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Graco ProMix PD3K Plus Operation

Graco ProMix PD3K Plus Operation

Proportioner for automatic spray applications
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Operation
ProMix® PD3K+
PD3K+ Proportioner
ProMix®
ProMix®
PD3K+
Automatic Spray
Automatic
Automatic
Spray Applications
Spray
Electronic positive
positive displacement
displacement proportioner
Electronic
Electronic
positive
displacement
Advanced Display
Display Module.
Module. For
Advanced
Advanced
Display
Module.
Important Safety
Safety Instructions
Important
Important
Safety
Read all warnings and instructions in this manual and in your
Installation and Repair/Parts manuals. Save these instructions.
See page 3 for model part numbers and
approvals information.
Proportioner for
Proportioner
Applications
Applications
proportioner for
for up
proportioner
for
For professional
professional use
use only.
For
professional
use
Instructions
Instructions
PROVEN QUALITY. LEADING TECHNOLOGY.
for
for
up to to to 4 4 4 - - - component
component materials.
materials. Automatic
up
component
materials.
only.
only.
3A6287E
Automatic system
system with
with
Automatic
system
with
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Summary of Contents for Graco ProMix PD3K Plus

  • Page 1 Operation ProMix® PD3K+ PD3K+ Proportioner Proportioner for ProMix® ProMix® PD3K+ Proportioner Automatic Automatic Spray Automatic Spray Applications Spray Applications Applications 3A6287E Electronic positive positive displacement displacement proportioner proportioner for for up up to to to 4 4 4 - - - component component materials.

  • Page 2: Table Of Contents

    Contents Contents Contents Related Manuals ..........3 Password Screen......... 67 System Screen 1 ......... 67 Models..............4 System Screen 2 ......... 68 Warnings ............. 7 System Screen 3 ......... 71 System Screen 4 ......... 72 Important Isocyanate (ISO) Information ....10 System Screen 5 .........

  • Page 3: Related Manuals

    Related Manuals Related Related Manuals Related Manuals Manuals Current manuals are available at www.graco.com. Manual Manual Manual No. Description Description Description Manual Manual No. Manual Description Description Description 332709 ProMix PD2K Proportioner for 333282 Color Change and Remote Mix Automatic Spray Applications, Manifold Kits, Instructions —...

  • Page 4: Models

    Models Models Models Models See Figs. 1–6 for component identification labels, including approval information and certification. Part Part Part No. Series Series Series Maximum Maximum Air Maximum Air Working Working Working Maximum Maximum Fluid Maximum Fluid Fluid Working Working Working Location Location Location of of of ProMix...
  • Page 5 Models Figure 3 Model AC2000 Identification Label Figure 4 Model AC0500 Identification Label Figure 5 Non-Intrinsically Safe Color Change Control (Accessory) Identification Label Figure 6 Intrinsically Safe Color Change Control (Accessory) Identification Label 3A6287E...
  • Page 6 Models Figure 7 Pump Expansion Kit (Accessory) Identification Label PART NO. DATE / SERIES RECOGNIZED COMPONENT SERIAL NO. 4003764 12-30 VDC Conforms to UL STD 508 4 AMP MAX Certified to CAN/CSA Type 1 ENCL STD C22.2 No. 14 Artwork No. U.S.

  • Page 7: Warnings

    Warnings Warnings 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 symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, 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.
  • Page 8 Warnings WARNING WARNING WARNING INTRINSIC SAFETY SAFETY INTRINSIC 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. •...
  • Page 9 Warnings WARNING WARNING WARNING PERSONAL PROTECTIVE PROTECTIVE EQUIPMENT EQUIPMENT PERSONAL 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: •...

  • Page 10: Important Isocyanate (Iso) Information

    Important Isocyanate (ISO) Information Important Isocyanate Isocyanate (ISO) (ISO) Information Information Important Important Isocyanate (ISO) Information Keep Keep Components Keep Components A A A and Components and B B B Separate Separate Separate Isocyanates (ISO) are catalysts used in two component materials.
  • Page 11 Important Isocyanate (ISO) Information Changing Materials Materials Changing Changing Materials NOTICE NOTICE 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. •...

  • Page 12: General Information

    General Information General Information Information General General Information • Reference numbers and letters in parentheses • To protect the screens from paints and solvents, in the text refer to numbers and letters in the clear-plastic protective shields (10 per pack) are illustrations.

  • Page 13: Advanced Display Module (Adm)

    6. The USB flash drive window automatically opens. If it does not, open the USB flash drive from within Windows® Explorer. 7. Open Graco folder. 8. Open system folder. If downloading data from more than one system, there will be more than one folder.

  • Page 14: Usb Upload Procedure

    NOTE: If the system configuration settings file was NOTE: NOTE: folder within the Graco folder. Each folder is installed, it is recommended to remove the file from labeled with the corresponding serial number of the UPLOAD folder on the USB flash drive. This will the ADM.

  • Page 15: Adm Keys And Indicators

    Advanced Display Module (ADM) ADM Keys Keys Keys and and Indicators Indicators Indicators NOTICE NOTICE NOTICE To prevent damage to the softkey buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails. Table 1 1 1 : : : ADM ADM Keys Keys and and Indicators...

  • Page 16: Soft Key Icons

    Advanced Display Module (ADM) Soft Key Key Icons Icons Soft Soft Icons The following icons appear in the ADM display, Function Function Function directly to the left or right of the soft key which activates that operation. NOTICE NOTICE NOTICE Press to stop all pumps Standby To prevent damage to the softkey buttons, do not...

  • Page 17: Navigating The Screens

    Advanced Display Module (ADM) Screen Icons Icons Screen Screen Icons Function Function Function As you move through the screens, you will notice Press to see QR Code for that icons are used frequently to simplify global system error. communication. The following descriptions explain what each icon represents.

  • Page 18: Pre-Operation Tasks

    Power On 1. Turn the AC Power Switch (P) ON (I = ON, Go through the Pre-Operation Checklist daily, before 0 = OFF). each use. 2. The Graco logo will display while the system Checklist ✔ ✔ ✔ Checklist Checklist initializes, followed by the Home screen.

  • Page 19: Flush Before Using Equipment

    Pre-Operation Tasks Flush Before Before Using Using Equipment Equipment Valve Settings Settings Flush Flush Before Using Equipment Valve Valve Settings The pump fluid section was tested with lightweight Dose valves and purge valves are factory set with the oil, which is left in the fluid passages to protect parts. hex nut (E) 1-1/4 turns out from fully closed.

  • Page 20: Pressure Relief Procedure

    Pressure Relief Procedure Pressure Relief Relief Procedure Procedure Pressure Pressure Relief Procedure With Color Color Change Change With With Color Change Follow the Pressure Pressure Relief Pressure Relief Relief Procedure Procedure Procedure whenever you see this symbol. NOTE: NOTE: The following procedure relieves all fluid and NOTE: air pressure in the system.

  • Page 21: Operation Using Advanced Display Module

    Operation Using Advanced Display Module (ADM) Operation Using Using Advanced Advanced Display Display Module Module (ADM) (ADM) Operation Operation Using Advanced Display Module (ADM) Prime and and Fill Fill the the System System Pre - - - Fill Fill the the Pump Pump Prime...

  • Page 22: Purging

    Operation Using Advanced Display Module (ADM) Purging Purging Purging Flush the the System System Flush Flush System To purge one color and fill with a new color, see Color Change, page Flush Flush Mixed Flush Mixed Mixed Material Material Material To avoid fire and explosion, always ground equipment and waste container.

  • Page 23: Shutdown

    Operation Using Advanced Display Module (ADM) Shutdown Shutdown Shutdown Color Color Color Change Change Change System System System 1. Relieve the pressure. 1. Flush out the mixed material to avoid potlife errors Pressure Relief Procedure, page and fluid setup in the lines. See Purging, page 2.

  • Page 24: Operation Using A Programmable Logic

    System Screen 6, page 73 on the mode of control. Graco recommends that Manual ADM. If it is set to ‘Network’ the discrete input Override be disabled during normal operation to is ignored and the spray device trigger signal is avoid driving the system in a way that conflicts with handled via the network communications.
  • Page 25 Operation Using a Programmable Logic Controller (PLC) 4–20 mA mA Flow Flow Control Control Set Set Point Point Input Input 4–20 4–20 Flow Control Point Input Figure 12 O = Output → EFCM pin 1 R = Return → EFCM pin 2 PD3K+ Discrete Input PLC (4–20 MA Signal) Discrete...

  • Page 26: Details

    Operation Using a Programmable Logic Controller (PLC) Communication Gateway Gateway Module Module (CGM) (CGM) Details Details Communication Communication Gateway Module (CGM) Details CGM Overview Overview Overview Installation Installation Installation Kit Part No. Field Bus Manual Part Part Field Field Manual Manual The CGM provides a control link between the PD3K+ system and a selected fieldbus.

  • Page 27: Network Communication I/O Data Map

    Operation Using a Programmable Logic Controller (PLC) Network Communication Communication I/O I/O Data Data Map Network Network Communication Data The PD3K+ has PLC Diagnostic Screens built into the software that assist in the system integration process. See Setup Mode Screens, page ProMix PD3K+ PD3K+ Network Network Outputs...
  • Page 28 Operation Using a Programmable Logic Controller (PLC) OUTPUT OUTPUT OUTPUT REGISTER REGISTER 01: REGISTER 01: Event Event Event Flag Flag Flag OUTPUT OUTPUT REGISTER OUTPUT REGISTER REGISTER 10: 10: Gun Gun Trigger Trigger Input Trigger Input Input Status Status Status The Event Flag register indicates a system error has The Gun Trigger Input Status register contains the occurred that requires user acknowledgment.
  • Page 29 Operation Using a Programmable Logic Controller (PLC) OUTPUT OUTPUT OUTPUT REGISTER REGISTER REGISTER 15: 15: Safety Safety Interlock Safety Interlock Input Interlock Input Input OUTPUT OUTPUT REGISTER OUTPUT REGISTER REGISTER 19: 19: Active Active Recipe Active Recipe Material Recipe Material Material C C C Status Status...
  • Page 30 Operation Using a Programmable Logic Controller (PLC) OUTPUT OUTPUT OUTPUT REGISTERS REGISTERS REGISTERS 25, 25, 26, 26, 27, 27, and and 28: 28: Pump Pump Pump OUTPUT OUTPUT REGISTER OUTPUT REGISTER REGISTER 29: 29: Actual Actual Pump Actual Pump 1 1 1 Flow Pump Flow Flow Rate...
  • Page 31 Operation Using a Programmable Logic Controller (PLC) Network Output Output Data Data Map Map (Read (Read Only) Only) Network Network Output Data (Read Only) Network Network Network Modbus Modbus Modbus Parameter Parameter Parameter Name Name Name Data Data Data Type Type Type Units...
  • Page 32 Operation Using a Programmable Logic Controller (PLC) Network Modbus Parameter Name Name Data Type Type Units Range Network Network Modbus Modbus Parameter Parameter Name Data Data Type Units Units Range Range Output Output Output ID ID ID Register Register Register 0005 41010 Actual Mix Ratio...
  • Page 33 Operation Using a Programmable Logic Controller (PLC) Network Network Network Modbus Modbus Modbus Parameter Parameter Parameter Name Name Name Data Data Data Type Type Type Units Units Units Range Range Range Output Output Output ID ID ID Register Register Register 0026 41052 uint32...
  • Page 34 Operation Using a Programmable Logic Controller (PLC) ProMix ProMix PD3K+ ProMix PD3K+ Network PD3K+ Network Inputs Network Inputs Inputs The ProMix PD3K+ Network Inputs are Write-Read capable, but should be treated as outputs from a PLC or other networking device. These registers allow the user to control system operation and configure system settings remotely. Invalid values (i.e.
  • Page 35 Operation Using a Programmable Logic Controller (PLC) INPUT INPUT INPUT REGISTER REGISTER 03: REGISTER 03: Mix Mix Control Control Set Control Set Point Point Point INPUT INPUT REGISTER INPUT REGISTER REGISTER 05: 05: Pump Pump Pump Flush Flush Sequence/Prime Flush Sequence/Prime Sequence/Prime Material...
  • Page 36 See Digital Inputs, page Dynamic Command Description, page NOTE: NOTE: Because timing is so critical for flow control, NOTE: Graco recommends that users provide a discrete input to minimize latency effects. 3A6287E...
  • Page 37 Operation Using a Programmable Logic Controller (PLC) Network Input Input Data Data Map Map (Write/Read) (Write/Read) Network Network Input Data (Write/Read) Network Network Network Modbus Modbus Modbus Parameter Parameter Name Parameter Name Name Data Data Data Units Units Units Range Range Range Input...
  • Page 38 Operation Using a Programmable Logic Controller (PLC) Network Network Network Modbus Modbus Modbus Parameter Parameter Parameter Name Name Name Data Data Data Units Units Units Range Range Range Input Input Input ID ID ID Register Register Register Type Type Type 0010 42100 uint32...

  • Page 39: Operation Flow Charts

    Operation Using a Programmable Logic Controller (PLC) Operation Flow Flow Charts Charts Operation Operation Flow Charts Purge Purge Purge Mode Mode Sequence Mode Sequence Sequence Purge A System Command NOTE: Purge B, C, and D Write ‘6’ to Input Re gis te r 00 command works similarly with solvent flow switch 2, 3, and 4.
  • Page 40 Operation Using a Programmable Logic Controller (PLC) Purge Recipe Recipe Sequence Sequence Purge Purge Recipe Sequence System Command Write ‘11’ to Input Re gis te r 00 No action taken. Either pumps are currently Is system in Standby running or an alarm condition or Pumps Of f? exists.
  • Page 41 Operation Using a Programmable Logic Controller (PLC) Inactive Pump Pump Flush Flush and and Prime Prime Sequences Sequences Inactive Inactive Pump Flush Prime Sequences Write Flush Sequence # Write Prime Material # (1-10) to Input Register 05 (1-54) to Input Register 05 NOTE: Be sure to read to appropriate Output Register* Write...
  • Page 42 Operation Using a Programmable Logic Controller (PLC) Line Fill Fill and and Flush Flush Sequences Sequences Line Line Fill Flush Sequences Write Material # Write Material # (1 - 54) to Input Register 05 (1 - 54) to Input Register 05 Write Line Flush Command Write Line Fill Command ‘10’...
  • Page 43 Operation Using a Programmable Logic Controller (PLC) Color Change Change Sequence Sequence Color Color Change Sequence NOTE: If the Inlet st ack is set t o S ingle , the Ma te ria l Re a dy fla g ne e ds to be s e t prior to s ta rting a re cipe cha nge .
  • Page 44 Operation Using a Programmable Logic Controller (PLC) Recipe Change Change Alarm Alarm Recovery Recovery Sequences Sequences Recipe Recipe Change Alarm Recovery Sequences Read Status of Output Register 00 Output Register 00 = Output Register 00 = Output Register 00 = Output Register 00 = ‘19’? ‘20’?
  • Page 45 Operation Using a Programmable Logic Controller (PLC) Mixing Mixing Sequence Mixing Sequence Sequence Mix Fill or Mix System Command W rite ‘4’ or ‘5’ to Input Register 00 System Mode = Standby: Mix Ready (Output Register 00 = ‘11’) No action taken. System is not in valid System Mode = System Mode = Mix...
  • Page 46 Operation Using a Programmable Logic Controller (PLC) Alarm Clearing Clearing Sequence Sequence Alarm Alarm Clearing Sequence NOTE: Some alarms put the system in Standby , more serious alarms shut the pumps down. If Clear Active Alarm an alarm condition is active the Write ‘1’...

  • Page 47: Command Structure (Dcs)

    Operation Using a Programmable Logic Controller (PLC) Network Communication Communication - - - Dynamic Dynamic Command Command Structure Structure (DCS) (DCS) Network Network Communication Dynamic Command Structure (DCS) Dynamic Dynamic Dynamic Command Command Command Description Description Description The Dynamic Command Structure (DCS) is used to 1) access data that requires some form of argument(s) or 2) consolidate data that requires multiple registers.
  • Page 48 Operation Using a Programmable Logic Controller (PLC) List of of of DCS DCS Commands Commands List List Commands Table Table Table 5 5 5 Dynamic Dynamic Commands Dynamic Commands with Commands with with Command Command ID ID ID Command ID ID ID Command Command Command...
  • Page 49 Operation Using a Programmable Logic Controller (PLC) Write Recipe Recipe Write Write Recipe The Write Recipe command allows users to configure component selections of a recipe remotely. See Recipe Screen 1, page 76, for more details on recipes and recipe parameters. The return registers will echo the arguments received.
  • Page 50 Operation Using a Programmable Logic Controller (PLC) Write Material Material Ready Ready Flag Flag Write Write Material Ready Flag The Write Material Ready Flag command is used to signal to the PD3K+ that the upstream material management has the appropriate component loaded at the inlet valve stack(s) of the pump(s) prior to a recipe change. This flag is only used when multiple materials for a pump are fed to the PD3K+ via a single valve at the inlet valve stack (i.e.
  • Page 51 Operation Using a Programmable Logic Controller (PLC) Read Recipe Recipe Read Read Recipe The Read Recipe command returns component selections for a desired recipe number. The number of the recipe to be read is the only argument. Example: Read Recipe 5 data as it is currently configured with Component A = 3, Component B = 2 (32), Component C = 1 (39).
  • Page 52 Operation Using a Programmable Logic Controller (PLC) Read Job Job Info Info Read Read Info The Read Job Info command is used to access data from any of the most recent 200 job logs. The argument is the chronological index of the job log, where 0 is the most recent job log and 199 is the 200 most recent.
  • Page 53 Operation Using a Programmable Logic Controller (PLC) Read Alarm Alarm Info Info Read Read Alarm Info The Read Alarm Info command allows remote access to any of the last 200 alarms logged by the ProMix PD3K+. The chronological index argument is the of the alarm log, where 0 is the most recent alarm and 199 is the 200 most recent.
  • Page 54 Operation Using a Programmable Logic Controller (PLC) Read Event Event Info Info Read Read Event Info The Read Event Info command allows remote access to any of the last 200 events logged by the ProMix PD3K+. chronological index The argument is the of the events log, where 0 is the most recent event and 199 is the 200 most recent.
  • Page 55 Operation Using a Programmable Logic Controller (PLC) Read Pump Pump Material Material Read Read Pump Material The Read Pump Material command returns the material number of the color or catalyst that is currently loaded in a user-specified pump. NOTE: This command will return ‘0’ if the pump is filled with solvent, or ‘61’ if the material is unknown. NOTE: NOTE: Example: Read what material is loaded in pump 1, which is currently color 2.
  • Page 56 Operation Using a Programmable Logic Controller (PLC) Read Grand Grand Totals Totals Read Read Grand Totals The Read Grand Totals command allows remote access to the material grand total volume data. No arguments are necessary for this command. Example: Read current Grand Total usage data. A = 132 gal, B = 128 gal, , C = 24 gal, D = 0 gal, A+B+C+D = 320 gal, Solvent = 11 gal DCS Register Register...

  • Page 57: Plc Diagnostic Screens

    Operation Using a Programmable Logic Controller (PLC) PLC Diagnostic Diagnostic Screens Screens Diagnostic Screens PLC Diagnostic Diagnostic Screens Diagnostic Screens 8 8 8 Screens These screens may be used to verify PLC communications by providing a real-time status of all Network Inputs and Outputs.

  • Page 58: Flow Control System

    The flow control system continually Point. monitors the desired outlet pressure compared to the actual outlet pressure. If the actual pressure remains NOTE: These inputs are timing critical. Graco NOTE: NOTE: 50% higher than the desired pressure for longer than...

  • Page 59: Run Mode Screens

    NOTE: grayed-out on the screens are not currently active. Opening Opening Screen Opening Screen Screen At power up, the Graco logo will display for approximately 5 seconds, followed by the Home screen. Figure 19 Opening Screen Home Screen Screen Home...
  • Page 60 Run Mode Screens Home Screen Screen Key Home Home Screen Description Details Description Description Details Details Date and Time Advanced Screen 1, page 91, to set. Menu Bar Run Screens. Use left and right arrow keys to scroll through the different Run screens: •...
  • Page 61 Run Mode Screens Description Description Description Details Details Details Spray Device Animation Shows mixed material in the spray device and displays active recipe at the spray device. Gun animation changes to show: NOTE: If the fluid stream has more than one mix manifold (maximum NOTE: NOTE: three), during Mix Fill, the stage numbers will be shown underneath the...

  • Page 62: Spray Screen

    Run Mode Screens Spray Screen Screen Spray Spray Screen NOTE: NOTE: NOTE: In normal operating mode, controlled by a PLC, the Spray Screen is display only. No changes can be made. This section provides information about the Spray Screen if manual override is enabled System Screen 6, page 73.

  • Page 63: Fill Screen

    Run Mode Screens Fill Screen Screen Fill Fill Screen NOTE: NOTE: NOTE: This screen is visible only if manual override is enabled on System Screen 6, page The Fill screen displays the following information for the pump assigned to the current component: •...

  • Page 64: Potlife Screen

    Run Mode Screens Potlife Screen Screen Potlife Potlife Screen The Potlife screen displays the current remaining potlife time of any mixed materials in the system. Each mixing stage (if more than one) will be shown with the recipe number that is currently loaded and the remaining potlife.

  • Page 65: Usage Screen

    Run Mode Screens Usage Screen Screen Usage Usage Screen The first two Usage screens display the current job usage and grand total usage of component A, B, C, D, A+B+C(+D), and solvent (S). Edits may be made only if manual override is enabled on System Screen 6, page 73.

  • Page 66: Jobs Screen

    Run Mode Screens Jobs Screen Screen Jobs Jobs Screen Additional information is available for system errors to assist with troubleshooting. To access this information for a system error that has occurred, first The Jobs screen displays the 200 most recent job numbers, recipes, and A+B+C(+D) volumes in a log, press to enter edit mode;...

  • Page 67: Setup Mode Screens

    Setup Mode Screens Setup Mode Mode Screens Screens Setup Setup Mode Screens Diagnostic Diagnostic Mode Diagnostic Mode Mode Press on any Run screen to enter the Setup screens. Select this box to display flow rate and pressure for each pump on the Home Screen, page NOTE: Selection fields and buttons that are NOTE:...

  • Page 68: System Screen 2

    Setup Mode Screens System Screen Screen 2 2 2 System System Screen System screen 2 sets the following system operating quickly fluid dynamics balance, which may result in parameters. nuisance Exceed Max Flow or Differential Pressure mixing alarms. The Mix Balance Interval set point may be used to enable a brief period at the start of a mix cycle for fluids to balance before generating any mixing alarms.
  • Page 69 Setup Mode Screens NOTE: NOTE: NOTE: The solvent push feature is only available for Flow Mode fluid control systems with single outlet color change valve configurations (see Custom Valve Mapping, page 84). The check box is only visible if the system is configured in this way.
  • Page 70 Setup Mode Screens Mix Volume Volume Percent Percent Volume Percent If needed, solvent may be pushed past the mix manifold and into the mix hose, or manifolds and hoses if multiple stages. To prevent atomizing If using an electrostatic gun, to reduce the risk solvent, it may only be dispensed to a percent of the of fire and explosion, confirm the mix hose total mix hose volume.

  • Page 71: System Screen 3

    Setup Mode Screens System Screen Screen 3 3 3 System System Screen Stall Stall Test Stall Test Pressure Test Pressure Pressure System screen 3 sets the following system operating parameters. Set the minimum stall test pressure. The setting should be approximately 50 psi (0.35 MPa, 3.5 bar) higher than the highest inlet pressure.

  • Page 72: System Screen 4

    Setup Mode Screens System Screen Screen 4 4 4 System System Screen NOTE: NOTE: The Gun NOTE: Gun selection field becomes enabled when the Number Number Number of of of Guns Guns Guns field is set to a value that is greater than 1.

  • Page 73: System Screen 5

    Setup Mode Screens System Screen Screen 5 5 5 System Screen Screen 6 6 6 System System Screen System System Screen System screen 5 sets the following system operating System screen 6 sets the following system operating parameters. parameters. Figure 45 System Screen 5 Figure 46 System Screen 6 Stage Stage...

  • Page 74: System Screen 7

    Setup Mode Screens System Screen Screen 7 7 7 System System Screen • Network — the signal is sent via a PC, PLC, or other networked device. System screen 7 sets the following system operating • Recipe — flow rate or pressure is set according to parameters.

  • Page 75: Gateway Screen

    Setup Mode Screens Gateway Screen Screen Gateway Gateway Screen Enable Enable Enable Uncheck Enable while setting the IP Address, Subnet System screen 4 sets the following system operating mask, Gateway, DNS1 or DNS2. When the settings parameters. are loaded, check the Enable box to write the new settings to the selected Gateway.

  • Page 76: Recipe Screen 1

    Setup Mode Screens Recipe Screen Screen 1 1 1 Recipe Recipe Screen Figure 49 Valid Recipe Screen 1 Figure 50 Invalid Recipe Screen Drive Pump Pump Drive Drive Pump Recipe Recipe Recipe Select the component pump that will be driving Enter the desired recipe number (1-40).

  • Page 77: Recipe Screen 2

    Setup Mode Screens Recipe Screen Screen 2 2 2 Recipe Recipe Screen Flush Sequence Sequence Flush Flush Sequence Enter the desired flush sequence (1-10). For hard to flush colors, select a longer sequence. The flush sequence applies only to cleaning of the pumps. Each component pump used in the recipe that has color change may have a unique flush sequence assigned.

  • Page 78: Recipe Screen 3

    Setup Mode Screens Recipe Screen Screen 3 3 3 Recipe Recipe Screen notifies the user of potential mix ratio inaccuracies while avoiding nuisance alarms. It is recommended that, once the system is fully installed and ready to use, the user load a recipe and then spray the mixed material.

  • Page 79: Flush Screen

    Setup Mode Screens Flush Screen Screen Flush Flush Screen Initial Flush Flush Initial Initial Flush Enter the initial flush volume (0 to 9999 cc). Wash Cycles Cycles Wash Wash Cycles A Wash Cycle activates the pump with the valves closed, to use pumping motion to thoroughly clean the pump.

  • Page 80: Purge Screen

    Setup Mode Screens Purge Screen Screen Purge Purge Screen Gun Purge Purge Time Time Purge Time Enter the gun purge time (0 to 999 seconds). Air/Solvent Chop Chop Air/Solvent Air/Solvent Chop Air/Solvent Chop replaces the standard Gun Purge Time parameter on the Purge screen. Instead the purge is split into three phases: First Purge, Chop, and Final Purge.

  • Page 81: Pump Screen 1

    Setup Mode Screens Pump Screen Screen 1 1 1 Pump Pump Screen Inlet Inlet Pressure Inlet Pressure Pressure NOTE: NOTE: NOTE: Your system may include 2, 3, or 4 pumps. Information for each pump is accessible under a Select one of the following: separate tab in the menu bar at the top of the screen.

  • Page 82: Pump Screen 2

    Setup Mode Screens Pump Screen Screen 2 2 2 Pump Pump Screen Default Default Settings Default Settings Settings Selected Selected Selected Pump screen 2 sets the pressure transducer settings for the pump. When the “Use Default Settings” box is selected, default settings are used for the calibration values, and the fields are grayed out.

  • Page 83: Pump Screen 3

    Setup Mode Screens Pump Screen Screen 3 3 3 Pump Screen Screen - - - Material Material Assignment Assignment Pump Pump Screen Pump Pump Screen Material Assignment Pump screen 3 sets the pressure alarm limits for the For systems using Multiple Guns, see pump.

  • Page 84: Custom Valve Mapping

    Setup Mode Screens Custom Valve Valve Mapping Mapping Custom Custom Valve Mapping For the PD3K+, every color change solenoid may be Pump Pump Air Pump Air Purge Purge Purge assigned to any unique, valid control module location. Select Enable to add an air purge valve to the pump inlet stack to allow for an air/solvent chop flush of the pump out the dump valve.
  • Page 85 Setup Mode Screens Pump Screen Screen - - - Valve Valve Assignment Assignment Pump Pump Screen Valve Assignment This screen allows the user to assign each individual color change valve solenoid in the system to a unique location. The list of valves will automatically populate based on the settings that apply to the pump.
  • Page 86 Setup Mode Screens If more than one valve is assigned a valid solenoid location, all instances of that location will be highlighted in red, and are considered invalid. Figure 68 Recipe Screen with invalid component valve location Figure 67 Pump Screen, Valve Assignment with duplicates A value of 0 for the control module, or 00 for the solenoid, indicates no previous location assignment...

  • Page 87: Calibration Screens

    Setup Mode Screens Calibration Screens Screens Calibration Calibration Screens Calibrate Calibrate Calibrate Screen Screen 1 1 1 Screen Calibrate Calibrate Screen Calibrate Screen 2 2 2 Screen Calibrate Screen 1 initiates a pump pressure check Calibrate Screen 2 initiates a volume test for the (stall test) for the selected pump.
  • Page 88 Setup Mode Screens Calibrate Screen Screen 3 3 3 Calibrate Calibrate Screen Calibrate Screen 3 initiates a calibration of an accessory solvent meter. During the test, the Volume Verification screen will appear. The meter and lines must be primed with solvent before doing the calibration.

  • Page 89: Maintenance Screens

    Setup Mode Screens Maintenance Screens Screens Maintenance Maintenance Screens Maintenance Maintenance Maintenance Screen Screen Screen 1 1 1 Maintenance Maintenance Screen Maintenance Screen 3 3 3 Screen Use this screen to set maintenance intervals. Set Maintenance screen 3 shows the current interval to 0 to disable the alarm.
  • Page 90 Setup Mode Screens Maintenance Screen Screen 4 4 4 Maintenance Screen Screen 5 5 5 Maintenance Maintenance Screen Maintenance Maintenance Screen Maintenance screen 4 is used to manually relieve Maintenance screen 5 displays cycle counts for a pump outlet pressure, or to configure automatic selected component, or solvent valve.

  • Page 91: Advanced Screen 1

    Setup Mode Screens Advanced Screen Screen 1 1 1 Advanced Advanced Screen Date Date Format Date Format Format Advanced screen 1 sets the following display parameters. Select mm/dd/yy, dd/mm/yy, or yy/mm/dd. Date Date Date Enter the date, using the format selected. Use two digits for the month, day, and year.

  • Page 92: Advanced Screen 2

    Setup Mode Screens Advanced Screen Screen 2 2 2 Advanced Advanced Screen Enable USB USB Downloads/Uploads Downloads/Uploads Enable Enable Downloads/Uploads Select this box to enable USB downloads and Advanced screen 2 sets display units (US or metric). uploads. Enabling USB activates the Download Depth field.

  • Page 93: Diagnostic Screens

    Setup Mode Screens Diagnostic Screens Screens Diagnostic Diagnostic Screens Diagnostic Diagnostic Diagnostic Screen Screen Screen 1 1 1 Diagnostic Diagnostic Screens Diagnostic Screens 3–10 Screens 3–10 3–10 Figure 87 Diagnostic Screen 1 Figure 89 Diagnostic Screen 3–10 Use this screen to test and verify proper wiring for Diagnostic screens 3–10 are only available for color all inputs to the EFCM.

  • Page 94: Calibration Checks

    Calibration Checks Calibration Checks Checks Calibration Calibration Checks Pump Pump Pressure Pump Pressure Check Pressure Check Check NOTE: Enter the transducer calibration data before NOTE: NOTE: 2. If the display is on a Run Mode screen, press doing the pressure check. to access setup screens.

  • Page 95: Pump Volume Check

    Calibration Checks Pump Volume Volume Check Check Solvent Meter Meter Calibration Calibration Pump Pump Volume Check Solvent Solvent Meter Calibration 1. The meter and lines must be primed with solvent 1. The pump and lines must be primed with a before doing the calibration.

  • Page 96: Color Change

    Color Change Color Change Change Color Color Change 6. Trigger the gun to complete the Mix Fill. NOTE: NOTE: NOTE: There is a 10 second delay without flow before the system will fault. 7. Wait for the system to complete the Mix Fill operation.

  • Page 97: System Errors

    There are three types: with internet access and a QR reader may use Advisory, Deviation, and Alarm. the QR code to access additional information on a webpage hosted by help.graco.com. Advisory records an event in the system, and will An Advisory Advisory clear itself after 60 seconds.

  • Page 98: To Clear Error And Restart

    System Errors To Clear Clear Error Error and and Restart Restart Gun Trigger Trigger Input Input Function Function Clear Error Restart Trigger Input Function NOTE: NOTE: NOTE: When a deviation or alarm occurs, be The Gun Trigger Input signals the controller when sure to determine the error code before resetting the gun is triggered.

  • Page 99: Error Codes

    System Errors Error Codes Codes Error Error Codes NOTE: NOTE: NOTE: When an error occurs be sure to determine the code before resetting it. If you forget which code occurred, use Errors Screen, page 66, to view the last 200 errors, with date, time, and description. Purge Errors Errors Purge...
  • Page 100 System Errors Mix Errors Errors Errors Code Type Description Problem Cause Solution Code Code Type Type Description Description Problem Problem Cause Cause Solution Solution F7S1 Alarm Flow The solvent flow switch Solvent flow switch is Clean or replace switch. Detected is indicating unexpected stuck in flow position.
  • Page 101 System Errors Pumping Pumping Pumping Errors Errors Errors NOTE: NOTE: 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.
  • Page 102 System Errors Code Type Description Problem Cause Solution Code Code Type Type Description Description Problem Problem Cause Cause Solution Solution DKD# Alarm Position Pump was unable to Not enough air is Ensure that at least 85 Failed Pump reach its drive position. supplied to the dosing PSI is being supplied to valves.
  • Page 103 System Errors Code Type Type Type Description Description Description Problem Problem Problem Cause Solution Code Code Cause Cause Solution Solution F1D# Alarm Flow Low Mix The pump was unable to There is a restriction Check that the gun Pump # maintain it's target flow in the hose or gun that is triggered and for...
  • Page 104 System Errors Pressure Errors Errors Pressure Pressure Errors NOTE: NOTE: 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.
  • Page 105 System Errors Code Type Type Type Description Description Description Problem Problem Problem Cause Solution Code Code Cause Cause Solution Solution QAB1 Differential Differential pressure There is a leak on the Check the system for Pressure A is low between driving second component side.
  • Page 106 System Errors Code Type Description Problem Cause Solution Code Code Type Type Description Description Problem Problem Cause Cause Solution Solution QDA1 Differential Differential pressure There is a leak on the Check the system for Pressure D is low between driving second component side.
  • Page 107 System Errors System System System Errors Errors Errors Code Code Code Type Type Type Description Description Description Problem Problem Problem Cause Cause Cause Solution Solution Solution EB00 Rec- Indicates system stop Stop Button Record of a stop button key on ADM was Pressed press.
  • Page 108 System Errors Communication Errors Errors Communication Communication Errors NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable NOTE: NOTE: component number, which can vary. The unit’s display will show the applicable number as the last digit in the code.
  • Page 109 System Errors USB Errors Errors Errors Code Code Code Type Type Type Description Description Description Problem Problem Problem Cause Cause Cause Solution Solution Solution EAUX Advisory USB Busy USB drive is inserted, Indicates USB port Wait for USB Idle. download is in is uploading or progress.
  • Page 110 B9SX Advisory Volume Grand total counter for The totalizer has Rollover solvent rolled over. reached maximum Solvent capable value and Lifetime started over at zero. WX00 Alarm Software An unexpected Call Graco technical Errors software error has support. occurred. 3A6287E...
  • Page 111 System Errors Calibration Calibration Calibration Errors Errors Errors NOTE: NOTE: 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.
  • Page 112 System Errors Maintenance Errors Errors Maintenance Maintenance Errors NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable NOTE: NOTE: component number, which can vary. For example, the MAD# code listed in this table will be displayed as MAD1 if the affected component is pump 1, MAD2 for pump 2, and so on.
  • Page 113 System Errors Alphanumeric Alphanumeric Alphanumeric Last Last Digits Last Digits Digits Alphanumeric Alphanumeric Alphanumeric Digit Digit Digit Component Component Component Number Number Number Alphanumeric Alphanumeric Digit Alphanumeric Digit Digit Component Component Number Component Number Number 3A6287E...

  • Page 114: Maintenance

    Maintenance Maintenance Maintenance Maintenance Preventive Maintenance Maintenance Schedule Schedule Cleaning the the ADM Preventive Preventive Maintenance Schedule Cleaning Cleaning The operating conditions of your particular system Use any alcohol-based household cleaner, such as determine how often maintenance is required. glass cleaner, to clean the ADM. Establish a preventive maintenance schedule by recording when and what kind of maintenance is needed, and then determine a regular schedule for...

  • Page 115: Appendix A: Integration With Allen Bradley

    This appendix outlines how to integrate a ProMix PD3K+ with an Allen Bradley Studio 5000 Programmable Logic Controller (PLC). To integrate, the ProMix PD3K+ must have the Ethernet/IP protocol for PLC CGM (Graco Part number CGMEPO) installed prior to performing this procedure.
  • Page 116 Ethernet directory shown by the figure in step 1). b. Description (optional): Use any description desired. c. IP Address (required): Enter the static IP address of the Graco EtherNet/IP CGM installed in the ProMix PD3K+. d. Input: Assembly Instance (required): Enter “100”, which is a device-specific parameter for the Graco EtherNet/IP CGM.
  • Page 117 Enter a Requested Packet Interval (RPI) value. NOTE: NOTE: NOTE: Graco recommends a value of 50 ms or greater. b. If desired, select the available checkboxes. c. Click the OK button to save all changes and exit this screen.

  • Page 118: Appendix B: Multiple Guns

    Appendix B: Multiple Guns Appendix B: B: B: Multiple Multiple Guns Guns Appendix Appendix Multiple Guns A ProMix PD3K+ Automatic system normally exceed eight. To configure a component as common Common box operates with a single spray device, but may be to multiple spray devices, check the Common Common configured to used multiple (up to three maximum)

  • Page 119: Spray Screen

    Appendix B: Multiple Guns Spray Screen Screen Fill Screen Screen Spray Spray Screen Fill Fill Screen The Spray screen provides the same information The Fill screen operates the same as with a single and operating capabilities as with a single spray spray device (see Fill Screen, page 63).

  • Page 120: Maintenance Screen 5

    Appendix B: Multiple Guns Maintenance Screen Screen 5 5 5 Operation With With a a a PLC Maintenance Maintenance Screen Operation Operation With Color change valves may be manually overridden All spray devices defined for the system are required from Maintenance Screen 5 the same as with a single to have provided for them a unique gun trigger spray device (see Maintenance Screen 5, page...

  • Page 121: Technical Data

    Technical Data Technical Technical Data Technical Data Data Positive Displacement Displacement U.S. Metric Positive Positive Displacement U.S. U.S. Metric Metric Proportioner Proportioner Proportioner Maximum fluid working pressure: AC1000 Air Spray Systems 300 psi 2.1 MPa, 21 bar 1500 psi 10.5 MPa, 105 bar AC2000 Air-Assisted Spray Systems Maximum working air...
  • Page 122 Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations. This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts.

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