Graco ProMix PD2K Use and care manual

Repair-Parts
ProMix® PD2K Proportioner for
Automatic Spray Applications 332709D
EN
Electronic positive displacement proportioner for fast-setting two-component materials. System for
automatic dispense, with Advanced Display Modules. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual and in your
installation, operation, and associated component manuals. Save
these instructions.
See page 3 for model part numbers and
approvals information.
PROVEN QUALITY. LEADING TECHNOLOGY.

Contents
Models............................................................... 3
Related Manuals ................................................ 6
Warnings ........................................................... 7
Important Isocyanate (ISO) Information................ 10
Material Self-ignition..................................... 10
Important Acid Catalyst Information ..................... 12
Troubleshooting.................................................. 14
System Troubleshooting............................... 14
Error Code Troubleshooting.......................... 15
Power Barrier Board Diagnostics .................. 28
Isolation Board Diagnostics .......................... 29
Enhanced Fluid Control Module (EFCM)
Diagnostics .................................... 30
Pump Module Diagnostics ............................ 31
Advanced Display Module Diagnostics........... 32
Notes ................................................................ 33
Electrical Schematics.......................................... 34
Standard Models (AC1000, AC2000)............. 34
Dual Panel Models (AC1002, AC2002)........... 40
Optional Cables and Modules ....................... 46
Communications Options (for PLC and
AWI) ....................................... 47
Repair................................................................ 48
Before Servicing .......................................... 48
Pressure Relief Procedure............................ 49
Repairing the Advanced Display Module
(ADM)............................................ 50
Servicing the Control Box ............................. 51
Servicing the Fluid Section ........................... 60
Parts.................................................................. 64
Proportioner Parts (Standard Models) ........... 64
Proportioner Parts (Dual Panel
Models).......................................... 67
Control Box Parts......................................... 70
Control Box Parts (Dual Panel Models)........... 73
Solenoid Manifold Parts................................ 76
Technical Data ...................................................77
2332709D

Models
Models
See Figs. 1–7 for component identification labels, including approval information and certification.
Part No. Series Maximum Air Working
Pressure
Maximum Fluid Working
Pressure
Location of PD2K and
Electrical Control Box
(ECB) Labels
AC0500
AC0502
A100 psi (0.7 MPa,
7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
AC1000
AC1002
A100 psi (0.7 MPa,
7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
AC2000
AC2002
A100 psi (0.7 MPa,
7.0 bar)
1500 psi (10.34 MPa,
103.4 bar)
0359 II 2 G
.7 7 100
MAX AIR WPR
MPa bar PSI
2.068 20.68 300
MAX FLUID WPR
MPa bar PSI
PART NO. SERIES
Artwork No. 294021 Rev. F
Read Instruction Manual
Warning: Substitution of components
may impair intrinsic safety.
SERIAL
ProMix® PD2K / PD1K
Electronic Proportioner
MAX TEMP 50°C (122°F)
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
MFG. YR.
Intrinsically Safe (IS) System. Install
per IS Control Drawing No. 16P577.
Control Box IS Associated
Apparatus for use in non hazardous
location, with IS Connection to color
change and booth control modules
Apparatus for use in:
Class I, Division 1, Group D T3
Hazardous Locations
II 2 G
Ex ia IIA T3
FM13 ATEX 0026
IECEx FMG 13.0011
FM16US0241
FM16CA0129
Intrinsically safe
equipment for Class I,
Div 1, Group D, T3
Ta = 2°C to 50°C
Figure 1 Model AC1000 and AC1002 (Low Pressure)
Identification Label
Artwork No. 294024 Rev. D
SERIES NO. MFG. YR.
PART NO.
AMPS
VOLTS 90-250 ~
7 AMPS MAX
POWER REQUIREMENTS
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
II (2) G
[Ex ia] IIA Gb
FM13 ATEX 0026
IECEx FMG 13.0011
Intrinsically safe connections
for Class I, Div 1, Group D
Ta = 2°C to 50°C
Install per 16P577 50/60 Hz
ProMix®PD2K / PD1K
Um: 250 V
FM16US0241
FM16CA0129
Figure 2 24M672 and 26A188 Control Box
Identification Label
Continued on the next page.
332709D 3

Models
.7 7 100
MAX AIR WPR
MPa bar PSI
10.34 103.4 1500
MAX FLUID WPR
MPa bar PSI
PART NO. SERIES
Artwork No. 294022 Rev. F
Read Instruction Manual
Warning: Substitution of components
may impair intrinsic safety.
SERIAL
ProMix® PD2K / PD1K
Electronic Proportioner
MAX TEMP 50°C (122°F)
Intrinsically Safe (IS) System. Install
per IS Control Drawing No. 16P577.
Control Box IS Associated
Apparatus for use in non hazardous
location, with IS Connection to color
change and booth control modules
Apparatus for use in:
Class I, Division 1, Group D T3
Hazardous Locations
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
MFG. YR.
II 2 G
Ex ia IIA T3
FM13 ATEX 0026
IECEx FMG 13.0011
FM16US0241
FM16CA0129
Intrinsically safe
equipment for Class I,
Div 1, Group D, T3
Ta = 2°C to 50°C
Figure 3 Model AC2000 and AC2002 (High
Pressure) Identification Label
.7 7 100
MAX AIR WPR
MPa bar PSI PART NO. SERIES
Artwork No. 294280 Rev. E
Read Instruction Manual
Warning: Substitution of components
may impair intrinsic safety.
SERIAL
ProMix® PD2K / PD1K
Electronic Proportioner
MAX TEMP 50°C (122°F)
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
MFG. YR.
Intrinsically Safe (IS) System. Install
per IS Control Drawing No. 16P577.
Control Box IS Associated
Apparatus for use in non hazardous
location, with IS Connection to color
change and booth control modules
Apparatus for use in:
Class I, Division 1, Group D T3
Hazardous Locations
II 2 G
Ex ia IIA T3
FM13 ATEX 0026
IECEx FMG 13.0011
FM16US0241
FM16CA0129
Intrinsically safe
equipment for Class I,
Div 1, Group D, T3
Ta = 2°C to 50°C
POWER REQUIREMENTS
AMPSVOLTS
90-250 ~ 7 AMPS MAX
50/60 Hz Um: 250 V
Figure 4 Model AC0500 and AC0502 Identification Label
Figure 5 Non-Intrinsically Safe Color Change Control (Accessory) Identification Label
Artwork No. 294055 Rev. C
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
.7 7
MAX AIR WPR
MPa bar PSI
COLOR CHANGE CONTROL
ProMix®PD2K / PD1K
100
PART NO. SERIES SERIAL MFG. YR.
Intrinsically safe equipment
for Class I, Div 1, Group D, T3
Ta = 2°C to 50°C
Install per 16P577
II 2 G
Ex ia IIA T3 Gb
FM13 ATEX 0026
IECEx FMG 13.0011
FM16US0241 FM16CA0129
Figure 6 Intrinsically Safe Color Change Control (Accessory) Identification Label
4332709D

Models
Figure 7 Pump Expansion Kit (Accessory) Identification Label
332709D 5

Related Manuals
Related Manuals
Current manuals are available at www.graco.com.
Manual No. Description
332458 PD2K Proportioner Installation
Manual, Automatic Systems
332564 PD2K Proportioner Operation
Manual, Automatic Systems
3A4486 PD2K Dual Panel Proportioner
Operation Manual, Automatic
Systems
332339 Pump Repair-Parts Manual
332454 Color Change Valve Repair-Parts
Manual
332455 Color Change Kits Instructions-
Parts Manual
Manual No. Description
333282 Remote Mix Manifold
Instructions-Parts Manual
332456 Pump Expansion Kits
Instructions-Parts Manual
334183 Modbus TCP Gateway Module
Instructions-Parts Manual
334494 ProMix PD2K CGM Installation Kits
Instructions-Parts Manual
334512 Isolated Pump Expansion Kits
Instructions-Parts Manual
6332709D

Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance and repair of this equipment. The exclamation
point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risks. When these
symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard
symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help
prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic
drop cloths (potential static arc).
• 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.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are antistatic or conductive.
•Stop operation immediately if static sparking occurs or you feel a shock, Do not use equipment until
you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause
electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
332709D 7

Warnings
WARNING
INTRINSIC SAFETY
Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe
equipment will create a hazardous condition and can cause fire, explosion, or electric shock. Follow
local regulations and the following safety requirements.
• Be sure your installation complies with national, state, and local codes for the installation of
electrical apparatus in a Class I, Group D, Division 1 (North America) or Class I, Zones 1 and 2
(Europe) Hazardous Location, including all of the local safety fire codes (for example, NFPA 33,
NEC 500 and 516, OSHA 1910.107, etc.).
• To help prevent fire and explosion:
• Do not install equipment approved only for a non-hazardous location in a hazardous location.
See model ID label for the intrinsic safety rating of your model.
• Do not substitute system components as this may impair intrinsic safety.
• Equipment that comes in contact with the intrinsically safe terminals must be rated for Intrinsic
Safety. This includes DC voltage meters, ohmmeters, cables, and connections. Remove the unit
from the hazardous area when troubleshooting.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin.
This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate
surgical 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 Relief Procedure when you stop dispensing and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure and disconnect all power sources.
TOXIC FLUID OR FUMES
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.
8332709D

Warnings
WARNING
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but
is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical 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 energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and
create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
332709D 9

Important Isocyanate (ISO) Information
Important Isocyanate (ISO) Information
Isocyanates (ISO) are catalysts used in two
component materials.
Isocyanate Conditions
Spraying or dispensing fluids that contain
isocyanates creates potentially harmful mists,
vapors, and atomized particulates
• Read and understand the fluid manufacturer’s
warnings and Safety Data Sheet (SDS) to know
specific hazards and precautions related to
isocyanates.
• Use of isocyanates involves potentially
hazardous procedures. Do not spray with the
equipment unless you are trained, qualified,
and have read and understood the information
in this manuals and in the fluid manufacturer’s
application instructions and SDS.
• Use of incorrectly maintained or mis-adjusted
equipment may result in improperly cured
material. Equipment must be carefully
maintained and adjusted according to
instructions in the manual.
• To prevent inhalation of isocynate mists, vapors,
and atomized particulates, everyone inthe
work area must wear appropriate respiratory
protection. Always wear a properly fitting
respirator, which may include a supplied-air
respirator. Ventilate the work area according to
instructions in the fluid manufacturer’s SDS.
• Avoid all skin contact with iscocyanates.
Everyone in the work area must wear chemically
impermeable gloves, protective clothing and
foot coverings as recommended by the fluid
manufacturer and local regulatory authority.
Follow all fluid manufacturer recommendations,
including those regarding handling of
contaminated clothing. After spraying, wash
hands and face before eating or drinking.
Material Self-ignition
Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings
and Safety Data Sheet (SDS).
Keep Components A and B Separate
Cross-contamination can result in cured
material in fluid lines which could cause serious
injury or damage equipment. To prevent
cross-contamination:
•Never interchange component A and component
B wetted parts.
• Never use solvent on one side if it has been
contaminated from the other side.
10 332709D

Important Isocyanate (ISO) Information
Moisture Sensitivity of Isocyanates
Exposure to moisture (such as humidity) will cause
ISO to partially cure; forming small, hard, abrasive
crystals, which become suspended in the fluid.
Eventually a film will form on the surface and the ISO
will begin to gel, increasing in viscosity.
NOTICE
Partially cured ISO will reduce performance and
the life of all wetted parts.
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere.
Never store ISO in an open container.
• Keep the ISO pump wet cup or reservoir (if
installed) filled with appropriate lubricant. The
lubricant creates a barrier between the ISO and
the atmosphere.
• Use only moisture-proof hoses compatible with
ISO.
• Never use reclaimed solvents, which may
contain moisture. Always keep solvent
containers closed when not in use.
• Always lubricate threaded parts with an
appropriate lubricant when reassembling.
NOTE: The amount of film formation and rate of
crystallization varies depending on the blend of ISO,
the humidity, and the temperature.
Changing Materials
NOTICE
Changing the material types used in your
equipment requires special attention to avoid
equipment damage and downtime.
• When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.
• Always clean the fluid inlet strainers after
flushing.
• Check with your material manufacturer for
chemical compatibility.
• When changing between epoxies and urethanes
or polyureas, disassemble and clean all fluid
components and change hoses. Epoxies often
have amines on the B (hardener) side. Polyureas
often have amines on the A (resin) side.
332709D 11

Important Acid Catalyst Information
Important Acid Catalyst Information
Only the PD2K Acid Catalyst Model Proportioners are designed for acid catalysts (“acid”) currently used in
two-component, wood-finishing materials. Current acids in use (with pH levels as low as 1) are more corrosive than
earlier acids. More corrosion-resistant wetted materials of construction are required, and must be used without
substitution, to withstand the increased corrosive properties of these acids.
Acid Catalyst Conditions
Acid is flammable, and spraying or dispensing acid creates potentially harmful mists, vapors, and atomized
particulates. To help prevent fire and explosion and serious injury:
• Read and understand the acid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific hazards
and precautions related to the acid.
• Use only genuine, manufacturer’s recommended acid-compatible parts in the catalyst system (hoses, fittings,
etc). A reaction may occur between any substituted parts and the acid.
• To prevent inhalation of acid mists, vapors, and atomized particulates, everyone in the work area must wear
appropriate respiratory protection. Always wear a properly fitting respirator, which may include a supplied-air
respirator. Ventilate the work area according to instructions in the acid manufacturer’s SDS.
• Avoid all skin contact with acid. Everyone in the work area must wear chemically impermeable gloves, protective
clothing, foot coverings, aprons, and face shields as recommended by the acid manufacturer and 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 the work area. Eliminate all ignition
sources.
• Store acid in the original container in a cool, dry, and well-ventilated area away from direct sunlight and
away from other chemicals in accordance with acid manufacturer’s recommendations. To avoid corrosion of
containers, do not store acid in substitute containers. Reseal the original container to prevent vapors from
contaminating the storage space and surrounding facility.
12 332709D

Important Acid Catalyst Information
Moisture Sensitivity of Acid Catalysts
Acid catalysts can be sensitive to atmospheric
moisture and other contaminants. It is recommended
the catalyst pump and valve seal areas exposed to
atmosphere are flooded with ISO oil, TSL, or other
compatible material to prevent acid build-up and
premature seal damage and failure.
NOTICE
Acid build-up will damage the valve seals and
reduce the performance and life of the catalyst
pump. To prevent exposing acid to moisture:
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere.
Never store acids in an open container.
• Keep the catalyst pump and the valve seals filled
with the appropriate lubricant. The lubricant
creates a barrier between the acid and the
atmosphere.
• Use only moisture-proof hoses compatible with
acids.
• Always lubricate threaded parts with an
appropriate lubricant when reassembling.
332709D 13

Troubleshooting
Troubleshooting
NOTE: Check all possible remedies before disassembling the system.
System Troubleshooting
Problem Cause Solution
Inadequate power supply. See Technical Data, page 77.
Power switch is off. Turn switch on.
Main power is shut off. Turn main power switch on.
Exhausted fluid supply. Refill and reprime pump.
Clogged fluid outlet line, valves, etc. Clear.
Unit will not operate.
Fluid dried on piston rod. Disassemble and clean pump. See
pump manual. In future, stop pump
at bottom of stroke.
Inadequate power supply. See Technical Data, page 77.
Exhausted fluid supply. Refill and reprime pump.
Clogged fluid outlet line, valves, etc. Clear.
Pump output low on both strokes.
Worn piston packings. Replace. See pump manual.
Heldopenorworndosingvalves. Check and repair. See pump
manual.
Pump output low on only one stroke.
Worn piston packing. Replace. See pump manual.
No output. Improperly installed dosing valves. Check solenoid connections to
valves. See pump manual.
Exhausted fluid supply. Refill and reprime pump.
Heldopenorworndosingvalves. Check and repair. See pump
manual.
Pump operates erratically.
Worn piston packing. Replace. See pump manual.
14 332709D

Troubleshooting
Error Code Troubleshooting
System errors alert you of a problem and help
prevent off-ratio spraying. There are three types:
Advisory, Deviation, and Alarm.
NOTE: Dual Panel systems (AC0502, AC1002
and AC2002) have most of the same error codes,
but may apply to a specific Mix Unit. Refer to
the PD2K Dual Panel Operations, Automatic
System, manual for those specific error codes. See
Related Manuals, page 6 .
An Advisory records an event in the system, and will
clear itself after 60 seconds. The four-digit error code
will be followed by “-V”.
ADeviation records an error in the system but does
not shut down the equipment. The deviation must be
acknowledged by the user. The four-digit error code
will be followed by “-D”.
If an Alarm occurs, operation stops. The four-digit
error code will be followed by “-A”.
If any of the three system error types occur:
• Alarm buzzer sounds (unless in silent mode).
• Alarm popup screen shows the active alarm code.
• Status bar on the Advanced Display Module shows
theactivealarmcode.
• Alarm is saved in the date/time stamped log.
NOTE: ARecord saves relevant system events in the
background. These are informational only and can
be reviewed on the Events screen, which displays
the 200 most recent events, with date, time, and
description.
NOTE: When an error occurs be sure to determine
the code before resetting it. If you forget which code
occurred, the Errors screen displays the 200 most
recent errors, with date, time, and description.
NOTE: In some error codes listed below, a # symbol
is shown as the last digit. This symbol represents the
applicable pump number, which can vary. The unit’s
display will show the applicable pump number as the
last digit in the code.
332709D 15

Troubleshooting
Purge Errors
Code Type Description Problem Cause Solution
ETD1 Devia-
tion
Autodump
Color (A)
Passed
System has completed
an auto dump of the
contents from the pump
all the way out to the gun.
Potlife time has expired
and the system was not
purged, so the system
refilled with color.
No action required.
ETE0 Record Purge Not
Complete
The system was unable
to complete a purge
sequence.
An indication that the
system either could
not complete or was
interrupted before
completing a gun purge.
No action required.
Solvent flow switch not
working.
Replace the switch.
ETO1 Alarm Autodump
Failed
Potlife time has
expired and the system
attemptedtoflushthe
mixed material contents
out of the gun. The
solvent flow meter or
solvent flow switch did
no indicate any flow
taking place during the
attempted purge.
Gun is not in gun flush
box.
Ensure the gun is
replaced in the gun
flush box and cover is
closed when not in use.
ETS1 Devia-
tion
Autodump
Solvent
Passed
System has completed
an auto dump of the gun
contents only.
Potlife time has expired
and the system was not
purged, so the system
performed an autodump
with solvent.
No action required.
Gun is not in gun flush
box.
Ensure the gun is
replaced in the gun
flush box and cover is
closed when not in use.
SGD1 Alarm Gun Flush
Box Open
GFB was left open when
the system was trying to
attempt a purge.
GFB pressure switch not
wired/working.
Double check that the
pressure switch is wired
properly to the EFCM.
Solvent flow switch not
working.
Replace switch.
Solvent flow is too low
to actuate the solvent
switch.
Increase solvent
pressure to drive a
high purge flow rate
Gun is not triggered. Operator must continue
flushing for configured
time, until the booth
control indicates purge is
completed.
SPD1 Alarm Gun Purge
Incomplete
The system timed out
without reaching the
user-specified volume of
solvent for a purge.
Mix manifold was not set
to flush position, blocking
solvent flow to the spray
gun.
Setmanifoldtoflush
position.
16 332709D

Troubleshooting
Mix Errors
Code Type Description Problem Cause Solution
Solvent flow switch is
stuck in flow position.
Clean or replace switch.F7S1 Alarm Flow
Detected
Solvent Gun
The solvent flow switch
is indicating unexpected
solvent flow. There is a leak through
the solvent cutoff valve.
Check for leaks and
repair valve.
One or both solvent flow
switches are stuck in flow
position.
Clean or replace the
switch(es).
F7S2 Alarm Flow
Detected
Solvent Mix
The solvent flow switches
indicate that both are
flowing solvent at the
same time.
*This only applies to
systems with mix-at-wall.
There is a leak through
one or both of the solvent
cutoff valves.
Check for leaks and
repair valve(s).
Purge process was not
completed.
Make sure purge process
is completed.
QPD1 Alarm,
then
Devia-
tion
Potlife
Expired
Potlife time has expired
before the system has
moved the required
amount of material
(potlife volume) through
the mixed material line.
Solvent supply shut off or
empty.
Verify solvent supply is
available and on, supply
valves are open.
QP## Devia-
tion
Potlife
Expired
Recipe ##
Potlife time has expired
before the system has
moved the required
amount of material
(potlife volume) through
the mixed material line in
an inactive gun loaded
with recipe ##.
*This only applies to
systems with multiple
guns.
An inactive gun has
mixed material for recipe
## loaded and has
not dispensed enough
material in the required
amount of time.
Purge the inactive gun.
Mix manifold not set to
spray position.
Setmanifoldtospray.
Spray gun was not
triggered.
Allow flow through gun
during fill process until
the fill complete LED
stops flashing.
SND1 Alarm Mix Fill
Incomplete
The system timed out
before the mix fill cycle
loaded the gun with
mixed material.
Restrictions in mixer,
manifold, or spray gun.
Fix restrictions.
332709D 17

Troubleshooting
Pumping Errors
NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable
component number, which can vary. The unit’s display will show the applicable number as the last digit in the
code. For example, the F1S# code listed in this table will be displayed as F1S1 if the affected component is pump
1, F1S2 for pump 2, and so on.
Code Type Description Problem Cause Solution
System has a leak
or open valve that is
allowing unrestricted
flow.
Inspect system for leaks.
Pump is cavitating,
cycling without
restriction.
Verify that the pump
is being supplied with
material.
Viscosity of material is
too thin for nozzle size.
Reduce nozzle size to
create more restriction.
Reduce paint pressure to
lower the flow rate.
DA0# Alarm Exceeded
Maximum
Flow Pump
#
Pump was driven to
its maximum allowed
speed.
System pressure or
Flow Setpoint is too high
(causing the pump to
work too hard).
Reduce the pressure or
the Flow Setpoint.
No material in 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, fittings, and seals.
Inspect all valve seats
and needles for wear,
and replace worn piston
or throat seals.
DF0# Alarm No Stall Up
Pump #
Pump failed the stall
test; did not stall on the
upstroke.
Valve failure, seal failure,
worn rod or cylinder.
Replace inlet and outlet
valve and seal for
up stroke. Replace
piston and throat seals.
Replace rod and cylinder
as necessary.
DG0# Alarm No Stall
Down Pump
#
Pump failed the stall
test; did not stall on the
downstroke.
Valve failure, seal failure,
worn rod or cylinder.
Replace inlet and
outlet valve and seal
for down stroke. Replace
piston and throat seals.
Replace rod and cylinder
as necessary.
DH0# Alarm No Stall
Pump #
Pump failed the stall
test; did not stall on
either the upstroke or the
downstroke.
Valve failure, seal failure,
worn rod or cylinder.
Replace inlet and outlet
valve and seal for up and
down strokes. Replace
piston and throat seals.
Replace rod and cylinder
as necessary.
18 332709D

Troubleshooting
Code Type Description Problem Cause Solution
Not enough air is
supplied to the dosing
valves.
Ensure that at least 85
PSI is being supplied to
thedosingvalves.
DKD# Alarm Position
Failed
Pump #
Pump was unable to
reach it’s drive position.
Thepressureatthe
pump outlet is too high.
Check for an obstruction
downstream of the pump
that would increase
pressure. Ensure the
feed pressure is within
1/2 – 1/3 of the target
pressure.
DKF# Alarm Position
Overspeed
Pump #
Pump moved beyond it’s
drive position.
The pump was knocked
out of position.
Thereisnofluidpressure
at the outlet of the pump,
run the pump at a lower
pressure to fill the lines.
Check that the feed
pressure is not more
than 1/2 – 1/3 greater
than the target pressure.
EBH# Rec-
ord
Home
Complete
Pump #
Record of pump homing
is complete.
An indication on the
display that the pump
completed the home
function
No action required.
Pump dose valves did
not actuate.
Verify air pressure to
solenoid valves. Verify
the valves are actuating.
Motor could not drive
pumps and linear
actuator.
Verify motor is driving
the pump.
EF0# Alarm Timeout
Startup
Pump #
Pump tried but was not
able to move to the
home position within a
specified 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
position within a specified
amount of time.
Pump is filled with thick
paint and could not drive
piston to end of stroke.
Motor or drive is worn or
damaged.
Observe motor and drive
assembly to verify that
the motor is generating
force.
F1D# Alarm Flow Low Mix
Pump #
The Mix Unit was unable
to maintain it's target flow
rate.
There is a restriction
in the hose or gun that
is preventing the pump
from dispensing at it's
target rate.
Check for restrictions in
the hose along the entire
fluid path after the pump
andalsothatthegunis
triggered.
332709D 19

Troubleshooting
Code Type Description Problem Cause Solution
There is a restriction on
the outlet side of the
pump or color stack.
Make sure there are no
restrictions in the color
stack and that the dump
valve is actuating.
Thick viscosity paint
requires more pressure
to pump.
Increase non-mix
pressure if necessary
to create flow during the
fill function.
F1F# Alarm Flow Low Fill
Pump #
There has been no flow
or low flow during a pump
fill operation.
The pumps do not have
to move for the system to
build enough pressure to
meet the setpoint.
Increase non-mix
pressure if necessary
to create flow during the
fill function.
F1S# Alarm Flow Low
Purge Pump
#
There has been 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
system or the gun was
open when the system
went into Idle mode.
Verify there are no leaks
in the system. Make
sure the air flow switch
is actuating properly.
Do not trigger the gun
without atomizing air.
F8D1 Alarm Flow Not
Detected
No flow while mixing. Restriction in the outlet
side of the pump or color
stack.
Make sure there are no
restrictions in the system.
F9D# Alarm Flow
Unstable
Pump #
The pump flow rate
did not stabilize while
entering Idle mode.
Potential leak in the
system.
Check the system for
leaks and run manual
stall test.
20 332709D