssignment.............83
CustomValveMapping................................84
CalibrationScreens......................................87
MaintenanceScreens...................................89
AdvancedScreen1......................................91
AdvancedScreen2......................................92
AdvancedScreen3......................................92
AdvancedScreen4......................................92
DiagnosticScreens......................................93
CalibrationChecks..............................................94
PumpPressureCheck.................................94
PumpVolumeCheck....................................95
SolventMeterCalibration.............................95
ColorChange.....................................................96
MultipleColorSystems.................................96
ColorChangeDoesNotInitiate....................96
SystemErrors....................................................97
On-ScreenHelp...........................................97
ToClearErrorandRestart............................98
GunTriggerInputFunction...........................98
ErrorCodes.................................................99
Maintenance....................................................114
PreventiveMaintenanceSchedule..............114
Flushing....................................................114
CleaningtheADM......................................114
AppendixA:IntegrationwithAllenBradley
PLC....................................................115
AppendixB:MultipleGuns................................118
SprayScreen.............................................119
FillScreen.................................................119
MaintenanceScreen5...............................120
OperationWithaPLC................................120
TechnicalData.................................................121
CaliforniaProposition65...................................121
23A6287E

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
332455ColorChangeKits,Instructions—
Parts
Manual Manual
ManualNo. No. No.Description Description Description
333282ColorChangeandRemoteMix
ManifoldKits,Instructions—Parts
332456PumpExpansionKits,Instructions
—Parts
334183ModbusTCPGatewayModule,
Instructions—Parts
334494ProMixPD2KCGMInstallation
Kits,Instructions—Parts
3A6287E3

Models
Models Models
Models
30
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 ofProMix ProMix ProMixPD PD PD
and and
andElectrical Electrical ElectricalControl Control ControlBox Box Box
(ECB) (ECB)
(ECB)Labels Labels Labels
Withlow–pressurepumps:
300psi(2.068MPa,20.68
bar)
AC0500A100psi(0.7MPa,7.0bar)Withhigh–pressure
pumps:
1500psi(10.34MPa,
103.4bar)
AC1000A100psi(0.7MPa,7.0bar)300psi(2.068MPa,20.68
bar)
AC2000A100psi(0.7MPa,7.0bar)1500psi(10.34MPa,
103.4bar)
Figure1ModelAC1000Identi󰘰cationLabel
Figure224M672ControlBoxIdenti󰘰cationLabel Continuedonthenextpage.
43A6287E

Models
Figure3ModelAC2000Identi󰘰cationLabel
Figure4ModelAC0500Identi󰘰cationLabel
Figure5Non-IntrinsicallySafeColorChangeControl(Accessory)Identi󰘰cationLabel
Figure6IntrinsicallySafeColorChangeControl
(Accessory)Identi󰘰cationLabel
3A6287E5

Models
Figure7PumpExpansionKit(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
Figure8CGMIdenti󰘰cationLabel
63A6287E

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
solventthroughtheequipmentcancausestaticsparking.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
areantistaticorconductive.
•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.
3A6287E7

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.
•ReadSafetyDataSheets(SDSs)forhandlinginstructionsandtoknowthespeci󰘰chazardsofthe
󰘱uidsyouareusing,includingtheeffectsoflong-termexposure.
•Whenspraying,servicingequipment,orwhenintheworkarea,alwayskeepworkarea
well-ventilatedandalwayswearappropriatepersonalprotectiveequipment.SeePersonal
ProtectiveEquipmentwarningsinthismanual.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicableguidelines.
83A6287E

Warnings
WARNING WARNING
WARNINGPERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,including
eyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotectiveequipmentincludesbut
isnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolventmanufacturer.
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestratedsystem
component.SeeTechnical Technical
TechnicalSpeci󰘰cations Speci󰘰cations Speci󰘰cationsinallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
Technical
Speci󰘰cations Speci󰘰cations
Speci󰘰cationsinallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.For
completeinformationaboutyourmaterial,requestSafetyDataSheets(SDSs)fromdistributor
orretailer.
•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.
3A6287E9

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.
103A6287E

ImportantIsocyanate(ISO)Information
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.
3A6287E11

GeneralInformation
General General
GeneralInformation Information Information
•Referencenumbersandlettersinparentheses
inthetextrefertonumbersandlettersinthe
illustrations.
•Besureallaccessoriesareadequatelysizedand
pressure-ratedtomeetsystemrequirements.
•Toprotectthescreensfrompaintsandsolvents,
clear-plasticprotectiveshields(10perpack)are
available.OrderPartNo.197902fortheAdvanced
DisplayModule.Cleanthescreenswithadrycloth
ifnecessary.
123A6287E

AdvancedDisplayModule(ADM)
Advanced Advanced
AdvancedDisplay Display DisplayModule Module Module(ADM) (ADM) (ADM)
ADM ADM
ADMDisplay Display Display
TheADMdisplayshowsgraphicalandtext
informationrelatedtosetupandsprayoperations.
Fordetailonthedisplayandindividual
screens,seeRunModeScreens,page59,or
SetupModeScreens,page67.
Keysareusedtoinputnumericaldata,entersetup
screens,navigatewithinascreen,scrollthrough
screens,andselectsetupvalues.
NOTICE NOTICE
NOTICE
Topreventdamagetothesoftkeybuttons,donot
pressthebuttonswithsharpobjectssuchaspens,
plasticcards,or󰘰ngernails.
123
456
789
0.
Figure9AdvancedDisplayModule
USB USB
USBDownload Download DownloadProcedure Procedure Procedure
UsetheUSBportontheADMtodownloadorupload
data.
1.EnableUSBdownloads.See
AdvancedScreen3,page92.
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.
3A6287E13

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
theProMixPD3K+systemUSBport.
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.
143A6287E

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.
Numeric Numeric
NumericKeypad Keypad KeypadUsetoinputvalues.SeeADMDisplay,page13.
Cancel Cancel
Cancel
Usetocanceladataentry󰘰eld.
Setup Setup
Setup
PresstoenterorexitSetupmode.
Enter Enter
Enter
Presstochoosea󰘰eldtoupdate,tomakeaselection,tosaveaselectionorvalue,to
enterascreen,ortoacknowledgeanevent.
3A6287E15

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
editabledataonascreen.
UseUp/Downarrowsto
movebetweendata󰘰elds
onthescreen.
ExitScreen
Presstoexitscreenafter
editing.
Accept
Presstoacceptcalibration
value.
Cancel
Presstocancelorreject
calibrationvalue.
PrimePump
Presstostartapump
primingprocedure.
Line/Fill/Run
Presstostartaline󰘰ll
procedure.
Mix
Presstostartaspray
procedure.
Purge
Presstostartapurge
procedure.
SolventPurge
Presstoengagesolvent
pushsequence,when
applicable.
Pre-FillPump
Presstomarkpumpas
󰘰lled.
(Onlyforapplicable
pumps.)
Key Key
KeyFunction Function Function
Standby
Stop
Presstostopallpumps
andputsystemin
Standby.
PressureCheck
Presstostartapump
pressurecheck.
VolumeCheck
Presstostartapump
volumecheck.
JobComplete
Presstologthematerial
usageandincrementthe
jobnumber.
CounterReset
Presstoresetthecurrent
usagecounter.
MoveCursortoLeft
AppearsontheUserID
Keyboardscreen.Useto
movecursortotheleft.
MoveCursortoRight
AppearsontheUserID
Keyboardscreen.Useto
movecursortotheright.
EraseAll
AppearsontheUserID
Keyboardscreen.Useto
eraseallcharacters.
Backspace
AppearsontheUserID
Keyboardscreen.Useto
eraseonecharacterata
time.
UpperCase/Lower
Case
AppearsontheUser
IDKeyboardscreen.
Usetochangecase
(upper/lower).
Info
Presstogetmore
informationonactive
systemerror.
Troubleshoot
Presstosee
troubleshooting
informationforsystem
error.
163A6287E

AdvancedDisplayModule(ADM)
Key Key
KeyFunction Function Function
QRCode
PresstoseeQRCodefor
systemerror.
RecipePage
Presstoaccessadditional
infoforthatrecipe.
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
MaterialC
MaterialD
MaterialA+B+C
Solvent
Calendar Time
Alarm/Advisory
Deviation
3A6287E17

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,page19,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
.Thesystemstatuswill
changefrom“SystemOff”to“Startup.”Once
thepumpsarepoweredandareintheHome
position,thesystemstatuswillchangefrom
“Startup”to“Standby.”
Figure10PowerSwitch
Initial Initial
InitialSystem System SystemSetup Setup Setup
1.Changeoptionalsetupselectionsto
desiredparameters,asdescribedin
SetupModeScreens,page67.
2.Setrecipeand󰘱ushinformationas
describedinRecipeScreen1,page76and
FlushScreen,page79.
183A6287E

Pre-OperationTasks
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.
Figure11ValveAdjustment
3A6287E19

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.CommandthesystemtoStandby.From
MaintenanceScreen5ontheADM,checkthe
boxinthe󰘰eldlabeledGunforthecoloror
catalystinthepump.Triggerthespraydeviceto
relievepressure.Repeatforeachpumpinthe
system.
3.Flushtheremotemixmanifoldandspraydevice.
SeeFlushMixedMaterial,page22.
4.Shutoffthesolventsupplypump.Torelieve
pressure,commandthesystemtoPurgeand
triggerthespraydevice.Whenthepressureis
relieved,commandthesystemtoStandbyto
avoidgettingaPurgeIncompletealarm.
5.Ifpressureremainsinthesolventlinebetween
thesolventsupplypumpandthesolventvalve:
•VERYSLOWLYloosena󰘰ttingtorelieve
pressuregradually.
•Loosenthe󰘰ttingcompletely.
With With
WithColor Color ColorChange Change Change
NOTE: NOTE:
NOTE:Thefollowingprocedurerelievesall󰘱uidand
airpressureinthesystem.
1.Turnoffthesupplypumps.Openthedrainvalve
onthesupplyline󰘱uid󰘰ltertorelievepressurein
thesupplylines.Dothisforeachcolor.
Ifusinganelectrostaticgun,shutoffthe
electrostaticsbefore󰘱ushingthegun.
2.Triggertheguntorelievepressure.From
MaintenanceScreen5ontheADM,checkthe
boxinthe󰘰eldlabeledGunforeachcolorinthe
system,tomanuallyopeneachcolorvalve.
3.SetthesystemtoRecipe0to󰘱ushthepumps
andtopurgetothespraydevice.Holdthegun
triggeropenafterthesolventvalveshutsoffto
relieveallpressure.When󰘱ushingiscomplete
thesystemwillgotoStandby.
4.Shutoffthesolventsupplypump.Setthesystem
toRecipe0to󰘱ushsolventfromthepumpsand
topurgetothespraydevice.Commandthe
systemtoStandbyafterjustacoupleofseconds,
toavoidgettingaPurgeIncompletealarm.
5.Ifpressureremainsinthesolventlinebetween
thesolventsupplypumpandthesolventvalve:
•VERYSLOWLYloosena󰘰ttingtorelieve
pressuregradually.
•Loosenthe󰘰ttingcompletely.
6.VerifyontheADMHomeScreenthatneither
pumpisshowinganypressure.
203A6287E