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332562B, ProMix PD2K Electronic Proportioner, Operation ...

332562B, ProMix PD2K Electronic Proportioner, Operation ...

Product catalog summary

Overview:
The ProMix® PD2K Electronic Proportioner is a manual system designed for the precise mixing of two-component materials, aimed at reducing waste. It features an Advanced Display Module (ADM) for professional use.

Important Safety Instructions:
Users must adhere to all safety warnings and instructions, including:

Fire and Explosion Hazard: Operate in well-ventilated areas, eliminate ignition sources, and ensure all equipment is grounded.
Electric Shock Hazard: Proper grounding is essential, and power should be disconnected before servicing.
Intrinsic Safety: Follow local regulations for hazardous locations and do not substitute system components.
Skin Injection Hazard: High-pressure fluids can cause serious injury; follow pressure relief procedures.
Moving Parts Hazard: Avoid contact with moving parts and ensure protective guards are in place.
Toxic Fluid or Fumes: Use appropriate personal protective equipment and handle materials according to MSDS guidelines.

Isocyanate (ISO) Information:
Isocyanates can create harmful mists and vapors. Adequate ventilation or supplied-air respirators are necessary. Prevent cross-contamination and moisture exposure to avoid equipment damage.

Operation:
Includes pre-operation checklists, system setup, spraying, purging, and shutdown procedures. Emphasizes the importance of flushing before use and following pressure relief procedures.

Advanced Display Module (ADM):
Details on navigating the ADM, including USB download/upload procedures, key functions, and screen navigation.

Maintenance:
Outlines preventive maintenance schedules, flushing, and cleaning procedures. Emphasizes the importance of using genuine replacement parts and following technical data specifications.

Technical Data:
Includes specifications for maximum air and fluid working pressures, and details on model identification labels.

Related Manuals:
Lists additional manuals for repair, installation, and parts instructions.

Component Identification and Definition:
The system includes several key components:

Electrical Control Box: Houses the Enhanced Fluid Control Module (EFCM), power supplies, solenoid valves, and other control elements.
Fluid Components: Include mix manifold, color/catalyst valve stacks, pumps, and pressure transducers.
Advanced Display Module (ADM): Used for setup, operation, and monitoring, located in non-hazardous areas.
Booth Control: Used for daily operations, located in hazardous areas.

Glossary of Terms:
Defines key terms such as Advanced Display Module (ADM), Enhanced Fluid Control Module (EFCM), Intrinsically Safe (IS), and Potlife Time.

Installation and Operation:
Outlines typical installations for different models and describes the operation of the ADM and booth control, including key functions and indicators for system management.

Keypad Functions:

Up Key: Scrolls recipe numbers and pressure values up.
Down Key: Scrolls recipe numbers and pressure values down.
Enter Key: Selects recipe and starts color change sequence; accepts pressure value change.

Pre-operation Checklist:

Ensure system is grounded and all connections are tight and correct.
Check fluid supply containers and dose valves settings.
Set fluid supply pressures appropriately.
Flush equipment with compatible solvent before use.

Power On Procedure:

Turn on AC power switch.
Wait for system initialization and press Start key to change status to Standby.

Initial System Setup:

Adjust setup selections and set recipe and flush information.
Prime and fill the system, ensuring proper air pressure and purging if necessary.

Spraying Procedure:

Set mix manifold to SPRAY position and press Mix to load material.
Adjust flow rate by changing target pressure.
Turn on atomizing air and check spray pattern.

Purging and Flushing:

Follow purging procedure to change colors or flush mixed material.
Flush system before first use, servicing, or storage.

Pressure Relief Procedure:

Turn off supply pumps and relieve pressure by triggering the gun.
Follow specific steps for systems with or without color change.

Valve Settings and Shutdown:

Adjust dose and purge valves as needed.
Flush mixed material and follow pressure relief procedure before shutdown.

Run Mode Screens:

Home Screen displays system status, pump flow rates, and pressures.
Spray Screen shows active recipe, target ratio, and actual ratio.

Spray Screen Modes: The spray system operates in different modes such as Standby, Mix, and Idle. Each mode displays critical information like target pressure, actual pressure, flow, potlife remaining, and gun animation.

Run Mode Screens:

Fill Screen: Allows selection of material (Color, Catalyst, Solvent) and includes options for flushing lines. Instructions for priming and filling the system are provided.
Usage Screen: Displays job usage and total usage of components. Users can log jobs and manage user IDs.
Jobs Screen: Logs the 200 most recent jobs with details like job numbers, recipes, and volumes.
Errors and Events Screens: Log the 200 most recent error and event codes with descriptions.

Setup Mode Screens:

Password Screen: Requires a 4-digit password to access setup screens.
System Screens: Configure system parameters such as pump numbers, pressure settings, solvent meter, and autodump functions. Includes diagnostic mode and settings for multiple guns.
Recipe Screen: Manage recipes, including mix ratios, potlife time, and pressure limits. Allows flushing of systems and purging of guns.
Flush Screen: Configure flush sequences, gun purge times, and wash cycles to ensure thorough cleaning.
Pump Screens: Define pump characteristics like size, inlet pressure, and valve mapping. Supports multiple pumps with individual settings.

Key Parameters and Recommendations:

Mix Pressure Tolerance: Default is 75%.
Mix Idle and No Flow Timeout: Default is 5 seconds.
Stall Test Pressure: Should be 50 psi higher than the highest inlet pressure.
Mix Fill Set Point: Used to decrease fill time, default is 0.
Multiple Guns Feature: Tracks pot life for up to 60 guns.
Flush Sequences: Longer sequences for hard-to-flush colors.

Setup Mode Screens:

Pump Screen 2: Configures pressure transducer settings. Default settings can be used or custom calibration values entered. Invalid entries revert to defaults.
Pump Screen 3: Sets pressure alarm limits. Inlet fields are active only if monitoring is enabled. Alarm ranges vary by system pressure.
Calibrate Screens: Initiate tests for pump pressure, volume, and solvent meter calibration. Priming is required before tests. Results are compared to expected values for accuracy.
Maintenance Screens: Set and view maintenance intervals and statuses for various components. Alarms can be reset, but some tests cannot be disabled.
Advanced Screens: Configure display settings, including language, date/time format, and units. USB data management and software version information are also available.

Calibration Checks:

Pump Pressure Check: Conducted during initial setup, material changes, monthly maintenance, or after pump service. Ensures valves are not leaking.
Pump Volume Check: Verifies dispensed volume accuracy using a gravimetric method. Discrepancies require test repetition.
Solvent Meter Calibration: Adjusts the K-factor based on measured solvent volume. Accurate calibration requires proper line pressure and no air presence.

Color Change Procedures:

Single Color Systems: Follow flushing and priming procedures before loading new color.
Multiple Color Systems: Involves standby mode, manifold flushing, and recipe selection. Ensures proper color change and system readiness.

System Errors:

Errors are categorized as Advisory, Deviation, or Alarm. Each type has specific responses and logging procedures. Alarms require cause correction before resuming operations.
Air Flow Switch (AFS): Monitors air flow to prevent continuous spraying in case of pump failure.

System Overview: The document provides a comprehensive guide on system errors, focusing on error codes, their descriptions, causes, and solutions. It covers various types of errors including purge, mix, pumping, pressure, communication, USB, and miscellaneous errors.

Purge Errors: These errors are related to the air and solvent flow switches. Common issues include stuck switches, leaks, and insufficient solvent flow. Solutions involve cleaning or replacing switches, checking for leaks, and adjusting pressure settings.

Mix Errors: These errors occur during the mixing process, often due to solvent flow issues or incomplete purge processes. Solutions include ensuring proper manifold settings and verifying solvent supply.

Pumping Errors: These errors involve issues with pump operation, such as leaks, cavitation, and pressure problems. Solutions include inspecting for leaks, adjusting pressure settings, and replacing worn components.

Pressure Errors: These errors are related to pressure transducers and involve issues like low or high pressure at the inlet or outlet. Solutions include verifying transducer connections and adjusting pressure settings.

Communication Errors: These errors occur when the system loses communication with modules like the Advanced Display Module (ADM) or Color Change Module. Solutions involve checking and replacing CAN cables as necessary.

USB Errors: These errors involve issues with USB data transfer, such as busy ports or configuration errors. Solutions include waiting for processes to complete and ensuring compatible USB devices are used.

Miscellaneous Errors: This section includes various other errors not categorized elsewhere, with solutions typically involving system checks and component replacements.

Error Codes and Descriptions:
The document provides a detailed list of error codes related to system operations, calibration, and maintenance. Each code is associated with a specific type of advisory or alarm, describing the issue and potential solutions. For example, codes like B9A0 and B9AX indicate volume rollover advisories for materials, while WX00 signals a software error requiring technical support.

Calibration and Maintenance:
Calibration errors are recorded with codes such as END# and ENT#, indicating tests run on pumps and solvent meters. Maintenance errors are flagged with codes like MAD# and MEB#, advising when maintenance is due on various components such as pumps and valves.

Preventive Maintenance:
The document emphasizes the importance of establishing a preventive maintenance schedule based on system operating conditions. It includes guidelines for flushing and cleaning procedures to ensure optimal performance.

Technical Data:
Technical specifications for the Positive Displacement Proportioner are provided, including maximum fluid working pressure, air supply requirements, mixing ratio range, and fluid compatibility. The document specifies the operating and storage temperature ranges, as well as the weight and sound data of the equipment.

Warranty Information:
Graco offers a twelve-month warranty from the date of sale, covering defects in material and workmanship. The warranty is conditional upon proper installation, operation, and maintenance. It excludes general wear and tear and damages caused by improper use or non-Graco components.

Contact Information:
For further assistance, Graco provides contact details for placing orders and obtaining product information. The document also notes that Graco reserves the right to make changes without notice and includes a disclaimer regarding the accuracy of the information at the time of publication.

Catalog excerpts

332562B, ProMix PD2K Electronic Proportioner, Operation ...-1

Positive displacement proportioning of 2-component materials helps reduce waste. Manual system with Advanced Display Module. For professional use only. Important Safety Instructions Read all warnings and instructions in this manual and in your PD2K Installation and Repair/Parts manuals. Save these instructions. See page 3 for model part numbers and approvals information. PROVEN QUALITY. LEADING TECHNOLOGY.

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332562B, ProMix PD2K Electronic Proportioner, Operation ...-3

See Figs. 1-7 for component identification labels, including approval information and certification. Maximum Fluid Working pressure pumps: With high- pressure pumps: Electronic Proportioner Intrinsically safe Intrinsically Safe (IS) System. Install location, with IS Connection to color change and booth control modules Class I, Division 1, Group D T3 Hazardous Locations Read Instruction Manual Warning: Substitution of components may impair intrinsic safety. PART NO. SERIES SERIAL Figure 1 Model MC1000 (Low Pressure) Identification POWER REQUIREMENTS Intrinsically safe connections Figure 2 24M672...

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332562B, ProMix PD2K Electronic Proportioner, Operation ...-4

Electronic Proportioner Intrinsically safe Figure 5 Non-lntrinsically Safe Color Change Control (Accessory) Identification Label

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332562B, ProMix PD2K Electronic Proportioner, Operation ...-5

ProMix" PD2K/PD1K COLOR CHANGE CONTROL PART NO. SERIES SERIAL MFG. YR. MAX AIR WPR - rli ~- Intrinsically safe equipment Figure 6 Intrinsically Safe Color Change Control (Accessory) Identification Label Intrinsically safe Figure 7 Booth Control Identification Label PART NO. SERIES SERIAL MFG. YR. EXPANSION PUMP Figure 8 Pump Expansion Kit (Accessory) Identification Label

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332562B, ProMix PD2K Electronic Proportioner, Operation ...-6

Related Manuals Related Manuals Manual No. PD2K Proportioner Repair-Parts Manual, Manual Systems Color Change Kits InstructionsParts Manual PD2K Proportioner Installation Manual, Manual Systems 3rd and 4th Pump Kits Instructions-Parts Manual Mix Manifold Instructions-Parts Manual PD1K Pump Expansion Kits Instructions-Parts Manual Pump Repair-Parts Manual Color Change Valve Repair-Parts Manual

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332562B, ProMix PD2K Electronic Proportioner, Operation ...-7

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-specic risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specic hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable. FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent re and...

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332562B, ProMix PD2K Electronic Proportioner, Operation ...-8

INTRINSIC SAFETY Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe equipment will create a hazardous condition and can cause re, 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 re codes (for example, NFPA 33, NEC 500 and 516, OSHA 1910.107, etc.)....

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332562B, ProMix PD2K Electronic Proportioner, Operation ...-9

TOXIC FLUID OR FUMES Toxic uids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed. • Read MSDSs to know the specic hazards of the uids you are using. • Store hazardous uid in approved containers, and dispose of it according to applicable guidelines. • Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment. 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...

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332562B, ProMix PD2K Electronic Proportioner, Operation ...-10

Important Isocyanate (ISO) Information Important Isocyanate (ISO) Information Isocyanates (ISO) are catalysts used in two component materials. Keep Components A and B Separate Isocyanate Conditions Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates. Read material manufacturer’s warnings and material MSDS to know specic hazards and precautions related to isocyanates. Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufcient ventilation in the work area. If sufcient ventilation is not...

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332562B, ProMix PD2K Electronic Proportioner, Operation ...-11

Important Isocyanate (ISO) Information Changing Materials NOTICE Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime. • When changing materials, ush the equipment multiple times to ensure it is thoroughly clean. • Always clean the uid inlet strainers after ushing. • Check with your material manufacturer for chemical compatibility. • When changing between epoxies and urethanes or polyureas, disassemble and clean all uid components and change hoses. Epoxies often have amines on the B (hardener) side. Polyureas often have amines on...

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332562B, ProMix PD2K Electronic Proportioner, Operation ...-12

Glossary of Terms Advanced Display Module (ADM) - the user interface for the system. See Advanced Display Module, page 16. Enhanced Fluid Control Module (EFCM) - the uid controller for the system. Grand Total - a non-resettable value that shows the total amount of material dispensed through the system. Idle - if the gun is not triggered for a user-settable value, the system enters Idle mode. Trigger the gun to resume operation. Intrinsically Safe (IS) - refers to the ability to locate certain components in a hazardous location. Job Total - a resettable value that shows the amount of material...

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332562B, ProMix PD2K Electronic Proportioner, Operation ...-13

Overview Usage This electronic two-component paint proportioner can blend most two-component paints, including quick-setting paints (those with a pot life of 5 minutes and greater). • The system dispenses Material A, monitors uid ow, and continually dispenses Material B at ratio. • Can proportion at ratios from 0.1:1 to 50.0:1 (depending on material, ow rate, pump size selection, and mix point). • Will display the last 200 jobs, 200 errors, and 200 events with date, time, and description. Component Identication and Denition Component • Enhanced Fluid Control Module (EFCM) • 24 V Power Supply...

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