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Graco 3A0869H User's Manual

1. IH q 500 0 spi F gm uwpio rm 74 9 gx apo EH jc 3050 9 995 9 LOOLOL COOOL SA 200101 SA 200101 SA Eis 1 07 50 dn 19S pJOMSSEd Fic 15 Setup Mode Screen page 1 3A0869H 28 Display Module M e MN 0 ME 0000 y 8 0000000 OQ 0 0000 X E y We i OOOO I 5 a GLO chya TH ame LEO 9526110 9 270000 JO 2210000 e 0000 E 5 9 gt 10 02 5 995 SA 200101 SA dn 1es 16 Setup Mode Screen page 2 29 3A0869H Display Module oet Password to 9909 See Configure 3 Screen 20 then enter it here Password 08 2570 1608 Press E to exit Setup Press to reenter Setup Setup Home Screen 17 displays with Troubleshooting options System Outputs 1 Set Up Home System Inputs TO 4 T Mem lt A brane 8 25 10 161635 082500 06 082570 Font VS 002033 VS 002032 VS 10 200 VC 0 03 0082 Push to enter forced mode System Outputs 2 System Outputs 2 To Membrane Test
2. fji HIHI H 508 i FHI 1 IP ti16336a Fic 18 Power Switch 2 Graco logo will display after five seconds followed by Run Mix Spray Screen 2 08 25 10 13494 Fic 19 Run Mix Spray Screen 2 Initial System Setup 1 Change optional setup selections to desired param eters as described in Configure 1 4 Screens 18 21 page 46 2 Set recipe and flush information as described in Recipe 0 Screen 27 Recipe 1 1 Screen 28 and Recipe 1 2 Screen 29 page 47 3 Set maintenance timers for meters solvent valves dose valves fluid filters and air filters as described in Maintenance 1 3 Screens 24 26 page 48 31 Basic Operation Prime the System NOTE See Run Mode Details pages 42 43 for further screen information if needed DA 1 Adjust the main air pressure Most applications require about 80 psi 552 kPa 5 5 bar air pressure to operate properly Do not use less than 75 psi 517 kPa 5 2 bar w 2 If this is the first time starting up the system or if lines may contain air purge as instructed in Purg ing page 34 The equipment was tested with light weight oil which should be flushed out to avoid contaminating your material 3 From Run Home Screen 1 press sure that the system is Standby mode Standby 08 250 B26 C 216 R BS 1 0 iod 0 00 4 Adjust component A and fluid supplies
3. A N SWALSAS 54 04 NOW IW OC OLAV YALA v e uv 9 8 S edW 9 86 ISd 011 68 JAVA 337134 934 1074 V SWALSAS 54 04 9 gj Wa V YOLOW a 1931 3A0869H 72 Schematics Non Hazardous Location Pneumatic Schematic PL GION110S AVM QIvNOILdO 3ATVA NS lt d JAAZL gt GION3105 aly NOLO 3NWA PT V 3500 NOLO GION110S 7 b INVA 1500 QION310S N eRe ME 83504 uU L4 xn aly GIONSTOS d 7m v LV 3504 GION110S AYM V 35414 H lt m QION310S AVY 5 OL 1401 8 6 SW31SAS 5 LAdNI 391193319 JAA v UV Z 154 001 NOUDIW S OLNY JONVO 2 NOUDIW 0C OLNV Yall v uv8 9 7 8 S 24 1 9 86 54 011 68 ub 1527 M YOLVINDIY HV A gt 1014 V 9 YOLOW KINO SINAISAS SdWnd 1 V V 40101 301111538 73 3A0869H Schematics Hazardous Location Electrical Schematic UNUSED U
4. Material Self ignition Some materials may become self igniting if applied too thickly Read material manufacturer s warnings and material MSDS 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 of the equipment s wetted parts never interchange component A resin and component B isocyanate parts MER eee 3A0869H Moisture Sensitivity of Isocyanates Isocyanates ISO are catalysts used in two component coatings ISO will react with moisture such as humidity to form 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 vis cosity If used this partially cured ISO will reduce perfor mance and the life of all wetted parts NOTE The amount of film formation and rate of crystal lization varies depending on the blend of ISO the humidity and the temperature To prevent exposing ISO to moisture e Always use a sealed container with a desiccant dryer in the vent or a nitrogen atmosphere Never store ISO in an open container e Use moisture proof hoses specifically designed for ISO such as those supplied with your system e Never use reclaimed solvents which may contain moisture Always keep solvent containers closed when not in use e Never use so
5. Valve is leaking Replace valve seat valve or valve valves closed Gun manifold or line is leaking Repair leak downstream of meters 64 3A0869H Dynamic Dosing Restrictor Selection Graphs Dynamic Dosing Restrictor Selection Graphs Use the graphs on pages 66 70 as a guide to determine the correct restrictor size for your desired flow and mate rial viscosity Table 6 lists the available restrictor sizes Example Application air spray system with a 5 1 mix ratio Fluid Supply 1 1 pumps at 100 psi 7 bar 0 7 MPa Flow Hate 300 cc min at the gun Select the Restrictor Size choose either the 0 040 or 0 070 orifice to ensure that the pressure differen tial is not more than 10 20 psi 0 7 1 4 bar 0 07 0 14 MPa provided the fluid viscosities are similar to those tested e If the viscosity of component B is lower than the vis cosity of the chart used for selection you may need to use a smaller restrictor or decrease the pressure differential e viscosity of component B is higher than the viscosity of the chart used for selection you may need to use a larger restrictor or increase the pres sure differential e In systems using an air assisted gun if the fluid pressure of component is higher than the compo nent A pressure from the charts you may need to use a larger restrictor or increase the pressure dif ferential 3A0869H Table 6 Restrictor Sizes Code Orifice size Parno
6. to clear the maintenance total that is highlighted A confirmation screen appears Use to highlight and press m the v to clear the batch totals No other button press will clear the totals Press on the to return to the active Maintenance Screen without clearing 48 Maintenance Recommendations The following table shows recommended starting values for maintenance Maintenance needs will vary based on individual applications and material differences Recommended Maintenance Frequency Solvent Valves 1 000 000 cycles Fluid Filter 5 days daily check is recommended Component Air Filter Pumps Dose Valves Meters 3A0869H Calibration 1 and 2 Screens 22 and 23 NOTE See Meter Calibration page 32 for detailed instructions Calibration 1 Screen 22 displays if i is selected on Setup Home Screen 17 This screen displays the k factor cc pulse for Meter A with fluid A1 A2 and if present and Meter B The system starts at the default factor s for the meters Factor values update automati cally as needed based on calibration results from Cali bration 2 Screen 23 Factor values also can be set on this screen from O to 0 873 cc pulse 0 19 AS Meter factors Home Fic 46 Calibration 1 Screen 22 Press to display Calibration 2 Screen 23 This screen allows the user to perform a calibration It dis plays Meter A with fluid A1 A2 and A3
7. These restrictors are included in Injection Kit 15U955 These restrictors are optional sizes not included the Injection Kit 65 Dynamic Dosing Restrictor Selection Graphs Differential Pressure between A and B 58 Dynamic Dosing Performance 1 1 Ratio 90 centipoise fluid 100 psi A side pressure 66 psi bar MPa 4000 276 27 6 3500 241 24 1 3000 207 20 7 2500 172 17 2 2000 138 13 8 1500 103 10 3 1000 69 6 9 Key 2 Restrictor 3 Restrictor 4 Restrictor 7 Restrictor 1000 69 6 9 750 52 5 2 500 34 3 4 375 26 2 6 250 17 1 7 125 8 6 0 86 500 1000 1500 2000 2500 3000 Flow Rate cc min Detail View 0 500 1000 4000 3A0869H Dynamic Dosing Restrictor Selection Graphs psi bar MPa 1400 97 9 7 1200 Key tn 83 8 3 2 Restrictor 3 Restrictor S 1000 4 Restrictor lt 69 6 9 7 Restrictor 800 55 5 5 9 2 600 44 4 1 d 400 28 2 8 200 14 1 4 0 0 500 1000 1500 2000 2500 3000 3500 4000 Flow Rate cc min Detail View 400 28 2 8 300 21 2 1 200 14 1 4 100 7 0 7 50 3 4 0 34 0 0 500 1000 59 Dynamic Dosing Performance 5 1
8. flush box is not used trigger the gun into a grounded metal pail until the color change sequence is 428 complete If your system has two guns trigger both guns at the same time NOTE The color change timer does not start until the gun is triggered and fluid flow is detected If no flow is detected within 2 minutes the color change operation aborts The Display Module enters Standby mode at the previous color Error SG occurs if the gun flush box is open Error SAD1 or SAD2 occurs if the AFS is on Trigger the gun or guns while the system flushes the current color purges with solvent and loads the new color NOTE If your system uses 2 guns you must trigger both guns simultaneously during the entire color purge solvent purge and load color sequence NOTE If you do not see clear solvent flow the system did not flush successfully Stop the color change Look for a clog in the line or increase the flush time 6 During color change the Recipe icon blinks on and off and you ll see the number of the current color and the new color When the color change is com plete Standby is highlighted When you are ready to spray remove the gun from the gun flush box if used and close its door NOTE The gun flush box door must be closed for the atomizing air valve to open Press to start spraying 35 Basic Operation Purge Color Change Detail Purge Flush The Purge Sequence flushes th
9. 11 1 1 140 9 7 0 9 120 8 3 0 8 100 7 0 7 80 5 5 0 55 60 4 1 0 41 40 2 8 0 28 20 1 4 0 14 Ke 2 Restrictor 3 Restrictor 4 Restrictor 7 Restrictor 500 1000 1500 2000 2500 3000 3500 4000 Flow Rate cc min Detail View 40 2 8 0 28 30 2 1 0 21 20 1 4 0 14 10 0 7 0 07 0 500 1000 62 Dynamic Dosing Performance 30 1 Ratio 90 centipoise fluid 100 psi A side pressure 70 3A0869H Dynamic Dosing Restrictor Selection Graphs 3A0869H 71 dvd Cl 21215400 JAVA 33734 YIMOd JNIJYNL 5NOT1 09 1 vNoUdo dL a lv QION310S avva Nl 00 S az OS AYM INVA ovs 173500 OS V 39919 e aT GIONTIOS YNN LSAWHX4 uv Hazardous Location System Pneumatic Schematic Schematics Schematics Q103INVW OL 3901 8 8 UV ISd 81 UOIVNU3LIV 03318 JAWA v 8 8 Z 54 001 NOUDIIN 5 OLAV 8 8 VAN 1079 8 dWAd m V 35f v5 8 YOLOW LAdNI
10. as needed for your application Use low est pressure possible Standby Q 9 NOTE Do not exceed the maximum rated working pressure shown on the system identification label or the lowest rated component in the system Q 5 Open the fluid supply valves to the system 6 Ifusing an electrostatic gun shut off the electrostatics before spray ing 7 If using gun flush box place the gun in the box and close the lid 8 Use to change to desired color recipe 32 9 Press eo The system will purge then load mixed material to the gun If the gun flush box is not used trigger the gun into a grounded metal pail until the system returns to Standby Meter Calibration NOTE See Calibration 1 and 2 Screens 22 and 23 page 49 for further screen information if needed Calibrate the meter e The first time the system is operated e Whenever new materials are used in the system especially if the materials have viscosities that differ significantly e As part of regular maintenance to retain meter accu racy e Whenever a flow meter is serviced or replaced NOTE e Meter factors on Calibration 1 Screen 22 are updated automatically after the calibration pro cedure is completed You also may manually edit them if desired e All values on this screen are in cc or cc pulse regardless of the units set in Configure 4 Screen 21 1 Before cal
11. 5 VDC B PRESSURE COMMON TRANSDUCER Al SHIELD LINEAR SENS B SIG UNUSED REED SWITCH_BTM DOWN REED SWITCH_TOP UP REED SWITCH_COM LINEAR SENS B 5 VDC LINEAR SENS B COM UNUSED UNUSED 2 UNUSED 3 UNUSED 4 UNUSED NUSED gt Qo r LINEAR SENSOR REED SWITCH CABLE B REED SWITCH B LINEAR SENSOR P P 11 T SS3NUVH 318 2 H313W GION310S Schematics 77 Dimensions and Mounting Dimensions and Mounting 14 74 in 37 1 01 0 55 in 1274 in 2 5 cm 1 4 cm 32 Y 78 3A0869H Technical Data Technical Data ProMix 2KE Meter Based Systems 08 See Models page 0 7 MPa 7 0510 0 7 MPa 52 16 7 bar TT 5 micron minimum filtration required clean and dry air 30 micron minimum filtration required clean and dry air 1316301 up to 1 user selectable External power supply requirements 85 250 Vac 50 60 Hz 2 amps maximum draw 15 amp maximum circuit breaker required 8 to 14 AWG power supply wire gauge Operating temperature range 41 to 122 5 to 50 Approximate weight 200 Ib 91 kg Environmental conditions rating indoor use pollution degree 2 installation category Fluids handled one or two component solvent and waterborne paints polyurethanes epoxies e acid catalyzed varnishes Sound
12. Lock icons Fic 23 System Lock Mode Power down and power back up again to clear the lock and put the new settings into effect The lock ensures that the selection was intended and prevents operation with incorrect settings Valve Settings Dose valves and purge valves are factory set with the hex nut 1 1 4 turns out from fully closed This setting limits maximum fluid flow rate into integrator and mini mizes valve response time To open dose or purge valves for high viscosity materials turn hex nut E counterclockwise To close dose or purge valves for low viscosity materials turn clockwise See FIG 24 11581 24 Valve Adjustment 38 Follow Purging page 34 Close main air shutoff valve on air supply line and on ProMix 2KE Non IS Systems Shut off ProMix 2KE power 0 position NOTE The system will restart in Recipe 0 3A0869H Use of Optional USB Module Use of Optional USB Module USB Logs Job Log 1 See example FIG 25 The job log records total vol umes for each job that the system performs up to 2000 It records the date time user number job number total A volume total B volume mix ratio and the recipe used Job total volumes are in cubic centimeters A log entry is made whenever a new job is initiated which occurs when batch totals are cleared when the job number is incremented from Run Job Number Screen 38 or when a color change is performed Job info
13. box Number Dosing of guns type Number of colors Home Fic 38 Configure 1 Screen 18 Press to highlight the desired field Press to display the dropdown menu for that field Press to choose from the menu options and to set Press to move to the next field e Press to move through Configure 2 Screen 19 Configure 3 Screen 20 and Configure 4 Screen 21 NOTE If you change system type meter to pump number of guns dosing type or number of colors a ver ification screen appears Use to highlight and press on the V to make the change or on the X to return to Configure 1 Screen 18 without making a change If a change is made the system locks so that you cannot spray or mix Power down and power back up again to clear the lock and put the new settings into effect The lock ensures that the selection was intended and prevents the user from attempting to operate with incorrect settings C8250 Fic 39 Confirm Change of System Type Configure 2 Screen 19 allows users to set for each gun the hose length 0 1 to 45 7 m 0 3 to 150 ft and hose diameter 0 1 to 1 inch The system uses this informa tion to calculate pot life volume The pot life volume tells the system how much material must be moved to trigger a reset of the pot life timer It also tells the system the volume needed to fill during a load sequence A change in any of these fields will trigger the lock See NOTE in previous
14. if applicable 3A0869H Setup Mode Details 08 25 10 1616437935 0 Software Version Display Module Fluid Control Module USB Module Vs 107 002 VC 101001 Calibration Configure Fic 37 Setup Home Screen 17 Recipe Settings e Press a soft key button to select one of the four Setup Mode screen sections Configure Recipe Maintenance 4 Or Calibration hz Press to toggle between Run Mode and Setup Mode Configure 1 4 Screens 18 21 Configure 1 Screen 18 displays if Ee is selected on Setup Home Screen 17 This screen allows users to set up the system type pump or meter the type of dos ing sequential or dynamic number of guns 1 or 2 and the system color configuration 1 or 3 NOTE If 1 gun is selected users can enable a gun flush box yes The gun flush box option is avail able only for 1 gun systems NOTE If your application requires only 2 colors the system is still configured for 3 colors Select 3 from the dropdown menu Dynamic vs Sequential Dosing See page 51 and fol lowing for a description of each type of dosing to help you select the best option for your system The options are 50cc Select for sequential dosing 50 dose size 100 Select for sequential dosing 100cc dose size Al B Select for dynamic dosing 45 Setup Mode Details System Gun flush type 08 25 10
15. life of less than 5 minutes event The optional USB upgrade kit will log 500 errors and up to 2000 jobs e Has dynamic dosing capabilities It dispenses mate rial A monitors fluid flow and dispenses material B e For systems with one gun an optional Gun Flush in doses to cause the mixture to stay on ratio Box provides an automated flushing system for a manual spray gun Component Identification and Definition Table 1 Component Description Control Box Advanced Fluid Control Module Power supply or alternator Solenoid valves Air flow switch es Optional USB Module Audible alarm Optional pressure switch for gun flush box Fluid Module Mix manifold which includes the fluid integrator and static mixer Color catalyst valve stacks includes pneumatically operated dose valves for material A1 and B additional dose valves A2 and A3 optional as well as solvent valves Meters Display Module Used to set up display operate and monitor the system Used for daily painting functions including choosing recipes reading clearing alarms and placing the system in Spray Standby or Purge mode Installation General Information e protect the Display Module screens from paints and solvents clear plastic protective shields are Reference numbers and letters in parentheses in available in packs of 10 Part No 24G821 Clean the text refer to numbers and letters in the illustra the screens with a dry cloth if necessary tions
16. 10 3A0869H POWER FILTER POWER SUPPLY CAN CABLE 20 CAN CABLE Installation Non Hazardous Locations USER INTERFACE 10 CAN CABLE MODULE 50 OPTION USB MODULE CABLE ASSEMBLY FLUID CONTROL MODULE CABLE ASSEMBLY FLOW FLOW METER A METER B G3000 G3000 G3000HR G3000HR 53000 53000 CORIOLIS CORIOLIS 2 Non Hazardous Location Installation 3A0869H 11 Installation Display Module 1 Use the screws provided to mount the bracket for the Display Module on the front of the Control Box or on the wall as you prefer 2 Snap the Display Module into the bracket 3 Connect one end of the CAN cable provided to J6 on the Display Module either port 4 The other end of the cable comes from the factory connected as shown depending on the configura tion of your system e Wall Power Systems with USB Module Connect the CAN cable to P3 on the USB Mod P3 ule e Wall Power Systems without USB Module Connect CAN cable to J8 on the Advanced J8 Fluid Control Module e Alternator Power Sys tems with or without USB Module Connect CAN cable to J3 on the alternator 116456 12 Air Supply Requirements Compressed air supply pressure 75 100 psi 517 700 kPa 5 2 7 bar Air hoses use grounded hoses that are correctly sized for your system Trapped air can cause a pump or dispens
17. Be sure all accessories are adequately sized pressure rated to meet system requirements e There must be a shutoff valve between each fluid supply line and the ProMix 2KE system e A100 mesh minimum fluid filter must be installed on component A and B fluid supply lines 3A0869H 9 Installation Intrinsically Safe Installation Requirements 1 Theinstallation must meet the requirements of the National Electric Code NFPA 70 Article 504 Resp Article 505 and ANSI ISA 12 06 01 Do not substitute or modify system components as this may impair intrinsic safety For installation 2 Multiple earthing of components is allowed only if high integrity equipotential system realized between maintenance or operation instructions read the points of bonding instruction manuals Do not install equipment 3 install per EN 60079 14 and applicable hazardous location See the identification label for neal end national codes the intrinsic safety rating for your model Hazardous Classified Locations Class 1 Div 1 Group D T3 US and Canada Class 1 Zone 1 Group ATEX only USER INTERFACE 10 CAN CABLE MODULE 50 OPTION ALTERNATOR 2 CAN CABLE USB MODULE MODULE CABLE ASSEMBLY FLUID 20 CAN CABLE CONTROL MODULE CABLE ASSEMBLY FLOW FLOW METER METER B G3000 G3000 G3000HR G3000HR 53000 53000 1 Hazardous Location Installation
18. Press on Run Mix Spray Screen 2 from any screen to put the system in Standby Trigger the gun to relieve pressure If you are using a high pressure gun engage the trigger lock Remove spray tip and clean tip sepa rately If using an electrostatic gun shut off the electrostat ics before flushing the gun Set the solvent supply pressure regulator at a pres sure high enough to completely purge the system in a reasonable amount of time but low enough to avoid splashing or an injection injury Generally a setting of 100 psi 0 7 MPa 7 bar is sufficient If using a gun flush box place the gun into the box and close the lid Press on Run Mix Spray Screen 2 The purge sequence automatically starts If the gun flush box is not used trig ger the gun into a grounded metal pail until the purge sequence is com 48 IN plete lt When done purging the system automatically switches to Standby mode 3A0869H 8 Ifthe system is not completely clean repeat step 6 NOTE If necessary adjust purge sequence times so only one cycle is required 9 Trigger the gun to relieve pressure Engage trigger lock 10 If spray tip was removed reinstall it 11 Adjust the solvent supply regulator back to its nor mal operating pressure NOTE The system remains full of solvent NOTE If your system uses 2 guns you must trigger both guns simultaneously during a purge to purge both guns and lines Ver
19. SHIELD GRN 74 3A0869H Hazardous Location Electrical Schematic continued p 5 Mo gt 23 9 069 Ui 3A0869H SOLENOID METER CABLE HARNESS J8 CAN L 1 CAN 2 V_CAN_RTN 3 CAN_H 4 SHIELD 5 J4 UNUSED 1 ALARM 2 COMMON 3 PURGE A 4 4 DOSE A1 5 J12 412VDC 1 FLOW METER A SI 2 COMMO 3 DOSE A2 4 DOSE A3 5 J2 5 VDC 1 PRESSURE 2 TRANSDUCER COMMON 3 4 SHIELD 5 J14 LINEAR SENS A SIG 1 UNUSED 2 REED SWITCH BTM DOWN 3 REED SWITCH TOP UP 4 REED SWITCH COM 5 LINEAR SENS A 5 VDC 6 LINEAR SENS A COM 7 UNUSED 8 mz Uf 225 J25 UNUSED 1 AZ UNUSED 2 TA UNUSED 3 gt UNUSED 4 gt T J25 UNUSED 1 UNUSED 2 UNUSED 3 UNUSED 4 REED SWITCH A LINEAR SENSOR FLUID CONTROL MODULE UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED AFS 1 COMMON PURGE B DOSE B Un d gt NUT 3 12VDC FLOW METER B SIG COMMON GFB INPUT AFS 2 GFB OUTPUT Un C 3 B PRESSURE TRANSDUCER Al SHIELD Un RUN 82 lt 575 ad 5 LINEAR SENS B SIG UNUSED REED SWITCH BTM DOWN REED SWITCH TOP UP REED SWITCH COM LINEAR SENS B 5 VDC LINEAR SENS B COM UNUSED Un UNUSED UNUSED UNUSED UNUSED N
20. Screen 35 From Setup Home Screen 17 with Troubleshooting active press to display Troubleshooting System Inputs Screen 35 An X displays in the box to indicate if Air Flow Switch 1 or 2 is on and if the gun is in the Gun Flush Box This screen also displays Meter A and Meter B pulses The fields relating to pump function can be ignored ordewn Proseures not used ween not used 08 2510 0e Meter Pulses Pump A up Gun in Gun or down Flush Box not used Fic 49 Troubleshooting System Inputs Screen 35 Press EA then again to move to Trouble shooting System Outputs Screen 37 Press PI to move to the Membrane Test Screen 36 Membrane Test Screen 36 From Setup Home Screen 17 with Troubleshooting active press EA then again Membrane Test Screen 36 displays You could also press then again This screen allows an authorized user to test the buttons on the Display Module membrane When in this screen all buttons lose their predefined functions and the soft keys are not defined When a properly working button is pressed an X appears in the box 08 25 10 Fic 50 Membrane Test Screen 36 Press three times to return to Setup Home Screen 17 Direct access to any other screen is not possible 50 Troubleshooting System Outputs Screen 37 From Setup Home Screen 17 with Troubleshooting active press P to display Troubleshooting System Ou
21. Screen number Error code Potlife state LCD Display Ratio Operation mode see AN 08 2570 T2542 213 ACA B page 24 for key Potlife timer Navigation keys Flow rate Soft keys Enter key Navigation Keys Error Reset Standby Key Key Setup Key ti16319a Fic 13 Display Module Display Keys are used to input numerical data enter setup screens navigate within a screen scroll through Shows graphical and text information related to setup screens and select setup values and spray operations The screen backlight is factory set to remain on The user may set a number of minutes NOTICE the screen can be inactive before the backlight dims See Configure 3 Screen 20 page 46 Press any key to restore To prevent damage to the soft key buttons do not press the buttons with sharp objects such as pens plastic cards or fingernails NOTE The Display Module and bracket can be removed from the cover of the electrical box and mounted remotely if preferred Key Error Reset Use to clear alarm so cause can be fixed Also use Setup Press to enter or exit to cancel a data entry field Standby Stops the current Enter Press to choose a field to ene Pte into standby d update to make a selection or kevs P h to save a selection or value oft Keys Press to select the specific screen or operation Left Hight Arrows Use to move shown on the display directly lt m from
22. a working fire extinguisher in the work area SPECIAL CONDITIONS FOR SAFE USE To prevent the risk of electrostatic sparking the equipment s non metallic parts should be cleaned only with a damp cloth 4 3A0869H Warnings ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding setup or usage of the system can cause electric shock e Turn off and disconnect power at main switch before disconnecting any cables and before servicing 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 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 e Only models with model numbers 24F084 24F087 utilizing the air driven alternator are approved for installation in a Hazardous explosive atmosphere Location See Models page 3 Be sure your installation complies with national state and local codes for the installation of electrical apparatus in a Class Group D Division 1 North America or Class Zones 1 and 2 Europe Hazardous Location including all of the local safety fire codes NFPA 33 NEC 500 and 516 and OSHA 1910 107 To help prevent fire and explosion Do
23. and Meter B k factors the target dispense volume the actual dis pense volume settable from O to 9999 cc and the material to dispense Meter B Selected Meter A k factor material dispense volume Actual dispense volume Start Meter A Cancel Meter Home or Meter B Calibration Calibration Fic 47 Calibration 2 Screen 23 3A0869H Setup Mode Details Press to highlight the meter you wish to cali brate Press e An X displays in the box Press to start the calibration on the checked meter A with fluid A1 A2 or A3 or B Press e to cancel the calibration Press to highlight the actual dispense vol ume field Press to set the volume from 0 to 9999 cc Press to move between digits Press to change a digit Press when field is correct Use to toggle between Calibration 1 Screen 22 and Calibration 2 Screen 23 Troubleshooting Screens 35 37 Screens for testing system controls can be accessed by setting the password to 9909 See Configure 3 Screen 20 page 46 to set or change the password After setting the password to 9909 press to exit Setup Press to reenter Setup Setup Home Screen 17 displays with troubleshooting screen options Troubleshooting screen options appear here 08 25 10 WS 002033 WS 002032 VS 107 001 VC 0 03 0082 Fic 48 Setup Home with Troubleshooting 49 Setup Mode Details Troubleshooting System Inputs
24. gun flush box the gun mixed material is not in the box when purge is active Solvent Purge See Purging on page 34 The system purges until the preset purge time is complete To prevent mixed material from curing in the equipment do not shut off power Follow one of the solutions at right New Mixed Material Purge Go to Mix mode and spray the required volume to restart the potlife timer Solvent line valve or meter is plugged Check components and clean repair or or stuck replace as necessary Solvent pump is not working Check and repair pump See pump manual for repair procedures and replacement parts Atomizing air is stuck on Replace air flow switch Gun is not in Gun Flush Box Insert the gun into the Gun Flush Box Gun Flush Box air shutoff is not working Test using Troubleshooting Screens See page 49 Repair replace air shutoff valve as needed Inspect air line for kinks damage or loose connections Repair or replace as needed Gun line valve or meter is plugged Check components and clean repair or stuck replace as necessary Feeder pump or solvent pump is not Check and repair pump See pump turned on or is not working manual for repair procedures and replacement parts Check air line path See System Pneu matic Schematic page 72 or 73 Verify that solenoid is working Increase fluid pressure Air leak in atomizing air line Air lines or solenoids are plu
25. 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 The equipment is intrinsically safe when no external electrical components are connected it Do not connect download or remove USB device unless unit is removed from the hazardous explosive atmosphere location SKIN INJECTION HAZARD High pressure fluid from gun 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 spray without tip guard and trigger guard installed Engage trigger lock when not spraying Do not point gun at anyone or at any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Follow the Pressure Relief Procedure when you stop spraying 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 3A0869H 5 Warning
26. p To Setup Home 16 16435 0X y 7B AOU z OL Zh E LIL 3 17 Troubleshooting Screen Map 30 3A0869H Basic Operation Pre Operation Tasks Go through the Pre Operation Checklist in Table 2 Table 2 Pre Operation Checklist Checklist System grounded Verify all grounding connections were made See Grounding page 21 All connections tight and correct Verify all electrical fluid air and system connec tions are tight and installed according to the man ual instructions Fluid supply containers filled Check all supply containers A1 A2 and A3 if present B and solvent Dose valves set Check that the dose valves are set correctly Start with the settings recommended in Valve Set tings page 38 then adjust as needed Fluid supply valves open and pressure set Component A and B fluid supply pressures should be equal unless one component is more viscous and requires a higher pressure setting Solenoid pressure set 75 100 psi inlet air supply 0 5 0 7 MPa 5 2 7 bar Power On 1 IS Systems Alternator Power Supply Set pump air regulators to minimum setting Open main air valve to start air powered alternator Main air pres sure is displayed on gauge Display Module screen will display after five seconds 3A0869H Basic Operation Non IS Systems Wall Power Supplied Turn the AC Power Switch ON 0 OFF ON
27. paragraph 46 Gun 1 hose un length nose eng Gun 1 hose 2 0 25 diameter Gun 2 hose diameter Home Fic 40 Configure 2 Screen 19 Configure 3 Screen 20 allows users to set preferred language for optional USB Module date format date time password 0000 to 9999 and number of minutes to 99 of inactivity required before the backlight turns off Configure 4 Screen 21 allows users to set pre ferred units for distance and volume USB log language Date 08 2540 16306 format Password Date Daer25r Backlight timer Time Configure 3 08 25 70 163242018 Distance units Volume units Home Configure 4 Fic 41 Configure Screen 20 and Configure 4 Screen 21 3A0869H Recipe 0 Screen 27 The Recipe Screens allow the user to set up the basic recipes Recipe 0 Screen 27 displays if x is selected on Setup Home Screen 17 Recipe 0 allows users to set up a full flush independent of recipe purge timers with no material load It includes timers for first second and third flush See Recipe 1 2 Screen 29 page 47 for flush timer details Third flush time uses material set in next field Recipe 0250 164 0 number First flush time A purge Second flush time B purge Fic 42 Recipe 0 Screen 27 Recipe 1 1 Screen 28 Note about Settings of 0 If Ratio is set to O the sys tem will dispens
28. pressure level below 70 dBA Sound power level Below 85 dBA Materials of construction Wetted materials on all models 303 304 SST Tungsten carbide with nickel binder perfluoroelastomer PTFE 3A0869H 79 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by 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 Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty i
29. pump pul sation install a fluid regulator on the A and B supply lines upstream of the meters In systems with color change install the regulator downstream of the color catalyst valve stack Select a Component B Restrictor Size See Set Up the Fluid Manifold for Dynamic Dosing page 16 Use the charts on pages 66 to 70 to select an appropriate restrictor size based on the desired flow and mix ratio 3A0869H Dosing Options Select Dynamic Dosing 1 Onthe Display Module press to access Setup Home Screen 17 Select to display Configure 1 Screen 18 2 Select A B the dosing type drop down menu Balancing A B Pressure If component B pressure is too high it will push the com ponent A stream aside during B injection The valve will not open long enough causing a Ratio High error If component B pressure is too low it will not be injected in sufficient volume The valve will stay open too long causing a Ratio Low error Selecting the correct component B restrictor size and balancing the A B pressures will keep the system in the proper pressure range resulting in a consistent mix ratio FIG 53 shows the A to B pressure balance read at the proportioner inlet It is recommended that the compo nent B pressure be 5 15 higher than the component A pressure to keep the system in the control range hold the proper mix ratio and obtain properly mixed material If pressures are not balanced Pre
30. skip a flush in the sequence For example to skip the first flush A side purge enter 0 seconds The system goes immediately to the second flush followed by the third flush as user defined Third flush time uses material set in next field number First flush time purge Third flush Source Second flush time B purge FiG 44 Recipe 1 2 Screen 29 Press highlight the desired field and press to select Press to move between dig its Press to change a digit Press when field is correct Press to move through the Recipe screens 47 Setup Mode Details Maintenance 1 3 Screens 24 26 Maintenance 1 Screen 24 displays if is selected on Setup Home Screen 17 The Maintenance Screens display actual and target maintenance timers for meters and solvent valves Maintenance 1 Screen 24 dose valves Maintenance 2 Screen 25 and fluid filters and air filters Maintenance 3 Screen 26 Timers for meters are settable from O to 2 000 000 L or 0 to 528 344 gal lons Timers for valves are settable from O to 9 999 999 counts Timers for filters are settable from O to 9999 days Home Clear totals 000000 000000 Dose 0 valves X 5000000 g 5000000 tte 0 Maintenance 2 Fluid Filters NUES X 0000 P Of Maintenance 3 45 Setup Maintenance 1 3 Screens 24 26 e Press to move through the three mainte nance screens Press
31. t UNUSED UNUSED UNUSED UNUSED PUN LINEAR SENSOR B REED SWITCH B LINEAR SENSOR FERRITE Schematics 553 318V2 8 1 3105 5 Schematics Non Hazardous Location Electrical Schematic TERMINAL BLOCK L N GRND L GRND N LINE POWER FILTER L N 2A SWITCH ROCKER 2 1 I ll V V POWER SUPPLY UTTO MEMBRANE 76 BUTTON_DOWNARW UPARW CLEAR s 3 o e gt ENTER Z co co 123121 d rm zu gt 55 LED YELLOW LED BLUEA LED GREEN COM LEDS CAN L CAN V RTN CAN SHIELD USER INTERFACE MODULE UNUSED UNUSED UNUSED UNUSED GFB 1 PRESSURE SWITCH AIR FLOW SWITCH 2 SHIELD UNUSED UNUSED UNUSED UNUSED UNUSED USB BASE MODULE UON VCAN VCAN VCAN V CAN RTN V CAN V CAN RTN V CAN RTN BIT 3 BIT 2 GND n 4 CO N Ov Ui 22 CANH 23 VCANRTN 24 VCANRTN 25 BITO 26 BIT 1 27 VTOKEN 28 LOFO 29 HOLD 30 CS P4 CAN_L V_CAN V_CAN_RTN CAN_H SHIELD CHASSIS GND CHASSIS GND USB COMPONENT MODULE NO OO gt ALARM MANIFOLD PURGE A E D T DOSE A1 10 mz gt 229 PURGE B 12 13 iw DOSEB 14 DOSE A2 H DOSE A3 oes mz 25 S_ lt Gm i
32. the 1 4 npt m fitting F Remove the integrator G and discard 5 See 8 Remove the remaining parts from the restrictor housing H Retain the plug J and base K Discard all the used o rings 6 Rotate the restrictor housing H 180 so the set screw S is at top left as shown in Fic 8 Remove and retain the two setscrews S The position of these screws will be reversed when reassembled 7 Install one larger o ring 117 in the housing H Screw the injection cap M into the housing 8 Determine the desired flow range for your applica tion Select the appropriate size restrictor for your selected flow and ratio using the Dynamic Dosing Restrictor Selection Graphs on pages 66 70 as a guide Install the restrictor R in the base K 9 Assemble the smaller o ring L2 restrictor R and base one larger o ring L1 and plug J as shown 10 Install the two setscrews Install the long setscrew S at the front of the housing for ease of access 16 N2 N3 ti16334a 7 Disassemble Integrator and Static Mixer 3A0869H 11 Screw the static mixer SM into the injection cap M Install the retained fitting F on the static mixer tube and secure with the nut N1 These parts are included in the 15U955 Injection Kit H SM N1 Fic 8 Install 15U955 Injection Kit ti16335a 12 Follow instructions under Fluid Connections on page 14 NOTE Use
33. 2 08 00 624 EL RECORD 29 8 8 13 12 08 01 625 MESA ADVISORY 30 B 8 13 12 08 02 626 1 ADVISORY 31 8 8 13 12 08 03 627 1 ADVISORY 32 6 8 13 12 08 19 628 EQUI RECORD 33 8 8 13 12 22 23 1617 EL RECORD 34 8 8 13 12 26 25 1689 EL RECORD 35 B 8 13 12 26 57 1690 EL RECORD 36 B B 13 12 27 19 1691 EL RECORD E 8 8 13 12 28 33 1692 EL RECORD 38 B B 13 12 29 01 1693 EL RECORD 39 8 8 13 12 29 28 1694 EL RECORD 40 B 8 13 14 50 45 1695 EL RECORD 41 6 8 13 14 52 15 1696 EL RECORD 42 B B 13 15 19 49 1697 EL RECORD 43 B 8 13 15 33 55 1703 EL RECORD 44 B B 13 15 35 28 1706 EL RECORD 45 8 8 13 15 39 48 1707 EL RECORD 46 8 8 13 15 50 46 1710 EL RECORD 47 8 8 13 15 52 14 1711 EL RECORD 48 8 12 13 16 22 05 631 EL RECORD aga 8 12 13 16 22 06 632 MESA ADVISORY 50 8 12 13 16 22 07 633 MGA1 ADVISORY 51 B 12 13 16 22 08 634 1 ADVISORY EIS B 12 13 16 33 18 635 SFA2 ALARM _53 8 12 13 16 43 30 636 SFA2 ALARM 54 8 12 13 16 45 27 637 EQUI RECORD 55 B 12 13 17 51 42 638 SFA2 ALARM 56 B 12 13 17 52 33 639 SAD ALARM 57 B 12 13 17 53 37 640 SAD1 ALARM 58 B 12 13 17 54 07 641 ALARM 2 ALARMCSV Normal Ready CAPS E Fic 26 Sample Error Log Setup Language 08 25 10 1630418 dropdown m lt lt ENGLISH menu 08 2570 0000 The only setup required is to select the language in which you want to view the downloaded data Screens are icon b
34. 24F087 3 colors 1 catalyst 1 color 1 catalyst 3 colors 1 catalyst 3000 27 58 275 8 Approvals lt gt 0 54 APPROVED FM10 ATEX 0025 X Intrinsically safe and purged equipment for Class I Division 1 Group D 0 C to 54 C See Special Conditions for Safe Use in Related Manuals page 4 24F084 1 color 1 catalyst 3000 27 58 275 8 ProMix 2KE hazardous location equipment manufactured the United States with serial number beginning with A or 01 has ATEX FM and CE approvals as noted Equipment manufactured in Belgium with serial number beginning with M or 38 has ATEX and CE approvals as noted Approved for Non Hazardous Location Maximum Working Pressure USB Description psi MPa bar Port Approvals 24F080 1 color 1 catalyst 3000 27 58 275 8 24 081 3 colors 1 catalyst 3000 27 58 275 8 24 082 1 color 1 catalyst 3000 27 58 275 8 24F083 3 colors 1 catalyst 3000 27 58 275 8 C ProMix 2KE non hazardous location equipment manufactured the United States with serial number beginning with A or 01 has FM and CE approvals Equipment manufactured in Belgium with serial number beginning with M or 38 has CE approval 3A0869H 3 Warnings Related Manuals Description Manual Description oie 312782 Dosing Valve Instructions Parts 3A1325 ProMix 2KE Stand Kits 312784 Gun F
35. 3 5 Qasa saa 23 afa oa 24 Screen Summary 25 Ranges for User Inputs 26 Basic Operation 31 Pre Operation 5 5 31 ER kachaq eee ee 31 Initial System Setup 31 Prime the System 32 Meter Calibration 32 SP AV ING det todos ut nn chee 33 CC PR 34 Color Change 35 Purge Color Change Detail 36 Pressure Relief Procedure 37 LOCK MOOG 228 54 ws 2h oboe Eras 38 Valve Settings 38 ShUtdoWE tpe dd dea 38 Use of Optional USB Module 39 USB ded aed 39 o RUE Ed 40 Download Procedure 41 Recommended USB Flash Drives 41 Run Mode Details 42 Run Mix Spray Screen 2 42 Home Screen 1 42 Run Mix Batch Screen 3 42 Mix Totals Screen 4 43 Job Number Screen 38 43 Log Errors Screens 5 14 44 Setup Mode Details 45 Password Screen 16 45 Setup Home Screen 17 45
36. 5 Press to clear all batch totals A verification screen appears Use 2 highlight and press on v to clear the batch totals or on A to return to the Run Totals Screen 4 without clearing Ox 32 C 5116 Fic 33 Confirm Clear Batch Totals e Press to toggle between Run Mix Spray Screen 2 Run Mix Batch Screen 3 Run Mix Totals Screen 4 and Run Job Number Screen 38 3A0869H Run Mode Details Run Job Number Screen 38 Run Job Number Screen 38 displays if is selected from the Run Mix Totals Screen Use this screen to view and increment the job number as well as view and assign a 9 digit user number to the job 06 05 15 00 42 EJ 00015 Job number User number Increment job Home Fic 34 Run Job Number Screen 38 Press to set the user number Use to change each digit then to move to the next digit Press when finished Press gt increment the job number e Press to toggle between Run Mix Spray Screen 2 Run Mix Batch Screen 3 Run Mix Totals Screen 4 and Run Job Number Screen 38 43 Mode Details Run Log Errors Screens 5 14 Log Errors Screens 5 14 display if S selected from Run Home Screen 1 It displays the last 50 errors in the log Screen 5 displays errors 1 to 5 Screen 6 displays errors 6 to 10 etc 08 25 10 0 3t 2 Error codes Error icons Fic 35
37. 88 in in diameter It accepts a bulkhead strain relief fitting or conduit POWER SUPPLY L GRND N LINE POWER FILTER 1 Verify that electrical power at the main panel is shut off Open Control Box cover 2 Connect electrical cord to the terminal block as shown in FIG 10 SWITCH ROCKER 3 Close the Control Box Restore power 4 Follow instructions in Grounding page 21 Fic 10 Electrical Schematic 20 3A0869H Grounding The equipment must be grounded Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit Connect the ProMix 2KE ground wire to the ground screw Connect the clamp to a true earth ground If wall power is used to power controls ground electrical con nection according to local codes 15712 Fic 11 Ground Screw Power Switch Gun Flush Box Connect a ground wire from the Gun Flush Box ground lug to a true earth ground Flow Meters Verify that the meter cables are connected as shown in the Hazardous Location Electrical Schematic on page 74 75 Failure to properly connect the shield may cause incorrect signals NOTE The Coriolis meter can be used only on non IS systems 24F080 24F083 When installed on these sys tems the meter s hazardous location intrinsically safe status is voided 3A0869H Installatio
38. Configure 1 4 Screens 18 21 45 Recipe Screen 27 47 Recipe 1 1 Screen 28 47 Recipe 1 2 Screen 29 47 Maintenance 1 3 Screens 24 26 48 Maintenance Recommendations 48 Calibration 1 and 2 Screens 22 and 23 49 Troubleshooting Screens 35 37 49 Dosing Options 51 Sequential Dosing 51 Dynamic DOSING idem n eed o3 System 1 n Pd Gp wi es 55 System Alarms 55 System Advisory Record Codes 55 To Clear Error and Restart 55 Air Flow Switch AFS Function 55 System Idle Notice IDLE 56 GOdGS dete Speo hela ana 57 Alarm Troubleshooting 58 Dynamic Dosing Restrictor Selection Graphs 65 Schemall6S 2209 72 Dimensions and Mounting 78 Technical Data 79 Graco Standard Warranty 80 3A0869H Models Models ProMix 2KE systems are not approved for use in hazardous locations unless the base model all accessories all kits and all wiring meet local state and national codes Approved for Hazardous Location Class 1 Div 1 Group D North America Class 1 Zones 1 and 2 Europe Maximum Working Pressure Description psi MPa bar 24F085 24F086
39. E to reduce the fluid supply pressure Contact your Graco distributor for informa tion Slow actuation of component A or B See Ratio Low Error and Ratio High valves Error pages 61 62 Running a high mix ratio and a high It may be necessary to restrict the flow rate rate through the component B dose valve by adjusting its hex nut 3A0869H 63 System Errors System is in Mix mode and gun is only Fully trigger the gun partially triggered allowing air but no fluid QTA1 QTA2 or QTB1 Dose Time Error to pass through gun The gun trigger is active but Fluid flow rate is too low Increase flow rate no A pulses QTA1 QTA2 or no B pulses QTB1 are detected during the dose time selected Flow meter or cable failed or flow meter check meter sensor operation clogged remove meter cap to expose sensor Pass a ferrous metal tool in front of the 12792 If there is a meter or cable failure you will see a large difference between the amount of fluid dispensed and the flow meter volume displayed by the Display Module Clean or repair meter as nec essary Slow actuation of component A or B See Ratio Low Error and Ratio High valves Error pages 61 62 The supply pump is not turned on Turn on the supply pump There is an air leak downstream from the Check the air lines for leaks and repair air flow switch Leak Error ating and generating meter pulses I REAA or
40. M Display Module DM the alternator module See Alterna and USB Module have power green tor Module Power Output If the LED and are communicating amber proper voltage is not detected trou LED blinking bleshoot the Alternator Module If the proper voltage is detected verify the cable connecting the two modules is good If the cable is good replace the module There may be a short in one of the sole Replace the cable 16E890 noid meter cables connected to the AFCM The AFCM power supply may be bad as Replace the module indicated by the status LEDs red yellow green being off Verify the power supply works by disconnecting from the AFCM and connecting to another module either the Display Module or USB Module The DM and the AFCM have different ver Install the latest software from token kit sions of software installed 16D922 on all modules The red LED on the AFCM is on If on solid replace module If blinking contact your distributor NOTE If the AFCM loses communication no flickering amber LED but then comes back on the alarm will auto clear and will not log the alarm If the DM loses communication no flickering amber LED but then comes back on you will have to manually clear the alarm and there will be an alarm log If the USB module loses communication no flickering amber LED but then comes back on you will not get an alarm The module has been removed Put system in standby an
41. NUSED UNUSED UNUSED UNUSED 18 PSI ALTERNATOR L n o CAN 1 5 MODULE Pam MIN SHIELD Cn o 1 1 USB BASE 2 VCAN 2 USB COMPONENT 3 MODULE MODULE 4 V CAN 4 5 V CAN 5 6 CHASSIS GND 6 7 CHASSIS GND 7 8 V CAN 8 9 V CAN 9 0 BIT 3 0 1 2 1 2 GND 2 3 SCK 3 4 50 4 5 5 6 VCAN 6 7 VCAN 7 8 VCAN 8 9 V CAN 9 20 V CAN 20 21 CANL 21 22 CANH 22 23 VCANRTN 23 24 VCANRTN 24 25 BITO 25 26 BIT 1 26 27 VTOKEN 27 28 LOFO 28 29 HOLD 29 30 CS 30 d UNUSED UNUSED UNUSED UNUSED UNUSED USER INTERFACE MODULE BUTTON DOWNARW 1 ALARM BUTTON UPARW 2 BUTTON CLEAR 3 BUTTON STOP 4 BUTTON FUNCA 5 BUTTON FUNCI 6 BUTTON START 7 BUTTON RIGHTARW BUTTON LEFTARW BUTTON ENTER BUTTON FUNC3 PURGE BUTTON FUNC2 MEMBRANE COM BUTTONS DOSE A1 SHIELD i DES PURGE B LED_YELLOW 1 U LED BLUEA 2 LED GREEN 3 UNUSED DOSEB LED BLUEB 5 UNUSED 6 DOSE A2 LED RED 7 USED 8 COM LEDS 9 DOSE A3 5 8 GFB 1 GION11OS UNUSED UNUSED UNUSED UNUSED gt 3X CABLE PWR RED FLOW METER COM BLACK SIG WHITE SHIELD GRN AIR FLOW SWITCH 1 1 PRESSURE SWITCH SIG AIRFLOW SWITCH2 com 3X CABLE PWR RED BIDEN FLOW METERB COM BLACK SIG WHITE
42. Operation G 7 GRACO ProMix 2KE Meter Based Plural Component Proportioner EN Self contained electronic plural component paint proportioner For professional use only Important Safety Instructions Read all warnings and instructions in this manual Save these instructions See page 3 for model information including maximum working pressure and approvals ti15698a PROVEN QUALITY LEADING TECHNOLOGY Contents MOGGIS PEE 3 Related Manuals 4 csse nace ee eas EE etre RE 4 Important Two Component Material Information 7 Isocyanate Conditions 7 Material Self ignition 7 Keep Components A and B Separate 7 Moisture Sensitivity of Isocyanates 7 Changing Materials 7 Glossary Of Terms i i RR ERES 8 SUJET 9 SAGE tid dein 9 Component Identification and Definition 9 Installation 9 General Information 9 Intrinsically Safe Installation Requirements 10 Display Module 12 AICSUDDIV 2 Eh PLE 12 Fluid uy s ha 14 Tubing Chart and Diagrams 18 EIGCITICdl 2 RA PES 20 GrOuUnNdING 21 Check Resistance 21 Display Module 2
43. P 119861 Pressurized air line 18 28 4R X 6R GFB1 A ti16770a GFB1 C 2 GFB1 S 1113863 18 3A0869H Installation See Manual 312784 for full setup instructions for a gun flush box ze gem C s B Side ti6767a eH H 4R 3 k M Fall emi SR N trj LIN 5G LED i e eR 18 6G I Jg 1167684 ti16769a 3A0869H 19 Installation Electrical Power Connection non IS units only BA Co All electrical wiring must be completed by a qualified electrician and comply with all local codes and regulations Enclose all cables routed in the spray booth and high traffic areas in conduit to prevent damage from paint solvent and traffic The ProMix 2KE operates with 85 250 VAC 50 60 Hz ti16391a input power with a maximum of 2 amp current draw The power supply circuit must be protected with a 15 Fic 9 Control Box Electrical Connection amp maximum circuit breaker Not included with system TERMINAL BLOCK L N GRND e Power supply cord compatible to your local power configuration Wire gauge size must be 8 14 AWG e The input power access port is 22 4 mm 0
44. Potlife for al each gun 2 min Fic 29 Run Mix Spray Screen 2 e Press to toggle between Run Mix Spray Screen 2 Run Mix Batch Screen 3 Run Mix Totals Screen 4 and Run Job Number Screen 38 e Press q to access Run Home Screen 1 Run Home Screen 1 Screen Number 08 25 10 T5 1 06 M Errors Fic 30 Run Home Screen 1 42 e Press a soft key button to select one of the main Run Mode screen sections Mix or Errors Press to enter the Setup screens Run Mix Batch Screen 3 Run Mix Batch Screen 3 displays if is selected from Run Mix Spray Screen 2 Use the Mix Batch screen to dispense set volumes Target volume can be set from 1 to 9999 cc Material 08 250 15572943 1e Fic 31 Run Mix Batch Screen 3 Press to set the target dispense volume Use to change each digit then to move to the next digit Press when finished e Press to toggle between Run Mix Spray Screen 2 Run Mix Batch Screen 3 Run Mix Totals Screen 4 and Run Job Number Screen 38 3A0869H Run Mix Totals Screen 4 Run Mix Totals Screen 4 displays if is selected from Run Mix Batch Screen 3 Use this screen to view grand and batch totals for material A1 A2 A3 and material B and to clear batch totals if desired On 25 0 1559 2 1 Batch total Grand total Clear batch totals increment job Fic 32 Run Mix Totals Screen 4 Home 99
45. Ratio 90 centipoise fluid 100 psi A side pressure 3A0869H 67 Dynamic Dosing Restrictor Selection Graphs psi bar MPa 800 55 5 5 700 48 4 8 600 41 4 1 500 Key 2 Restrictor 3 Restrictor 4 Restrictor 7 Restrictor 34 3 4 400 28 2 8 300 21 2 1 200 14 1 4 Differential Pressure between A and B 100 7 0 7 200 14 1 4 150 10 1 0 100 7 0 7 50 3 4 0 34 500 1000 1500 2000 2500 3000 3500 4000 Flow Rate cc min Detail View 60 Dynamic Dosing Performance 10 1 Ratio 90 centipoise fluid 100 psi A side pressure 68 3A0869H Dynamic Dosing Restrictor Selection Graphs psi bar MPa 300 21 2 1 m 17 2 1 72 5 2 Restrictor 3 Restrictor 200 S 1414 z 8 150 10 3 1 03 5 amp 100 7 0 0 7 50 3 4 0 34 0 0 500 1000 1500 2000 2500 3000 3500 4000 Flow Rate Detail View 100 7 0 7 75 5 2 0 52 50 3 4 0 34 25 1 7 0 17 0 0 500 1000 61 Dynamic Dosing Performance 20 1 Ratio 90 centipoise fluid 100 psi A side pressure 3A0869H 69 Dynamic Dosing Restrictor Selection Graphs Differential Pressure between A and B psi bar MPa 200 14 1 4 180 12 4 1 2 160
46. Run Log Errors Screen 5 e Use to view the next page See FIG 57 page 55 for an explanation of the different error icons See Table 5 page 57 for an explanation of the different error codes 44 3A0869H Setup Mode Details Press on any screen to enter the Setup screens If the system has a password lock Password Screen 16 displays If the system is not locked password is set to 0000 Setup Home Screen 17 displays Password Screen 16 From any Run screen press to access the pass word screen Password Screen 16 displays if a pass word has been set Set the password to 0000 to prevent the Password Screen from displaying See Configure 3 Screen 20 page 46 to set or change the password 08570 16 06 Fic 36 Password Screen 16 e Press to enter the password 0000 to 9999 Press to move between digits Press to change a digit Press when field is correct Setup Home Screen 17 displays e Press to toggle between Run Mode and Setup Mode Select to display Run Home Screen 1 Enter ing an incorrect password also displays Run Home Screen 1 Setup Home Screen 17 Setup Home Screen 17 displays if is selected on any screen and the system is not locked or when a cor rect password is entered on Password Screen 16 The Setup Home screen displays the software versions of the boards in the Display Module Advanced Fluid Con trol Module and the USB Module
47. a minimum 20 ft 6 1 m x 1 4 in 6 mm ID gun fluid supply hose when using dynamic dosing If the material is harder to integrate use a longer hose 13 Tune the fluid pressure and flow 3A0869H Installation 17 Installation Tubing Chart and Diagrams Starting Ending re 7 Type Color Description Point Point mm Ar Green SoentVaweAOn 16 045640 _ Air 10 29 015640 _ Ai Green Solvent ValveBOn se 88 0156 40 _ Ar Green DoseVaweBOn 49 0 15640 _ Ar Green Dose Valve Az On 6G sa 015600 Ai Green Dose Vave 69 r Red Solvent Vave AO iR 0156 40 Ar DoseVaeATOf R 0 156 40 _ r Red 3R 0156 40 Ar Red DoseVaeBOR 0 15640 _ Ai Red DoseVaeA2Of 015640 _ Ar Dose Vat _ Ar Air to Pressure Gauge Ai 0156 40 _ Ar Natural Solenoid Air 02569 Fua Stack Ato Meter A4 037505 Fluid Valve Stack BtoMeterB A5 5 03505 Aterator air Exhaust 6 0527 ir Natural Air Regulator to Afemator A7 A7 0375 65 Used only on IS models IS Models A7 iil6773a ne GFBI S 9 ti6771a GFB1
48. all pressure regulators or a surge tank on the ProMix 2KE fluid inlets to reduce pulsation Contact your Graco distributor for additional information Fluid Connections 1 See FIG 6 Connect the solvent supply line to the 1 4 npt f solvent valve inlets SVA and SVB 2 Connect the component A supply line s e Single color system connect component supply line to the component A1 dose valve inlet DVA1 14 e Multiple color system connect supply lines to the component A2 and A3 dose valve inlets DVA2 DVA3 See FIG 6 NOTE Solvent supplied by a single source can cause cross contamination and damage to the system Install check valves or use separate solvent sources NOTE Paint Recirculating System Only e If you are recirculating paint use the standard inlet on Dose Valve A1 A2 or Dose Valve B the plug directly opposite it on the dose valve for the recirculation outlet The second port is on the back of the valve and must be reached from inside the control box Second port I 1 8 ti16338a FiG 5 Paint Recirculation Port e Another option is to use a tee fitting to recirculate NOTE Verify that all unused fluid ports on the color change valve stack are plugged before operation An open port will leak fluid 3 Connect the component B line to the component B dose valve inlet DVB NOTE The component A and B fluid meter inlets have fluid check valves to prevent backflo
49. als the controller when the gun is being triggered 2 4 gt z Atomizing air outlets A O 14 Atomizing CL OQ air inlets 9 Solenoid e NY air inlet P RN P 15709 Fic 4 Atomizing Air Connection 13 Installation Fluid Supply Requirements MPa bar PSI Do not exceed the pressure rating of the lowest rated component See the identification label To reduce the risk of injury including fluid injection you must install a shutoff valve between each fluid supply line and the mix manifold Use the valves to shut off fluid during maintenance and service ProMix 2KE models are available to operate air spray or air assisted systems with a capacity of up to 3800 cc min e Fluid supply pressure tanks feed pumps or circu lating systems can be used e Materials can be transferred from their original con tainers or from a central paint recirculating line e Seemanual 313599 for Coriolis meter installation and operation instructions NOTE The Coriolis meter can be used only on non IS systems 24F080 24F083 When installed on these sys tems the meter s hazardous location intrinsically safe status is voided e If you are using dynamic dosing see Fluid Connec tions this page See also Set Up the Fluid Mani fold for Dynamic Dosing page 16 NOTE The fluid supply must be free of pressure spikes which are commonly caused by pump stroke change over If necessary inst
50. an error occurs be sure to determine the error code before resetting it If you forget which code occurred use Run Log Errors Screens 5 14 page 44 to view the last 50 errors with date and time stamps To reset errors see Table 7 and Alarm Troubleshoot ing page 58 Many errors can be cleared by simply pressing 69 Air Flow Switch AFS Function Air or Air assisted Guns The air flow switch AFS detects air flow to the gun and signals the ProMix 2KE controller when the gun is trig gered The AFS functions with the flow meters to ensure that system components are functioning correctly For example if a flow meter fails or clogs pure resin or catalyst could spray indefinitely if the ProMix 2KE does not detect the condition and intervene which is why the AFS is so important If the ProMix 2KE detects through the AFS signal that the gun is triggered yet there is no fluid flow through the meter a Dose Time Alarm QTA1 or QTB1 occurs after 40 seconds and the system shuts down Operating Without Air Flow Switch Itis not recommended to run without an air flow switch If a switch fails replace it as soon as possible Airless Gun It is not recommended to use airless gun with the ProMix 2KE Two issues can arise from operating with out an air flow switch e Without a gun trigger air flow switch input the Pro Mix 2KE does not know it is spraying and will not generate a Dose Time Alarm This means there is no wa
51. are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com For patent information see www graco com patents TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 All written and visual data contained in this document reflects the latest product information available at the time of p
52. ased and do not change Navigate to Config ure 3 Screen 20 Select your language from the lan guage dropdown Fic 27 Select Language for USB Logs 40 3A0869H Download Procedure Remove proportioner from hazardous location before inserting downloading or removing the USB flash drive 1 Press EU on Run Mix Spray Screen 2 or from any screen to place the system in Standby NOTE The system will not operate with a USB flash drive in the port If you insert the flash drive while spray ing the system will stop and an alarm error will occur 2 Insert USB flash drive into USB port Use only Graco recommended USB flash drives see Rec ommended USB Flash Drives page 41 3 Data download begins automatically An LED on the flash drive blinks until the download is complete NOTE If you use a flash drive that does not have an LED open the Control Box An LED near the USB mod ule flashes until the download is complete 4 Remove flash drive from USB port uw To help prevent fire and explosion never leave the USB flash drive in the USB port USB Port FIG 28 USB Port 5 Insert USB flash drive into USB port of computer 3A0869H Use of Optional USB Module 6 The USB flash drive window automatically opens If it does not open USB flash drive from within Win dows Explorer 7 Open Graco folder 8 Open sprayer folder If downl
53. d install the The cable is disconnected or broken Put system in standby and reconnect or replace the USB cable 3A0869H Alarm and Description EQU2 USB Drive Error The USB drive has been inserted when the system is not in Standby SG Gun Flush Box Error gun flush box is enabled but the system does not detect a gun in the gun flush box during purge color change or auto dump SPSA or SPSB Purge Volume Error Insufficient volume during first 10 seconds of A or B purge sequence SAD1 or SAD2 Atomizing Air During Purge Atomizing air to Gun 1 SAD1 or Gun 2 SAD2 is detected when purge is selected or during purge sequence SFA1 SFA2 SFA3 or SFB1 PreMix Error In systems with a gun flush box insufficient quantity of resin color SFA1 SFA2 or SFA3 or catalyst SFB1 is detected during the 10 second PreMix sequence SHA1 SHA2 5 SHB1 PreFill Error Total PreFill sequence volume is not reached for color SHA1 SHA2 or or catalyst SHB1 during the 5 minute PreFill sequence 3A0869H System Errors Cause Most USB drives do not conform to IS standards so it is hazardous to use one Put system in Standby Insert the USB drive only in a non hazardous environ while the system is running ment The cover of the gun flush box is not Close the cover and clear the alarm closed Purge the system with solvent or fresh For systems with a
54. e 1 Screen 24 controls mainte nance timer actual and target for Meter A Meter B Solvent Valve A and Solvent Valve B e Maintenance 2 Screen 25 controls dose valves A1 and B maintenance timer actual and target Dose valves A2 and A3 are included if 3 colors are selected on Configure 1 Screen 18 e Maintenance Screen 26 controls fluid and air filter maintenance timers actual and target Calibration Screens 22 and 23 1 Color e Calibration 1 Screen 22 controls factors cc pulse for Meter A and Meter B e Calibration 2 Screen 23 allows the user to per form a calibration 3 Color e Calibration 1 Screen 22 controls k factors cc pulse for Meter B and for Meter A using col ors A1 A2 and A3 e Calibration 2 Screen 23 allows the user to per form a calibration Troubleshooting Mode The troubleshooting mode has three screen sections that allow an authorized user to troubleshoot system operation See FIG 17 page 30 System Inputs Screen 35 Membrane Test Screen 36 System Outputs and Manual Activation Screen 37 25 Display Module Ranges for User Inputs This table is a one sheet reference of the data range accepted for each user input See the page indicated in the table for further screen information if needed User Number Password 0000 disabled 6 Configure 1 18 System Type Meters 50cc Pump 75cc Pump 100cc Meters Pump 125cc Pump 150cc Pump Configure 1 18 Dosing Ty
55. e lines from the A amp B color stacks though the mix manifold and out to the gun s has pre assigned not selectable valve B has a pre assigned not selectable valve If you choose a third flush option it can be A or B not A and B You do not have an option to select something other than A or B valve For example if A was water and B was solvent The third flush options would have to be A water or B solvent You couldn t assign a third option like air The following should be the only selectable flush sequence options A B 0 A B A A 0 B 0 B O 0 0 0 There are 4 basic purge sequences as follows 1 Selecting the purge button on the pendant The purge sequence from the recipe that you are cur rently in is used The system is left full of solvent 2 Color Change from A1 A2 or to A1 A2 or A3 The purge sequence from the recipe you are leaving is used After the purge sequence completes the premix fill from the recipe that you are going to starts blinking recipe number etc 3 Color Change from A1 A2 or A3 to Zero The recipe zero purge sequence is used The system is left full of solvent 4 Color change from Zero to Zero The recipe zero purge sequence is used The system is left full of solvent NOTE Color Change from Zero to A1 A2 or A3 The system does not do a purge sequence It immediately starts the premix fill sequ
56. e the A material only If Potlife Time is set to O the potlife alarm is disabled Press to move through the Recipe screens The Hecipe Screens allow the user to set up the basic rec ipe Recipe 1 1 Screen 28 is for A1 color 1 and B In 3 Color systems Recipe 2 1 Screen 30 is for A2 color 2 and B and Recipe 3 1 Screen 32 is for color 3 and B These screens include the ratio of Material A1 A2 A3 to Material B 0 to 30 ratio tolerance 1 to 99 percent and potlife time 0 to 240 minutes Hatio Ratio tolerance FiG 43 Recipe 1 1 Screen 28 3A0869H Setup Mode Details Recipe 1 2 Screen 29 Note about Settings of 0 If a Flush time is set 0 that valve will not flush Recipe 1 2 Screen 29 includes timers for first second and third flush for A1 color 1 In 3 Color systems Rec ipe 2 2 Screen 31 and Recipe 3 2 Screen 33 allow users to set flush timers for the additional materials A2 and colors 2 and 9 e First flush Always A side purge using the A side flush material from the A purge valve e Second flush Always a B side purge using the B side flush material from the B purge valve e Third flush User settable to run the A purge valve the B purge valve for any required additional flush as selected in the dropdown for the third flush source A or B All flush times are settable from 0 to 240 seconds Set flush time to O seconds to
57. e valve to cycle unexpectedly which could result in serious injury from splashing or moving parts Use bleed type shutoff valves Air regulator and bleed type shutoff valve include in each air line to fluid supply equipment Install an additional shutoff valve upstream of all air line accessories to isolate them for servicing If using a Graco electrostatic PRO Gun a shutoff valve must be installed in the gun air line to shutoff the atomizing and turbine air to the gun Contact your Graco distributor for information on air shutoff valves for electrostatic applications Airline filter 10 micron or better air filter is rec ommended to filter oil and water out of the air supply and help avoid paint contamination and clogged solenoids 3A0869H Air Connections See the System Pneumatic Schematic on page 72 hazardous location or page 73 non hazardous loca tion 1 Tighten all ProMix 2KE system air and fluid line con nections as they may have loosened during ship ment 2 Connect the main air supply line to the main air inlet This air line supplies the solenoids and all pneu matic control valves Main Air Inlet 21115729 Fic 3 Air Connection 3A0869H Installation 3 Foreach gun in the system connect a separate clean air supply line to the air inlet of the air flow switch This air line supplies gun atomizing air The air flow switch detects air flow to the gun and sign
58. ence A SPSA SPSB alarm Not enough volume during purge is generated when the end of a purge phase is reached Time specified by user and the system has not totaled at least 10cc of material 36 Pre Mix Fill Premix fill sequence right after purge sequence loads 60 cc of the A1 A2 or A3 and B1 from the color stack to the mix manifold In the premix fill sequence a SFA1 SFA2 SFAS SFB1 alarm Premix fill low flow is generated if there are less than 10 ccs in 60 seconds SHA1 SHA2 SHA3 SHB1 alarm Not enough premix fill volume is generated if there are less than 50 ccs in 60 seconds NOTE Premix fill always starts with the side Mix Fill The mix fill sequence right after premix fill loads A1 A2 or A3 B1 mixed material Ratio specified by user out to the gun s It loads 110 of the volume of the hoses plus the volume of the manifold hose 1 hose 2 manifold x 1 1 SM mix fill low flow is generated if there are less than 50ccs in 60 seconds during a mix fill sequence SN Not enough mix fill volume is generated if less than the mix fill volume is loaded in 5 minutes during a mix fill sequence 3A0869H Basic Operation Pressure Relief Procedure 2 Shut off the A1 plus 2 and if using multiple colors and B fluid supply pumps pressure pots 3 Remove the Control Box cover 4 With the gun triggered push the manual override on To reduce the risk of skin injection relieve p
59. ended air pressure above e Fluid Seal in valve has failed See corresponding valve manual for repair instructions 3A0869H 61 System Errors R4 Ratio High Error The mix ratio is higher than the set tolerance for an A to B component volume compari son There is too little restriction in the system If the alarm occurs during start up after purging the flow rate was probably too high If the alarm occurred after you were spraying for some time the pressures from the fluid supplies could be unbal anced Slow actuation of the component A or B valves This can be caused by e Air pressure to the valve actuators is too low Something is restricting the solenoid or tubing and interrupting valve actu ation air Dose Valve B is turned in too far Dose Valve A1 A2 is open too far 62 Check that the system is fully loaded with material Check that the supply pump s cycle rate is set properly Check that the spray tip nozzle is properly sized for the flow and application and that it is not worn Check that the fluid regulator is set properly Restrict gun needle travel to slow down the initial fluid delivery rate until fluid hoses are loaded with material Adjust component A and B fluid supply regulator pressures until they are about equal f the pressures are already about equal verify that component A and B dose valves are operating prop erly Manually operate the Dose Val
60. ent Valve B DVAS3 Third Color Catalyst Valve SM Static Mixer SVA Solvent Valve A Fl Fluid Integrator Fic 52 Fluid Module Sequential Dosing 52 3A0869H Dynamic Dosing Overview Dynamic Dosing provides on demand proportioning eliminating the need for an integrator and therefore min imizing undesired material contact This feature is espe cially useful with shear sensitive and waterborne materials A restrictor injects component B into a continuous stream of component A The software controls the dura tion and frequency of each injection See 55 for a schematic diagram of the process Dynamic Dosing System Parameters The following parameters affect dynamic dosing perfor mance e Component A Flow Ensure that the supply pump is sized to provide sufficient and uninterrupted flow Note that component A provides majority of system flow at higher mix ratios e Component B Flow Ensure that the supply pump is sized to provide sufficient and uninterrupted flow e Component A Pressure Ensure precise pressure regulation It is recommended that the component A pressure be 5 15 lower than the component B pressure e Component B Pressure Ensure precise pressure regulation It is recommended that the component B pressure be 5 15 higher than the component A pressure NOTE When using dynamic dosing it is very important to maintain a constant well regulated fluid supply To obtain proper pressure control and minimize
61. er to zero K factor an assigned value that refers to the amount of material per pulse that passes through a meter Mix when cross linking of the resin A and catalyst B occurs Overdose Alarm when either the resin A or catalyst B component dispenses too much material and the system cannot compensate for the additional material Potlife Time the amount of time before a material becomes unsprayable Potlife Volume the amount of material that is required to move through the mix manifold hose and applicator before the potlife timer is reset Purge when all mixed material is flushed from the sys tem Purge Time the amount of time required to flush all mixed material from the system Ratio Tolerance the settable percent of acceptable variance that the system will allow before a ratio alarm OCCUIS Sequential Color Change the process when a color change is initiated and the system automatically flushes the old color and loads a new color Sequential Dosing Components A and B dispense sequentially in the necessary volumes to attain the mix ratio Standby refers to the status of the system 3A0869H Overview Overview Usage The ProMix 2KE is an electronic two component paint e proportion at ratios from 0 1 1 to 30 0 1 proportioner It can blend most two component paints It is not for use with quick setting paints those with a pot e Will display the last 50 errors with date time and
62. ibrating Meter A or Meter B prime the system with material See Prime the System page 32 2 Ifthe display is on a Run Mode screen press to access setup screens Press to display Calibration 1 Screen 22 K factors are shown for B and A1 A2 A3 if pres ent 3A0869H 4 Press to move to Calibration 2 Screen 23 5 Press to highlight the meter you wish to cali brate Press e An X displays in the box 6 Press to start the calibration on the checked meter A with fluid A1 A2 or A3 or B Press e to cancel the calibration 7 Trigger gun into a graduated cylinder Dispense a minimum of 200 300cc of material NOTE Stop triggering the gun when desired amount is reached Do not press e as it will cancel the calibra tion 8 The volume that the ProMix 2KE measured displays on the Display Module Volume measured by system displays here 0 119 cep E 0 119 O Enter dispensed volume here Fic 20 Dispensed Volume Comparison 9 Compare the amount on the Display Module to the amount in the graduated cylinder NOTE For maximum accuracy use a gravimetric mass method to determine the actual volumes dis pensed e lf the screen and actual volumes are different press to highlight the dispense volume field Press 9 Press Edo move between digits Press to change a digit Press when field is correct NOTE If the value is substantially different repea
63. id 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 You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury hearing loss inhalation of toxic fumes and burns This equipment includes but is not limited to Protective eyewear and hearing protection e Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer 3A0869H Important Two Component Material Information Important Two Component Material Information Isocyanate Conditions opraying or dispensing materials containing isocyanates creates potentially harmful mists vapors and atomized particulates Read material manufacturer s warnings and material MSDS to know specific hazards and precautions related to isocyanates Prevent inhalation of isocyanate mists vapors and atomized particulates by providing sufficient ventilation in the work area If sufficient ventilation is not available a supplied air respirator is required for everyone in the work area To prevent contact with isocyanates appropriate personal protective equipment including chemically impermeable gloves boots aprons and goggles is also required for everyone in the work area
64. ify that clean solvent flows from each gun If not repeat purge or clear clog blockage in sys tem Color Change Color Change Sequence Step 1 Color Purge The system flushes out the color with solvent The selected color change solvent valve opens during Purge Time and closes when the time expires Step 2 Catalyst Purge The system flushes out the catalyst with solvent The catalyst change solvent valve opens during Purge Time and closes when the time expires Step 3 Final Purge The system fills the line with the selected purge media usually solvent The selected purge valve opens during the Final Purge Time and closes when the time expires Step 4 Catalyst Fill The system fills the line with new catalyst The new catalyst valve opens during the Fill Time and closes when the fill volume is reached Step 5 Color Fill The system fills the line with new color The new color valve opens during the Fill Time and closes when the fill volume is reached Step 6 Mixed Material Fill The system fills the line with mixed material The system begins mixing compo nents A and B until the fill volume expires 3A0869H Basic Operation Color Change Procedures 1 Place the gun in the gun flush box if used and close the lid Press E on Run Mix Spray Screen 2 or from any screen to put the system in Standby Use the scroll keys 5 or to select the new color Press to begin the color change Sequence
65. leshooting see Alarm Troubleshooting beginning on page 58 Error Message Solution Ratio Low Error R1 e Increase A pressure or decrease B pressure e Use a smaller restrictor Ratio High Error R4 Increase B pressure Clean restrictor or use a larger size Verify B valve is opening properly 54 3A0869H System Errors NOTE Do not use the fluid in the line that was dis pensed off ratio as it may not cure properly System Alarms System alarms alert you of a problem to help prevent off ratio spraying If an alarm occurs operation stops and the following occurs e Alarm buzzer sounds e Status bar on the Display Module shows the alarm icon and code e Alarm is saved in the date time stamped log Error Code Indicator WS 002001 Spr VS 002001 VS 107 001 Vic 192 000 Fic 56 Display Module Alarm Codes System Advisory Record Codes Table 6 lists the advisory and record codes Advisories and records do not stop operation or sound an alarm If an advisory occurs the Status bar on the Display Mod ule shows the advisory icon and code System records do not display on the Status bar Both advisories and records are saved in the date time stamped log which can be viewed on the display or saved to a flash drive using optional USB port OB 250 1502 14 E 6 Record no icon Alarm icon Advisory icon 57 Error Log Icons 3A0869H System Errors To Clear Error and Restart NOTE When
66. lush Box Kit 15V826 1332 24H255 3 Color Valve Stack Kit 406714 Rebuild Kit for High Pressure SA 9393 ZA 2S3 VSB Mode Ki Dispense Valve 313542 406823 Dispense Valve Seat Kit Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion 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 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 If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem Keep
67. lvent on one side if it has been con taminated from the other side Always lubricate threaded parts with ISO pump oil or grease when reassembling Changing Materials e When changing materials flush the equipment mul tiple times to ensure it is thoroughly clean Always clean the fluid inlet strainers after flushing Check with your material manufacturer for chemical compatibility Glossary of Terms Glossary of Terms Coriolis Meter a non intrusive flow meter often used in low flow applications or with light viscosity shear sensi tive or acid catalyzed materials This meter uses vibra tion to measure flow Dose Size the amount of resin A and catalyst B that is dispensed into an integrator Dose Time Alarm the amount of time that is allowed for a dose to occur before an alarm occurs Dynamic Dosing Component A dispenses constantly Component B dispenses intermittently in the necessary volume to attain the mix ratio Grand Total a non resettable value that shows the total amount of material dispensed through the system Intrinsically Safe IS refers to the ability to locate cer tain components in a hazardous location Idle if the gun is not triggered for 2 minutes the system enters Idle mode Trigger the gun to resume operation Batch Total a resettable value that shows the amount of material dispensed through the system for one batch A batch is complete when the user resets the batch count
68. mbed incor rectly or solenoids are not working Flow rate is too low 59 System Errors Gun Flush Box is not triggering gun ss trigger is being pulled Adjust as m Start Error needed In systems with a gun flush Line or gun is plugged or restricted box insufficient volume of mixed material is detected Flow rate is too low during the 10 second mixed fill sequence Valve is stuck SN MixFill Complete Error Insufficient volume of mixed material is detected during the 5 minute mixed fill sequence QPD1 or QPD2 Have not sprayed enough volume to Potlife Error keep fresh mixed fluid in the mix mani Potlife has been exceeded for fold hose and gun the mixed material for Gun 1 QPD1 or Gun 2 QPD2 60 Clean line Clean line tip or filter or filter C fluid or decrease Clean valve or verify that solenoid is triggering valve properly Purge the mixed material line See page 34 Check that hose length and diameter have been entered correctly See Con figure 2 Screen 19 page 46 Spray the required volume to restart the potlife timer 3A0869H System Errors There is too much restriction in the Check that the system is fully system loaded with material R1 Ratio Low Error The mix ratio is lower than the set tolerance for an A to B component volume compari son Check that the supply pump s cycle rate is set properly Check that the spray tip nozzle is pr
69. n Feed Pumps or Pressure Pots Connect a ground wire and clamp from a true earth ground to the pumps or pots See pump or pressure pot manual Air and Fluid Hoses Use grounded hoses only Spray Gun Non Electrostatic Ground the spray gun through connection to a Graco approved grounded fluid sup ply hose e Electrostatic Ground the spray gun through con nection to a Graco approved grounded air supply hose Connect the air hose ground wire to a true earth ground Fluid Supply Container Follow local code Object Being Sprayed Follow local code Solvent Pails Used When Purging Follow local code Use only conductive metal pails con tainers placed on a grounded surface Do not place the pail container on a nonconductive surface such as paper or cardboard which interrupts the grounding con tinuity Check Resistance To ensure proper grounding resistance between components and true earth ground must be less than 1 ohm 21 Installation Key AN Control Box ground screw A Control Box ground wire By Gun Flush Box ground screw Gun Flush Box ground wire A Power cable Display Module Control Box 6N True Earth Ground check your local code for requirements jt A ti16466a Fic 12 Grounding 22 3A0869H Display Module Display Module
70. oading data from more than one sprayer there will be more than one sprayer folder Each sprayer folder is labeled with the corresponding USB serial number 9 Open DOWNLOAD folder 10 Open folder labeled with the highest number The highest number indicates the most recent data download 11 Open log file Log files open in Microsoft Excel by default However they can also be opened in any text editor or Microsoft Word NOTE All USB logs are saved in Unicode UTF 16 for mat If opening the log file in Microsoft Word select Uni code encoding Recommended USB Flash Drives It is recommended that users use the 4GB USB flash drive 16A004 available for purchase separately from Graco If preferred users may use one of the following 4 GB or less USB flash drives not available from Graco Crucial Gizmo 4GB USB flash drive model JDO4GB 730 Transcend JetFlash V30 4GB USB flash drive model TS4GJFV30 e OCZ Diesel 4GB USB flash drive model OCZUSBDSL4G 41 Mode Details Run Mode Details Run Mix Spray Screen 2 h Run Mix Spray Screen 2 displays at startup or if za is selected from Run Home Screen 1 Use the Mix Spray screen to control most mixing operations Target ratio 1 Gun Gun status 08 25 10 Bee 439 16 ABS 1 0 Actual M d 000 ratio min Lt 01 si Mix Standby Purge Hae 2 Guns Om25n0 2 5 4 43 516 1 0 U
71. operly sized for the flow and application and that it is not clogged Check that the fluid regulator is set properly If the alarm occurs during start up after Restrict gun needle travel to slow down purging the flow rate was probably too the initial fluid delivery rate until fluid high hoses are loaded with material If the alarm occurred after you were Adjust component A and B fluid supply spraying for some time the pressures regulator pressures until they are about from the fluid supplies could be unbal equal f the pressures are already anced about equal verify that component A and B dose valves are operating prop erly Slow actuation of the component A orB Manually operate the Dose Valve A1 valves This can be caused by A2 A3 and B solenoid valves by pressing and releasing solenoid valve override buttons Valves should snap open and shut quickly e Air pressure to the valve actuators is Increase air pressure Air pressure too low must be 75 120 psi 0 52 0 84 MPa 5 2 8 4 bar 120 psi is recom mended e Something is restricting the solenoid There may be dirt or moisture in the or tubing and interrupting valve actu air supply Filter appropriately ation air e Dose Valve 1 2 is turnedin e Refer to Valve Settings page 38 too far for adjustment guidelines Dose Valve B is open too far e Fluid pressure is high and air pres e Adjust air and fluid pressure See sure is low recomm
72. pe Dynamic A B 50 cc Sequential 50cc Sequential A B 50cc 100cc Sequential A B 100cc Gun Flush Box Enable Number of Guns Configure T 18 Number of Colors Configure 2 19 Configure 2 19 High 250 cc min or higher or Low 250 cc min Italian Japanese Korean Portuguese Russian Spanish Swedish Date Format Configure 20 Date Configure 3 20 Time Configure 3 20 Password 0000 disabled Configure 3 20 Distance Units Configure 4 21 Volume Units Hecipe 2 1 30 Note Enter 0 to dispense A only Hecipe 3 1 32 47 Recipe 1 1 28 Ratio Tolerance 1 to 99 percent 5 percent Recipe 3 1 32 47 1 1 28 Potlife Timer 0 to 240 minutes 60 minutes Mi eem Hecipe 3 1 32 47 Recipe 0 27 Flush Times First A purge to 240 seconds 60 seconds 1 2 29 Second B purge or Third Note If set to O the valve s will not flush Recipe 2 2 31 using A or B selected by user Recipe 3 2 33 Maintenance 1 24 Meter or Meter We 50 NE NN Maintenance 1 24 Solvent Valve A or B a A Maintenance 2 25 Dose 1 2 A3 orB 099999 Calibration 220 26 3A0869H Display Module lt 51000 ER ch 10443 12101 2571 OSEBO ung Fic 14 Run Mode Screen 27 3A0869H Display Module 62 e EE sE ZA oio
73. pres sure to component A and B fluid supplies or increase the regulated fluid pressure of mixed material If the fluid flow rate is too high reduce the air pressure to component A and B fluid supplies close the dose valves further or decrease the reg ulated fluid pressure of mixed material 4 Turn on atomizing air to the gun Check the spray pattern as instructed in your spray gun manual NOTE e Pressure adjustments of each component will vary with fluid viscosity Start with the same fluid pres sure for component A and B then adjust as needed e Do not use the first 4 5 120 150 cc of material as it may not be thoroughly mixed due to errors while priming the system NOTICE Do not allow a fluid supply tank to run empty It is pos sible for air flow in the supply line to turn gear meters in the same manner as fluid This can damage the meters and lead to the proportioning of fluid and air that meets the ratio and tolerance settings of the equipment This can further result in spraying uncatalyzed or poorly catalyzed material 34 Purging NOTE See Run Mode Details pages 42 43 for further screen information if needed Zw Purge the system at the end of potlife breaks in spraying that exceed the potlife overnight shutdown or end of shift the first time material is loaded into equipment servicing shutting down equipment for an extended period of time
74. r Error A 4 P6B1 Pressure Transducer Error B Advisory Codes No alarm system continues operat ing icon displays on active screen until cleared 3A0869H 47 8 System Errors Table 5 System Alarm Advisory Record Codes 79 MGA1 Fluid Filter A maintenance due MGB1 Fluid Filter B maintenance due MGP1 Air Filter maintenance due System defaults loaded Record Codes No alarm system continues operating no icon displays on active screen System powered on System setup changed System defaults loaded System performed an autodump after N A a potlife EQU1 USB Drive connected while in Standby N A 57 System Errors Alarm Troubleshooting Alarm and Description CA Communication Error The Display Module is not communicating with the Advanced Fluid Control Module CAU1 USB Communication Error The system detected a USB Module at last power up but does not detect it currently 58 Cause The CAN cable between the Display Verify that the cable is correctly con Module and the Advanced Fluid Control Module is not connected The CAN cable is cut or bent Verify that the cable has not been cut or bent at a radius smaller than 1 6 in 40 mm The cable or connector failed Replace cable Alternator Powered Systems Forany module that does not have power disconnect and check the Check that the Advance Fluid Control voltage on the cable produced by Module AFC
75. ressure the A1 A2 A3 and B dose valve solenoids to when you stop spraying before changing spray tips relieve pressure See FIG 22 and before cleaning checking or servicing equipment 5 Follow Purging procedure page 34 NOTE The following procedure relieves all fluid and air 6 Shut off the fluid supply to solvent valves A and B pressure in the ProMix 2KE system l l l 7 With the gun triggered push the manual override on the A and B solvent valve solenoids to relieve sol vent pressure See FIG 22 Verify that solvent pres sure is reduced to 0 1 Press E on Run Mix Spray Screen 2 or from any screen to put the system in Standby 8 Reinstall the Control Box cover 9 Manual overrides One 7 QU Solvent Valve A Solenoid Dose Valve Gun Flush Box Solenoid A1 Solenoid location if used 115730 Solvent Valve B Dose Dose Valve 1 A2 Solenoid Solenoid Solenoid location if used Fic 22 Solenoid Valves in Control 3A0869H 37 Basic Operation Lock Mode Shutdown NOTE Do not change system type number of guns 1 hose length hose diameter dosing type or number of colors when material is loaded in the system Change 2 these inputs only if system hardware is changed If you change one of these inputs the system locks so that you cannot spray or mix The lock icons display 06 25 10 13 324 4 BS 1 0 miri
76. rmation is displayed on the Display Module only through use of the optional USB Module P e Bde amp o r Mew Open Save Print Import Copy Paste Format Undo Redo Sheets Charts a G A Jab Log USB Serial Number 09001088 Software Part Number 15W201 Software Revision 1 10 001 User Number Job No Ratio Job Total 300000010 633 1 502 300000010 634 30 300000010 635 360 300000010 636 1 0 300000010 637 30 Time B 12 13 16 32 10 8 12 13 16 37 54 8 12 13 15 41 49 8 12 13 16 42 22 B 12 13 17 54 51 Date am n FIG 25 Sample Job Log 3A0869H 1 JOB CSV Es Autosum Sort A Z Sort Z A Gallery Toolbox Job Total NOTE User Number Ratio and Alarm 1 5 are dis played as of 2KE System Software version 1 03 001 USB Cube Software version 1 10 001 Error Log 2 See example in Fic 26 The error log records all errors generated by the system up to 500 It records the date time error number error code and error type for each error that occurs Without the USB the user can access the 50 most recent errors via the Display Module NOTE For both the Job Log and the Error Log when the log is full new data automatically overwrites old data When data in either log is downloaded via the USB it remains in the module until it is overwritten 0 4 a 100 Zoom Help WordArt Smar
77. s 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 Use equipment only for its intended purpose Call your distributor for information Houte 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 TOXIC FLUID OR FUMES HAZARD 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 flu
78. s conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc
79. screen to screen above each key Up Down Arrows Use to move among fields on a screen items on a dropdown menu or digits in a settable field 3A0869H 23 Display Module Icon Key The following tables present a printable version of the information on the ProMix 2KE icon card See Table 5 page 57 for a printable version of the error code information on the reverse side of the card General Icons 0999 Hose Length Hatio Volume 24 Spray Gun States Desorption Screen Shortcuts Description DON Spray Mix Spray In Flush Box Purge in Flush Box System Configuration f pun Deme Maintenance AS mem Locked Calibrate e Operation Modes Softkeys Alarm Log Pumps Description Description Mix Spray Mix Standby Purge Purge Color Change Reset Counter Dispense A otart Stop Standby Dispense B Batch Calibrate po Park 2 3A0869H Screen Summary Display Module NOTE This summary is a one page guide to the ProMix 2KE screens followed by screen maps For operating instructions see Basic Operation page 31 For further detail on individual screens see Run Mode Details page 42 or Setup Mode Details page 45 Run Mode The run mode has two screen sections that control the mixing operations Mix Screens 2 4 38 e Spray Screen 2 controls most mixing opera tions e Batch Screen 3 con
80. ssure Too High or B Pressure Too Low it may not be possible to hold the desired mix ratio The system will generate an off ratio alarm and stop operation NOTE In multi flow rate systems it is recommended that you set up the system to run properly at the highest flow rate to ensure adequate fluid supply across the flow rate range In dynamic dosing component A dose valve is con stantly on Component B dose valve will cycle on and off one cycle every 0 5 1 0 seconds indicates proper balance Monitor system performance by watching the Display Module for warning messages which provide informa tion on system performance and adjust pressures accordingly See Table 5 on page 57 53 Dosing Options e gang B Pressure conto Too Low Low e Too High B Pressure Too High A Pressure B Pressure Fic 53 A B Control Range with Properly Sized pressure Restrictor NOTE If the restrictor is too small it may be necessary to supply more differential pressure than is available in your system FiG 54 A B Control Range with Too Large a Restrictor To Static Component A continuous flow Proportioned Material Mixer gt TRE Component B pulsed injection FiG 55 Schematic Diagram of Dynamic Dosing Operation Table 4 Dynamic Dosing Troubleshooting Guide for complete system troub
81. t the calibration process until the dispensed volume and mea sured volume match 3A0869H Basic Operation 10 After the volume for A1 A2 A3 or B is entered the ProMix 2KE controller calculates the new k factor and shows it on Calibration 1 Screen 22 and Cali bration 2 Screen 23 11 Before you begin production clear the system of solvent and prime it with material a Goto Mix mode b Trigger the gun into a grounded metal pail until mixed material flows from the gun nozzle Spraying NOTE See Run Mode Details pages 42 43 for further screen information if needed DA w 1 Calibrate the meters as described in Meter Calibra tion page 32 Meter k factors will update automati cally based on calibration results Make additional manual changes if desired as described in Cali bration 1 and 2 Screens 22 and 23 page 49 2 Press The system will load the correct potlife volume based on hose length and diameter entered on Configure 2 Screen 19 Once material is loaded the system returns to Standby Press PR again to spray the active recipe 33 Basic Operation 3 Adjustthe flow rate The fluid flow rate shown on the Display Module screen is for either component A or B depending on which dose valve is open 08 2510 1326 443 Active REB 10 recipe Flow rate Fic 21 Flow Rate Display If the fluid flow rate is too low increase air
82. tArt Graphics H B Job Recipe Mo Alarm 1 488 1 0 2 SFA2 0 il 2 QLBX Alarm 2 Alarm 3 Alarm 4 Alarm 5 SAD SADI SFAZ 39 Use of Optional USB Module 2 ALARM CSV Pig 2 E O lt gt ft K Alarm Log 2 USB Serial Number 09001088 1 3 Saftware Part Number 15W201 _4 Software Revision 1 10 001 5 82 _6 Date Time Alarm Number Alarm Type of Alarm 8 7 26 13 0 00 10 618 1 ADVISORY _9 7 26 13 0 00 11 619 MGB1 ADVISORY 10 7 29 13 12 03 38 620 EL RECORD 11 7 29 13 12 03 39 621 5 ADVISORY 12 7 29 13 12 03 40 622 1 ADVISORY _13 7 29 13 12 03 41 623 MGB1 ADVISORY 114 218569986 12 03 48 624 EL RECORD 15 218569986 12 03 49 625 CA ALARM 16 218569986 12 03 50 626 MESA ADVISORY I 17 218569986 12 03 51 627 1 ADVISORY 18 218569986 12 03 52 628 MGB1 ADVISORY 19 218569986 12 03 53 629 ADVISORY 20 218569987 12 04 00 1617 EL RECORD 21 218569987 12 04 01 1618 ALARM _22 218569988 12 04 08 624 EL RECORD 23 218569988 12 04 09 625 CA ALARM 24 218569988 12 04 10 626 MESA ADVISORY PIS 218569988 12 04 11 627 MGA1 ADVISORY 26 218569988 12 04 12 628 1 ADVISORY 27 218569988 12 04 13 629 MGP1 ADVISORY 2B 6 8 13 1
83. tputs Screen 37 An X displays in the box to show an electrical state of On for the dose valves B and A1 A2 and A3 solvent valves B and A the gun trigger and the alarm Press to start Forced Mode A sec ond set of check boxes displays Manually actuate the valves alarm or gun trigger For properly working com ponents an X will display in the corresponding second box upon actuation Press a to exit Forced Mode Moving to any other screen also will exit Forced Mode Dose 082550 Tel 3688 06 Solvent Valves Valves Gun Trigger Alarm Start Forced Mode D82570 _1616 3588 ua Pr R DE 3 KOO Stop Forced Mode FiG 51 Troubleshooting System Outputs Screen 37 3A0869H Dosing Options Sequential Dosing Components A and B dispense sequentially in the nec essary volumes to attain the mix ratio 1 The operator presses to begin operation 2 The ProMix 2KE controller sends signals to activate the solenoid valves The solenoid valves activate Dose Valves A1 A2 or A3 depending on recipe selection and B Fluid flow begins when the gun is triggered 3 Components A1 and B are introduced into the fluid integrator Fl one at a time as follows a TheA side dose valve DVA1 DAV2 or DVA3 opens and fluid flows into the integrator b Flow Meter A MA monitors the fluid volume dispensed and sends electrical pulses to the ProMix 2KE controller The con
84. troller monitors these pulses and signals c When the target volume dispenses Dose Valve A closes NOTE The dispense volume of component A and B is based on the mix ratio and dose size set by the user and calculated by the ProMix 2KE controller Dosing Options d Dose Valve B DVB opens and fluid flows into the integrator and is aligned proportionately with component e Flow Meter B MB monitors the fluid volume dispensed and sends electrical pulses to the ProMix 2KE controller f When the target volume is dispensed Dose Valve B closes The components are pre mixed in the integrator then uniformly blended in the static mixer SM NOTE To control output from the static mixer to the gun install an optional fluid pressure regulator Components A and B are alternately fed into the integrator as long as the gun is triggered If the gun is not triggered for two minutes the sys tem switches to Idle mode which closes off the mix manifold dose valves When the gun is triggered again the ProMix 2KE continues the process where it left off NOTE Operation can be stopped at any time by pressing E or shutting off the main power switch Table 3 Sequential Dosing Operation 3A0869H 51 Dosing Options SVB DVB DVA2 and DVA3 behind SM ti15699a Key MA Component A Meter MB Component B Meter DVA1 Component A Dose Valve DVB Component B Dose Valve DVA2 Second Color Catalyst Valve SVB Solv
85. trols dispense of a set vol ume e Totals Screen 4 displays grand and batch totals for materials A1 A2 A3 and B e Job Number Screen 38 displays job number and user number Error Log Screens 5 14 e 10 screens 5 errors per page e Displays date time and error Setup Mode The setup mode has four screen sections that allow an authorized user to choose the exact settings needed for the system Configure Screens 18 21 Configure 1 Screen 18 controls system type pump or meter dosing type sequential or dynamic dosing gun flush box enable number of guns 1 or 2 and system color configuration 1 or 3 Configure 2 Screen 19 controls hose length and diameter for one or two guns and flow rate region for dynamic dosing e Configure Screen 20 controls language for optional USB Module date format date time password setting and backlight timer e Configure 4 Screen 21 controls units for dis tance and volume Recipe Screens 27 33 e Recipe 0 Screen 27 includes timers for the system first second and third flush and a third flush material selection 3A0869H e Recipe 1 1 Screen 28 and 1 2 Screen 29 control Material 1 Color 1 parameters and flush e Recipe 2 1 Screen 30 and 2 2 Screen 31 control Material 2 Color 2 parameters and flush Recipe 3 1 Screen 32 and 3 2 Screen 33 control Material 3 Color 3 parameters and flush Maintenance Screens 24 26 e Maintenanc
86. ublication Graco reserves the right to make changes at any time without notice Original instructions This manual contains English MM 3A0869 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2010 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Hevision H December 2014
87. ve A1 A2 A3 and B solenoid valves to check operation e Increase air pressure Air pressure must be 75 120 psi 0 52 0 84 MPa 5 2 8 4 bar 120 psi is recom mended e There may be dirt or moisture in the air supply Filter appropriately e Refer to Valve Settings page 38 for adjustment guidelines e Fluid pressure is high and air pres e Adjust air and fluid pressure See sure is low recommended air pressure above 3A0869H System Errors QDA1 QDA2 Valve seal or needle seat are leaking Repair the valve Overdose A Flow meter fluctuations caused by pres Check for pressure pulsations The A dose has overshot and sure pulsations when combined with B is too large for the mix manifold Turn on the circulating pumps and capacity all the booth equipment such as QDB1 fans and conveyors Overdose B l The B dose has overshot Check if the ProMix 2KE is reading forcing an A dose that when any fluid flow combined with B is too large If the ProMix 2KE shows there is for the mix manifold capacity fluid flow and there are no leaks from the gun or any other seals or fittings the flow meters are proba bly being affected by pressure pul sations Close all the manifold valves Close the fluid shutoff valve between the fluid supply system and the flow meter The flow indica tion should stop If necessary install pressure regu lators or a surge tank on the fluid inlets to the ProMix 2K
88. w 3X CABLE COM BLACK PWR RED FLOW METER A SIG WHITE SHIELD GRN AIR FLOW SWITCH 1 3X CABLE FLOWMETERS SIG gt e COM SIG 7 PWR RED COM BLACK SIG WHITE SHIELD GRN in r gt GROUND TERMINAL 3A0869H Non Hazardous Location Electrical Schematic continued 3A0869H RIN _ l e eaJ _ _11_ _ mDc S SxNLQLCLrIOO o T NO ON 10 SOLENOID METER CABLE HARNESS E EEE 7 TE P 2 2 2 5 L CAN CAN H SHIELD UNUSED ALARM COMMON PURGE A DOSE A1 J12 12VDC FLOW METER A SIG COMMON DOSE A2 DOSE A3 J2 PRESSURE AIC TRANSDUCER LINEAR SENS A SIG UNUSED REED SWITCH_BTM DOWN REED SWITCH_TOP UP REED SWITCH_COM LINEAR SENS A 5 VDC LINEAR SENS A COM UNUSED 31992 HOLIMS 9334 dOSN3S REED SWITCH LINEAR SENSOR n CA mm rn rn FLUID CONTROL MODULE _ CAN L CAN CAN RTN CAN H SHIELD UNUSED AFS 1 COMMON PURGE B DOSE B Cn d CON 12VDC FLOW METER B SIG COMMON GFB INPUT AFS 2 GFB OUTPUT
89. w from fluid supply pressure fluctuations Backflow can cause ratio inaccu racies 4 Connect the gun fluid supply line between the static mixer SM outlet and the gun fluid inlet 3A0869H Installation FI SVA SVB DVA1 DVB DVA2 and DVA3 behind CVB CVA ti15699a SM Key MA Component A Meter MB Component B Meter DVA1 Component A Dose Valve DVB Component B Dose Valve DVA2 Second Color Catalyst Valve SVB Solvent Valve B DVA3 Third Color Catalyst Valve CVB Meter B Check Valve SVA Solvent Valve A SM Static Mixer CVA Meter A Check Valve Fl Fluid Integrator Assembly Fic 6 Fluid Controls Sequential Dosing 3A0869H 15 Installation Set Up the Fluid Manifold for Dynamic Dosing NOTE For more information about Dynamic Dosing see page 53 NOTE When using dynamic dosing it is very important to maintain a constant well regulated fluid supply To obtain proper pressure control and minimize pump pul sation install a fluid regulator on the A and B supply lines upstream of the meters If you will be operating using dynamic dosing the fluid manifold must be set up properly for your application Order the 15U955 Injection Kit accessory 1 See FIG 7 Remove the screws A and static mixer bracket assembly B 2 Loosen the static mixer nut N1 Remove and retain the static mixer SM 3 Loosen the u tube nuts N2 and N3 Discard the u tube C and the static mixer fitting D 4 Remove and retain
90. y to detect a failed meter You could spray pure resin or catalyst for 2 minutes without knowing 55 System Errors e Since the ProMix 2KE does not know it is spraying because there is no gun trigger air flow switch input it will go into System Idle every 2 minutes when in Mix mode System Idle Notice IDLE This warning occurs if the ProMix 2KE is set to Mix h received the air flow switch signal gun trigger The Gun Idle icon ii is displayed In applications using the AFS triggering the gun clears the warning and you can start spraying again and 2 minutes have elapsed since the system last Without the AFS triggering the gun does not clear the alarm To start spraying again you must press E then then trigger the gun 56 3A0869H Error Codes Table 5 System Alarm Advisory Record Codes ums Alarm Codes Alarm sounds system stops icon dis plays until problem is solved and alarm is cleared so 43 SAD1 Atomizing Air During Purge Gun 1 43 SAD2 Atomizing Air During Purge Gun 2 SPSA Purge Volume Error A SPSB Purge Volume Error B PreMix Error Color Co PreMix Error Catalyst PreFill Error Color PreFill Error Catalyst 2 Potlife Error Gun 2 44 44 44 44 45 Overdose A B Dose too Short 46 Overdose B A Dose too Short Dose Time A Error Dose Time B Error QLAX Leak Error A QLBX Leak Error B P6A1 Pressure Transduce

Graco 3A0869H User's Manual

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