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Graco 3A0868G User's Manual

1. FIG 9 Grounding 20 pups Key N Control Box ground screw A Control Box ground wire A Pump B ground screw A Pump B ground wire A Pump A ground screw Pump A ground wire Gun Flush Box ground screw By Gun Flush Box ground wire Ay True Earth Ground check your local code for requirements Ads Power cable Display Module Control Box 116467 3A0868G Display Module Screen number Ratio LCD display ape c 0 00 Potlife timers Soft keys Navigation keys Standby key Setup key Fic 10 Display Module Display Shows graphical and text information related to setup and spray operations The screen backlight is factory set to remain on The user may set a number of minutes the screen can be inactive before the backlight dims See Configure 3 Screen 20 page 44 Press any key to restore NOTE The Display Module and bracket can be removed from the cover of the electrical box and mounted remotely if preferred Key Setup Press to enter or exit Setup mode e Enter Press to choose a field to update to make a selection or to save a selection or value Left Right Arrows Use to move from screen to screen 3A0868G Error code 13 39 4 213 gt Gis LE gt Display Module Potlife state Active recipe Operation mode see page 22 for key C ccin Nav
2. 1 Fic 24 Select Language for USB Logs 37 Use of Optional USB Module 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 38 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 To help prevent fire and explosion never leave the USB flash drive in the USB port USB Port 15712 25 USB Port 5 Insert USB flash drive into USB port of computer 38 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 downloading data from more than one sprayer there will be more than one sprayer folder Each sprayer folder is labeled
3. Userinput Meters 50cc Pump 75cc Pump 100cc Pump Meters 125cc Pump 150cc Pump 9 9 Configure 1 Configure 2 1 Configure 2 1 Gun 1 or Gun 2 hose diameter 0 1 to 1 inch 0 25 inches 1 Configure 2 Flow Rate Region High 250 cc min or higher or High Low lt 250 cc min Air Flow Switch On or Off On Chinese Dutch English French German Ital English ian Japanese Korean Portuguese Russian Spanish Swedish Configure 2 19 Configure 3 20 USB Log Language mm dd yy Configure 3 20 Date Format mm dd yy dd mm yy yy mm dd Configure 4 21 Volume Units Liters Gallons US Gallons Imperial Gallons US Configure 471 pa Bar MPA Recipe 1 1 Ratio 0 1 to 30 1 Note Enter 0 to dispense A only 2 Recipe 1 1 2 Ratio Tolerance 1 to 99 percent 5 percent 1 2 2 Recipe 1 1 Potlife Timer to 240 minutes 60 minutes Note If set to 0 potlife alarm is disabled Recipe 1 2 Flush Times First A purge to 240 seconds Second B purge or Third Note If set to 0 the valve s will not flush using A or B chosen by user 8 8 8 9 45 Maintenance 1 24 Pump A or Pump B 0 to 9 999 999 24 25 26 999 45 Maintenance 1 Solvent Valve or Solvent O to 9 999 999 ve 60 seconds Maintenance 2 Dose Valve A or Dose Valve B to 9 999 999 Fluid Filter A or B or Air Filter to 9999 days days Calibrat
4. 21 Br C desi ey dros 21 eo ACT 22 Screen Summary 23 Ranges for User Inputs 24 Basic Operation 29 Pre Operation Tasks 29 POWER wu ru gat d tu X anu is 29 Initial System Setup 29 Prime the System 30 Pump Calibration 31 e uscire e A oe Cr m e ers 32 e oic atr s 32 Pressure Relief Procedure 35 Lock Mode 35 Valve Settings 35 d Hd RC oe o 35 Use of Optional USB Module 36 USB 36 SEID 37 Download Procedure 38 Hecommended USB Flash Drives 38 Run Mode Details 39 Run Mix Spray Screen 2 39 Run Home Screen 1 39 Run Mix Batch Screen 3 39 Run Mix Totals Screen 4 40 Run Job Number Screen 38 40 Run Log Errors Screens 5 14 40 Run Pump Control Screen 15 41 Setup Mode Details 42 Password Screen 16 42 Setup Home Screen 17 42 Configure 1 4 Screens 18 21 43 Recipe 1 1 S
5. 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 pump pul sation install a fluid regulator on the A and B supply lines upstream of the meters Select a Component B Restrictor Size If you cannot maintain the desired flow and spraying ratio you may need to select a different restrictor Use the charts on pages 61 to 65 to select an appropriate restrictor size based on the desired flow and mix ratio 48 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 Selec
6. DOSE A1 12VDC FLOW METER A SIG COMMON DOSE A2 DOSE A3 Un A PRESSURE ALC TRANSDUCER E J14 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 4 J25 USED USED USED USED ec e 31892 HILIMS 9338 YOSNAS UNUSED UNUSED UNUSED UNUSED REED SWITCH A LINEAR SENSOR FLUID CONTROL MODULE Cn d L CAN V CAN RTN CAN H SHIELD UNUSED AFS 1 COMMON PURGE B DOSE 3 12 VDC FLOW METER SIG COMMON GFB INPUT AFS 2 GFB OUTPUT 5 VDC Al COMMON Al SHIELD 5 LINEAR SENS B SIG UNUSED REED SWITCH_BTM DOWN REED SWITCH_TOP UP REED SWITCH_COM LINEAR SENS 5 VDC LINEAR SENS COM UNUSED USED USED USED USED 1 UNUSED 2 UNUSED 3 UNUSED 4 UNUSED B REED SWITCH am Ow Un 4 C9 J LINEAR SENSOR PRESSURE TRANSDUCER LINEAR SENSOR REED SWITCH CABLE 1 5 2 11 222 SS3NUVH 318V2 8 1 3105 Schematics 71 Dimensions and Mounting Dimensions and Mounting 14 76 37 cm
7. NOTE Do not exceed the maximum rated working pres sure shown on the system identification label or the low Q AN 2 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 If this is the first time starting up the system or if lines may contain air purge as instructed in Purg ing page 32 The equipment was tested with light weight oil which should be flushed out to avoid contaminating your material From Run Home Screen 1 press a Make sure that the system is in Standby mode Press show the dropdown menu Press to highlight Pump A then press e Put Pump A into supply pail Adjust air pressure to component A pump for your application Use lowest pressure possible est rated component in the system 30 8 NOTE If using an electrostatic gun Open the fluid supply valve to the pump shut off the electrostatics before spraying 9 10 11 If using gun flush box place the gun in the box and close the lid Press gt The pump will run 12 cycles If the gun flush box is not used trig ger the gun into a grounded metal pail until the system returns to v 4 Standby Press o to stop the pump before 12 cycles are completed If the pump is not fully primed after 12 cycles press gt agai
8. cc IVNOLLdO B 3105 AYM 90140 3500 g gt ALL amva 24 3500 a V GION310S AYM GION310S eee INVA GION31OS AYM T 10 3105 YHN ISMWHX4 uv an ann V 30und CIOJINVW ms Q103INVW OL 3901 8 5 NR uva 97 85 ed A 3onvo 917 85 164 OLL S8 YSIS 2 IATA 43138 VAN me zi YOLWINOIY 3915 gt 1O1ld V dWNd 8 HOLOW m MP O SWILSAS SdWNd KINO SWALSAS SdWNd engen gt uva 21 ed ZL 16481 DAY HIV YOLYNYILIV NO8DIW 07 OLNV und V 3dAL 03118 JAVA TIVE v Z ed Z ISd 001 V YOLOW 557 30111938 3A0868G 66 Schematics Non Hazardous Location Pneumatic Schematic x PL 010 3105 AVM IYNOILdO frr oe AAA BS PE o H GIONS1OS 1WNOILdO Tm 3ATVA 873500 9 om GION31OS INVA zv 3500 GION3105 N e 3ATVA 839804 GION310S AYM 173500 GION31OS J L V 39319 GION310S AYM 4 83 1330W 15 G 103IN
9. 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 a to toggle between Run Mode and Setup Mode Select N 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 any screen and the system is not locked or when a cor rect password is entered on the Password Screen The Setup Home screen displays the software versions of the boards in the Display Module Advanced Fluid Con trol Module and the USB Module if applicable 42 08 25 10 7 18 T WS 101002 Software Version Display Module Fluid Control Module USB Module 107 002 VC 101001 Maintenance Calibration Configure Recipe 35 Setup Home Screen 17 e Press a soft key button to select one of the four Setup Mode screen sections Configure 3 Recipe SE Maintenance ab or Calibration s e Press to toggle between Run Mode and Setup Mode 3A0868G 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 and number of guns 1 or 2 NOTE If 1 gun is selected users can enable a gun flush box yes The gun flush box option is avail ab
10. 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 publication Graco reserves the right to make changes at any time without notice Original instructions This manual contains English MM 3A0868 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2010 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Revision G June 2014
11. date format date time password setting and backlight timer Configure 4 Screen 21 controls units for dis tance volume and pressure 3A0868G Recipe Screens 28 and 29 e Recipe 1 1 Screen 28 and 1 2 Screen 29 control Material 1 Color 1 parameters and flush Maintenance Screens 24 26 e Maintenance 1 Screen 24 controls mainte nance timer actual and target for Pump A Pump B Solvent Valve A and Solvent Valve B e Maintenance 2 Screen 25 controls dose valves A and B maintenance timers actual and target e Maintenance 3 Screen 26 controls fluid and air filter maintenance timers actual and target Calibration Screens 22 and 23 e Calibration 1 Screen 22 controls pump factors for Pump A and Pump B e Calibration 2 Screen 23 allows the user to per form a calibration Troubleshooting The troubleshooting mode has three screen sections that allow an authorized user to troubleshoot system operation See FIG 14 page 28 System Inputs Screen 35 Membrane Test Screen 36 System Outputs and Manual Activation Screen 37 23 Display Module Ranges for User Inputs This table is a one sheet reference of the data range options accepted for each user input and the default setting See the page indicated in the table for further screen information if needed 9 2 A A A A gt gt BR A HR HR FA 2 A gt A gt Range Options
12. erly erly and is operational P4A1 or P4B1 Pump air pressure is set too high Reduce pressure on air supply to sys Pressure High Error tem or pumps System detects a high pres Thermal expansion occurring in lines Relieve pressure if system has been sure reading on pump A idle Decrease environmental P4A1 or pump 4 1 temperature Pressure transducer malfunction Replace transducer Verity that cable and AFCM are operational P6A1 or P6B1 Pressure transducer malfunction Replace transducer Verify that cable Pressure Transducer Error and AFCM are operational System does not detect pres sure transducer P6A1 or pressure transducer B P6B1 58 3A0868G System Errors DDA1 DDB1 Fluid supply is empty Refill fluid supply system Diving Cavitation Error Displacement pump is not seating properly Rebuild 2 pump and DDB1 is diving or cavitating ATL Aiinfl dsuppysystem 0 m Air in fluid supply system Tighten al ftings 3 All fittings Park Error while pump is attempting to park EFB1 does not park does and the mix manifold not reach bottom change Dispense valve malfunction Clean or rebuild dispense valve Ver over ify that solenoid is operational Clear air lines to valve DFA1 or DFB1 Displacement pump is not seating properly Rebuild displacement pump and Stall Up Error replace packings balls and seats Pump A DFA1 or Pump B Dispense valve not seating sealing Repla
13. 52 for an explanation of the different error codes 3A0868G Run Pump Control Screen 15 Run Pump Control Screen 15 displays if S selected from the Run Home Screen Use this screen to manually start and stop a pump Pump Park selection dropdown og 25no 15 51 Start Stop Home 33 Run Pump Control Screen 15 e Press show the dropdown menu e Press to highlight then press to select a pump or the Park option e f Pump A or Pump is selected use gt or to start The selected pump will run for 12 cycles To stop before the 12 cycles are completed press o f Park is selected use to the pump to the bottom of the stroke to park it so pump rod is fully enclosed in the lower and material can t dry on shaft during break or overnight 3A0868G Run Mode Details 41 Setup Mode Details Setup Mode Details Press 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 The Password Screen displays if a pass word has been set Set the password to 0000 to prevent Password Screen 16 from displaying See Configure 3 Screen 20 page 44 to set or change the password sm 1 08 l6 I 34 Password Screen 16
14. Fic 20 System Lock Mode 4 e Lock icons 3A0868G Basic Operation 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 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 21 TI11581a Fic 21 Valve Adjustment Shutdown 1 Follow Purging on page 32 2 Close main air shutoff valve on air supply line and on ProMix 2KE Non IS Systems Shut off ProMix power O position 35 Use of Optional USB Module Use of Optional USB Module USB Logs Job Log 1 See example 22 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 and mix ratio Job total vol umes are in cubic centimeters A log entry is made when a new job is initiated which occurs when batch totals are cleared or when the job number is incre mented from Run Job Number Screen 38
15. Job infor mation is displayed on the Display Module only through use of the optional USB Module eoo New Open Save Print Import Copy Paste Format Undo fedo D E Job Log USB Serial Number 09001088 Software Part Number 15W201 Software Revision 1 10 001 Date Time 8 12 13 16 32 10 8 12 13 16 37 54 10 8 12 13 15 41 43 11 8 12 13 16 42 22 12 8 12 13 17 54 51 enun 300000010 633 1 502 300000010 634 30 300000010 635 0 360 300000010 636 1 0 300000010 637 30 0 49 22 Sample Job Log 36 User Number Job No Ratio Job Total Job Total Job Recipe Alarm 1 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 23 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 1 JOB CSV m mu ae 100 el Autosum Sort A Z Sort Z A Gallery Toolbox Sheets Charts EE G Zoom Help SmartArt
16. Ratio 90 centipoise fluid 100 psi A side pressure 3A0868G 61 Dynamic Dosing Restrictor Selection Graphs psi bar MPa 1400 97 9 7 1200 83 8 3 1000 69 6 9 800 Key 2 Restrictor 3 Restrictor 4 Restrictor 7 Restrictor 55 5 5 600 41 4 1 400 28 2 8 200 Differential Pressure between A and B 14 1 4 400 28 2 8 300 21 2 1 200 14 1 4 100 7 0 7 50 3 4 0 34 500 1000 1500 2000 2500 3000 3500 4000 Flow Rate cc min Detail View 0 500 1000 Fic 56 Dynamic Dosing Performance 5 1 Ratio 90 centipoise fluid 100 psi A side pressure 62 3A0868G Dynamic Dosing Restrictor Selection Graphs psi bar MPa 800 55 5 5 Key en 2 Restrictor 48 4 8 3 Restrictor 600 4 Restrictor 41 4 1 7 Restrictor 500 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 0 500 1000 1500 2000 2500 3000 3500 4000 Flow Rate cc min Detail View 200 14 1 4 150 10 1 0 100 7 0 7 50 3 4 0 34 0 500 1000 57 Dynamic Dosing Performance 10 1 Ratio 90 centipoise fluid 100 psi A side pressure 3A0868G 63 Dynamic Dosing Restrictor Selection Graphs psi bar M
17. Trapped air can cause a pump or dispense valve to cycle unexpectedly which could result in serious injury from splashing or moving parts Use bleed type shutoff valves 4 The other end of the cable comes from the factory connected as shown depending on the configuration of your system 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 isol hem for servicing Wall Power Systems line accessories to isolate them for servicing with USB Module Connect the CAN cable to P3 on the USB Mod ule 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 e Wall Power Systems Graco distributor for information on air shutoff valves without USB Module for electrostatic applications Connect CAN cable to J8 on the Advanced 18 Fluid Control Module e line filter a 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 e Alternator Power Sys tems with or without USB Module Connect CAN cable to J3 on the alternator 116456 3A0868G 13 Installation Air Connections Fluid Supply See the System Pneumatic Schematic on page 66 hazardous location or page 67 non hazardous loca tion Requi
18. appears Use to highlight and press on the to clear the batch totals or on the gt to return to Run Totals Screen 4 without clearing 1032 3 12 gt __ 51 218 Fic 30 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 40 Run Job Number Screen 38 Run Job Number Screen 38 displays if S 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 0024 42 Job number 2 123456789 User number Home Fic 31 Run Job Number Screen 38 e Press to set the user number Use to change each digit then to move to the next digit Press when finished e 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 Run Log Errors Screens 5 14 Run 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 5 Screen 6 displays errors 6 10 etc 08 25 0 1502 14 Error codes Error Icons Fic 32 Run Log Errors Screen 5 e Use to view the next page See 54 page 50 for an explanation of the different error icons See Table 3 page
19. electrical con nection according to local codes 7 Fic 8 Ground Screw Power Switch 15712 Gun Flush Box Connect a ground wire from the Gun Flush Box ground lug to a true earth ground 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 3A0868G Installation Air and Fluid Hoses Use grounded hoses only Spray Gun Follow the grounding instructions in your gun manual e 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 All 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 ensure proper grounding resistance between components and true earth ground must be less than 1 ohm 19 Installation 9 I les SS
20. for the dose valves B and A1 A2 and A3 are used only for meter systems solvent valves B and A the gun flush box and the alarm Press to start Forced Mode A second set of check boxes displays Use to highlight an output to test Manually actuate the valve alarm or gun trigger corresponding to the highlighted box For properly work ing components an X will display in the second box upon actuation Press e to exit Forced Mode Moving to any other screen also will exit Forced Mode Dose Valves Start Forced Mode BU BU 5 08 z 3 Stop Forced Mode Fic 48 Troubleshooting Screen Outputs Screen 37 47 Setup Mode Details Dynamic Dosing In typical operation ratios 1 1 and above component A dispenses constantly Component B dispenses intermit tently in the necessary volume to attain the mix ratio General Operating Cycle 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 Fic 52 for a schematic diagram of the process Dynamic Dosing System Parameters The following parameters affect dynamic dosing perfor mance
21. limited to Protective eyewear and hearing protection Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer Important Two Component Material Information Important Two Component Material Information Isocyanate Conditions Spraying or dispensing materials containing isocyanates creates potentially harmful mists vapors and atomized particulates Read material manufacturer s warnings and material MSDS to know 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 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 par
22. signals the controller when the gun is being triggered Fluid Connections dE 2 Connect the component A supply line s to the com ponent A dose valve inlet DVA See 5 page 15 Connect the solvent supply line to the 1 4 npt f solvent valve inlets SVA and SVB Atomizing 6 air outlets _ NOTE Paint Recirculating System Only e If you are recirculating paint use the standard inlet on Dose Valve A or Dose Valve B Remove the plug bbe EN ae 1 gt directly opposite it on the dose valve for the recircu lation outlet See FIG 5 y Solenoid W 3 Connect the component B line to the component B air inlet 5 p dose valve inlet DVB 15709 Fic 4 Connect atomizing air 4 Connect the gun fluid supply line between the mix manifold MM outlet and the gun fluid inlet 14 3A0868G Installation Component Inlet Remove plug recirculation outlet Solvent inlet 116755 SVA NJ D D RAN 22079 ii E L2 I UU DVB IJ ti15697a e f PB NT Key PA Component A Pump DVA Component A Dose Valve SVA Solvent Valve A PB Component B Pump DVB Component B Dose Valve SVB Solvent Valve B MM Mix Manifold FiG 5 Fluid Connections 3A0868G Installation Tubing Chart and Diagrams Dose Valve A On Ar Red SoventVaveAOR _ TR 01640 Ar DoseVaveAOf _ 22 0156 40 Air Red So
23. similar to those tested 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 If the 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 In systems using an air assisted gun if the fluid pressure of component A 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 Table 4 Restrictor Sizes One Size Pareno These restrictors are included Injection Kit 15U955 v These restrictors are optional sizes not included the Injection Kit 3A0868G Dynamic Dosing Restrictor Selection Graphs psi bar MPa 4000 276 27 6 3500 Key 241 24 1 2 Restrictor 3000 43 Restrictor 207 20 7 4 Restrictor 7 Restrictor 2500 172 17 2 2000 138 13 8 1500 103 10 3 1000 69 6 9 Differential Pressure between A and B 500 34 3 4 0 0 500 1000 1500 2000 2500 3000 3500 4000 Flow Rate cc min Detail View 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 0 500 1000 Fic 55 Dynamic Dosing Performance 1 1
24. 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 format If opening the log file in Microsoft Word select Unicode 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 e Crucial Gizmo 4GB USB flash drive model JDO4GB 730 Transcend JetFlash V30 428 USB flash drive model TS4GJFV30 e OCZ Diesel 4GB USB flash drive model OCZUSBDSL4G 3A0868G Run Mode Details Run Mix Spray Screen 2 b 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 1Gun Gun status 08 25 10 3 46 4 24 3 Ele a8 e amp 10 Actual m ratio OW rate 10 min Potlife time ud Mix Standby Purge Home 2 Guns 08 25 10 1339 4 243 E18 1 0 75 Potlife for Sal 10 Fic 26 Run Mix Spray Screen 2 e Press to toggle between Run Mix Spray Screen 2 Run Mix Batc
25. 1 0 in 0 55 in 5 cm 1 4 cm 12 76 In Depth 18 0 in 46 cm 33 5 in 85 cm Merkur 5 in 145 cm Merkur Bellows 65 in 165 cm 7 18 22 00 56 cm 72 3A0868G Technical Data Technical Data Models pages 3 and 4 07 MPa 7 bar 051007 MPa 5 2 o 7 bar d 5 micron minimum filtration required clean and dry air 30 micron minimum filtration required clean and dry air 0 1 1 to 301 20 to 5000 cps 100 mesh minimum 1 4 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 F 5 to 50 C Approximate weight 300 Ib 136 kg Environmental conditions rating indoor use pollution degree 2 installation category II Fluids handled one or two component solvent and waterborne paints polyurethanes epoxies acid catalyzed varnishes moisture sensitive isocyanates On ratio accuracy 2 5 Noise level Materials of construction Wetted materials on all models 303 304 SST Tungsten carbide with nickel binder perfluoroelastomer PTFE 3A0868G 73 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 exte
26. 125 UNUSED 1 UNUSED 2 UNUSED 3 UNUSED 4 A REED SWITCH A LINEAR SENSOR FLUID CONTROL MODULE Un UNUSED AFS 1 COMMON PURGE B DOSE B J7 UNUSED UNUSED UNUSED UNUSED UNUSED J5 12VDC FLOW METER SIG COMMON GFB INPUT AFS 2 GFB OUTPUT Al SHIELD LINEAR SENS SIG UNUSED REED SWITCH_BTM DOWN REED SWITCH_TOP UP REED SWITCH_COM LINEAR SENS 5 VDC LINEAR SENS B COM UNUSED 1 UNUSED 2 UNUSED 3 UNUSED 4 UNUSED 1 UNUSED 2 UNUSED 3 UNUSED 4 UNUSED B REED SWITCH O Un 4 B LINEAR B PRESSURE TRANSDUCER LINEAR SENSOR Schematics SENSOR FERRITE U A 2 2 lt 522 SS3NUVH 318V2 4IL3W AIONFTIOS 69 Schematics Non Hazardous Location Electrical Schematic TERMINAL BLOCK L N GRND L GRND N LINE POWER FILTER L N SWITCH ROCKER 2 1 1 V V CAN_L V_CAN V CAN RTN CAN SHIELD POWER SUPPLY CAN L V_CAN SHIELD UNUSED UNUSED UNUSED UNUSED UNUSED USER INTERFACE MODULE BUTTON_DOWNARW TTON_UPARW BUTTON_CLEAR BUTTON_STOP BUTTON_FUNC4 BUTTON_FUNC1 START N RIGHTARW N_LEFTARW ENTER BUTTON_FUNC3 BUTTON_FUNC2 MEMBRANE COM BUTTONS D PURGE A DOSE A1 PURGE B DOSE DOSE A2 DOSE A3
27. 3 MGB1 624 EL 625 626 MESA 627 1 628 MGB1 629 1 1617 EL 1618 CA 624 625 626 MESA 627 1 628 MGB1 629 MGPL 624 EL 625 MESA 626 MGA1 627 MGB1 628 EQUI 1617 1689 EL 1690 EL 1691 EL 1692 EL 1693 EL 1694 EL 1695 EL 1696 EL 1697 EL 1703 EL 1706 EL 1707 EL 1710 EL 1711 EL 631 632 MESA 633 MGA1 634 MGB1 635 SFA 636 SFA2 637 EQUI 638 SFA2 639 5 1 640 SADL 641 QLBX Fic 23 Sample Error Log Setup Type of Alarm ADVISORY ADVISORY RECORD ADVISORY ADVISORY ADVISORY RECORD ALARM ADVISORY ADVISORY ADVISORY ADVISORY RECORD ALARM RECORD ALARM ADVISORY ADVISORY ADVISORY ADVISORY RECORD ADVISORY ADVISORY ADVISORY RECORD RECORD RECORD RECORD RECORD RECORD RECORD RECORD RECORD RECORD RECORD RECORD RECORD RECORD RECORD RECORD RECORD ADVISORY ADVISORY ADVISORY ALARM ALARM RECORD ALARM ALARM ALARM ALARM The only setup required is to select the language in which you want to view the downloaded data Screens are icon based and do not change Navigate to Config ure 3 Screen 20 Select your language from the lan guage dropdown 3A0868G Use of Optional USB Module 2 ALARM CSV Fale m 4 e New Open Save Print Import Copy Paste Format Undo Redo fa 100 AutoSum Sort A Z Sort Z A Gallery Toolbox Zoom Help Language 087250 163041988 dropdown EE ENGLISH menu
28. A 52 522 Enclose all cables routed the spray booth and high traffic areas in conduit to prevent damage from paint Ground solvent and traffic Neutral The ProMix 2KE operates with 85 250 VAC 50 60 Hz 4162014 input power with a maximum of 2 amp current draw The power supply circuit must be protected with a 15 amp maximum circuit breaker Fic 6 Control Box Electrical Connection Not included with system TERMINAL 0 e Power supply cord compatible to your local power configuration Wire gauge size must be 8 14 AWG POWER e The input power access port is 22 4 mm 0 88 in in SUPPLY diameter It accepts a bulkhead strain relief fitting or conduit 1 Verify that electrical power at the main panel is shut off Open Control Box cover SWITCH ROCKER 2 Connect electrical cord to the terminal block as shown in FIG 6 3 Close the Control Box Restore power 4 Follow instructions in Grounding page 19 Fic 7 Electrical Schematic 18 3A0868G 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
29. 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 counter to zero 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 3A0868G Glossary of Terms 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 Pump Calibration Factor the amount of material dis pensed per inch of pump travel Purge when all mixed material is flushed from the sys tem Purge Time the amount of time r
30. CM and connecting to another module either the Display Module or USB Module sions of software installed kit 16D922 on all modules The red LED on the AFCM is on If on solid replace module 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 and install the USB Communication Error USB Module The system detected a USB The cable is disconnected or broken Put system in standby and reconnect Module at last power up but or replace the USB cable does not detect it currently 3A0868G 53 System Errors Alarm and Description EQU2 Most USB drives do not conform to IS stan Put system in Standby Insert the USB Drive Error dards so it is hazardous to use one while USB drive only in a non hazardous The USB drive has been the system is running environment inserted when the system is not in Standby SG The cover of the gun flush box is not Close the cover and clear the alarm Gun Flush Box Error closed A gun flush box is enabled Purge the system with solvent or but the system does not For systems with
31. FLOW METER B COM BLACK SIG WHITE 3X CABLE SHIELD GRN P4 1 UNUSED 2 UNUSED 3 UNUSED 4 UNUSED 5 UNUSED P1 J2 1 N USB COMPONENT 3 VCAN 3 MODULE 4 V CAN RTN 4 5 V CAN RTN 5 6 CHASSIS GND 6 7 CHASSIS GND 7 8 V CAN RTN 8 9 V CAN RTN 9 0 BIT3 0 1 BIT2 1 2 GND 2 3 SCK 3 4 50 4 5 5 6 V 6 7 V 7 8 V 8 9 V CAN RTN 9 20 V CAN RTN 20 21 CANL 21 22 CANH 22 23 V CAN RTN 23 24 V CAN RTN 24 25 BITO 25 26 BIT1 26 27 VTOKEN 27 28 LOFO 28 29 HOLD 29 30 ICS 30 gt oO MO hh dad gt GROUND LLL L JTERMINAL 3A0868G Hazardous Location Electrical Schematic continued SOLENOID METER CABLE HARNESS 711 7 Pf m Yooo O O gt gt 3 099909 uU 3A0868G J8 CAN L 1 4V CAN 2 CAN 3 CAN H 4 SHIELD 5 UNUSED 1 ALARM 2 COMMON 3 PURGE A 4 DOSE Al 5 J12 12 VDG 1 FLOW METER A SI 2 COMMO 3 DOSE A2 4 DOSE A3 5 J2 5VDC 1 A PRESSURE Al 2 TRANSDUCER COMMON 3 Al 4 SHIELD 5 114 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 ao UNUSED 8 22 5 J25 AD UNUSED 1 AZ UNUSED 2 T UNUSED 3 59 UNUSED 4 gt co m
32. Graphics WordArt H K L Alarm 2 Alarm 3 Alarm 4 Alarm 5 488 1 0 2 SPAS 0 3 1 2 SADI SAD1 SPAS 3A0868G 2 _ 3 Software Part Number 15W201 4 Software Revision 1 10 001 _5 un or 9484 lus 99 d 7 26 13 7 26 13 7 29 13 7 29 13 7 29 13 7 29 13 218569986 218569986 218569986 218569986 218569986 218569986 218569987 218569987 218569988 218569988 218569988 218569988 218569988 218569988 B 8 13 B 8 13 B 8 13 B 8 13 B 8 13 B 8 13 B 8 13 B 8 13 B 8 13 B 8 13 B 8 13 B 8 13 B 8 13 8 8 13 B 8 13 B 8 13 B 8 13 B 8 13 B 8 13 B 8 13 8 12 13 8 12 13 8 12 13 8 12 13 8 12 13 8 12 13 8 12 13 8 12 13 8 12 13 8 12 13 8 12 13 Normal View Time 0 00 10 0 00 11 12 03 38 12 03 39 12 03 40 12 03 41 12 03 48 12 03 49 12 03 50 12 03 51 12 03 52 12 03 53 12 04 00 12 04 01 12 04 08 12 04 09 12 04 10 12 04 11 12 04 12 12 04 13 12 08 00 12 08 01 12 08 02 12 08 03 12 08 19 12 22 23 12 26 25 12 26 57 12 27 19 12 28 33 12 29 01 12 29 28 14 50 45 14 52 15 15 19 49 15 33 55 15 35 28 15 39 48 15 50 46 15 52 14 16 22 05 16 22 06 16 22 07 16 22 08 16 33 18 16 43 30 16 45 27 17 51 42 17 52 33 17 53 37 17 54 07 2 ALARM CSV 4 Ready Alarm Number Alarm 618 MGAI 619 MGB1 620 EL 621 MESA 622 MGA1 62
33. INTERFACE MODULE 10 CAN CABLE 50 OPTION 18 PSI ALTERNATOR 2 CAN CABLE USB MODULE 1 5 mx MODULE MIN FLUID 20 CAN CABLE CONTROL MODULE LINEAR SENSOR REED SWITCH CABLE ee tul REED SWITCH LINEAR SENSOR PRESSURE TRANSDUCER FiG 1 Hazardous Location Installation 3A0868G LINEAR SENSOR REED SWITCH CABLE B REED SWITCH B LINEAR SENSOR B PRESSURE TRANSDUCER 11 Installation Non Hazardous Locations 10 CAN CABLE 50 OPTION LINE POWER POWER USB MODULE FILTER SUPPLY lt S FLUID CAN CABLE CONTROL MODULE LINEAR SENSOR LINEAR SENSOR REED SWITCH CABLE REED SWITCH CABLE A REED B REED SWITCH SWITCH A LINEAR B LINEAR SENSOR SENSOR PRESSURE B PRESSURE TRANSDUCER TRANSDUCER 2 Non Hazardous Location Installation 12 USER INTERFACE MODULE 3A0868G Installation Display Module Air Supply 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 Requirements e Compressed air supply pressure 75 100 psi 517 700 kPa 5 2 7 bar e Air hoses use grounded hoses that are correctly 2 Snap the Display Module P And sized for your system into the bracket ti16672a 3 Connect one end of the CAN cable provided to J6 on the Display Module either port
34. Merkur A 3500 24 1 241 ProMix 2KE non hazardous location equipment manufactured in 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 Related Manuals Description 406823 Dispense Valve Seat Kit 3A1244 Graco Control Architecture Module Programming Description 312792 Merkur Displacement Pump 312793 Merkur Bellows Displacement Pump 312796 NXT Air Motor 406714 Rebuild Kit for High Pressure 313542 Dispense Valve 4 3A0868G Warnings 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
35. Operation gt 7 ProMix 2KE 3 0868 Pump Based Plural Component Proportioner EN Self contained electronic two component paint proportioner For professional use only Important Safety Instructions Read all warnings and instructions in this manual Save these instructions See pages 3 4 for model information including maxi mum working pressure and approvals ti15696a PROVEN QUALITY LEADING TECHNOLOGY Contents Med rw rue a ROS ace 3 cts hed oe aden ne 5 Important Two Component Material Information 8 Isocyanate Conditions 8 Material Self ignition 8 Keep Components A and Separate 8 Moisture Sensitivity of Isocyanates 8 Changing Materials 8 Glossary of Terms 9 OVERVIEW ansehen 10 anne nie 10 Component Identification and Definition 10 Installation 10 General Information 10 Intrinsically Safe Installation Requirements 11 Display Module 13 Air SUDDIV Se petites ale sim ett 13 Fluid Supply 14 Tubing Chart and Diagrams 16 a wae on ER 18 GIOUNGIAG a3 9 93 rar Y Ios ica cet ded 19 Display Module
36. Pa 300 21 2 1 250 Key 17 2 1 72 2 Restrictor 3 Restrictor 4 Restrictor 7 Restrictor 200 14 1 4 150 10 3 1 03 100 7 0 0 7 50 3 4 0 34 Differential Pressure between A and B 0 500 1000 1500 2000 2500 3000 3500 4000 Flow Rate cc min Detail View 100 7 0 7 75 5 2 0 52 50 3 4 0 34 25 1 7 0 17 0 500 1000 58 Dynamic Dosing Performance 20 1 Ratio 90 centipoise fluid 100 psi A side pressure 64 3A0868G Dynamic Dosing Restrictor Selection Graphs psi bar MPa 200 14 1 4 180 12 4 1 2 Ke 160 i estrictor Mate 4 Restrictor 140 lt 7 Restrictor Ba 9 7 0 9 120 83 08 Q 100 7 0 7 5 7 0 7 D 80 5 5 0 55 lt 60 4 1 0 41 c 40 8 2 8 0 28 20 1 4 0 14 0 0 500 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 59 Dynamic Dosing Performance 30 1 Ratio 90 centipoise fluid 100 psi A side pressure 3A0868G 65 Schematics Schematics Hazardous Location System Pneumatic Schematic 48 Cl ZL ISd OZ 3ATVA 331138 AlddNS Y4MOd 4NIGYNL 38nL5NO1 09 X TO 2 1
37. SB LED_YELLOW GION11OS AM IAA TL COM LEDS UNUSED UNUSED UNUSED UNUSED GION310S AIR FLOW SWITCH 1 GFB 1 PRESSURE SWITCH AIR FLOW SWITCH 2 70 3X CABLE vn PWR RED FLOW METER COM BLACK SIG WHITE a 7 Er 7 3X CABLE PWR RED FLOW METER B COM BLACK SIG WHITE SHIELD GRN lt gt or 227 Lom 29 P1 2 1 VCAN 1 USB BASE 2 VCAN 2 USB COMPONENT 1 3 MODULE MODULE 4 V CAN RTN 4 5 V CAN RTN 5 6 CHASSIS GND 6 7 CHASSIS GND 7 8 V CAN 8 9 V CAN 9 0 BIT3 0 1 BIT 2 1 2 GND 2 3 SCK 3 4 50 4 5 5 6 CAN 6 7 CAN 7 8 V CAN 8 9 V CAN RTN 9 20 V CAN RTN 20 21 CANL 21 22 22 23 V RTN 23 24 V CAN 24 25 BITO 25 26 BIT 1 26 27 VTOKEN 27 28 LOFO 28 29 HOLD 29 30 ICS 30 1 2 3 4 5 TP NE 6 MANIFOLD Le es RED 5 BLACK RED BLACK RED Bee gt BLACK RED _ BLACK SHIELD GRN GROUND EIN EIS TERMINAL 3A0868G Non Hazardous Electrical Schematic continued SHIELD OR Sau PBwu 34086880 gt 23 09 Saum 4 C N20 SOLENOID METER CABLE HARNESS 17 11 22 E _ 1 am J8 CAN_L CAN Un A gt UNUSED ALARM COMMO PURGE A
38. VW G103INVW OL 3901 8 8 KINO SWALSAS SdWNd INdNI EE OZ OLNY v 391193318 JAVA TIVE v V uva Z ed 2 ISd 001 NOWIIN 5 uvg 9 9 ed OLNY 3onv9 9 86 ISd OLL S8 DJY 8 YIV Wa 2 anv 10148 D 10119 Y dWhd 8 YOLOW SW31SAS SdNNd V dOLOW dfbfd3W YOLV 10538 67 3A0868G Schematics Hazardous Location Electrical Schematic 18 PSI 1 5 FCM MIN MEMBRANE 68 133333333 4525 SE 2 ww 33 wo Ov Un I 00 gt USER INTERFACE MODULE m oS 1 2 3 4 5 UNUSED UNUSED UNUSED UNUSED UNUSED PURGE A Ba DOSE A1 lt 258 PURGE B DOSEB DOSE A2 DOSE A3 0103105 MME AIR FLOW SWITCH 1 GFB 1 PRESSURE SWITCH AIR FLOW SWITCH 2 SIG a SIG USB BASE MODULE MANIFOLD Leo ae BLACK RED BLACK RED Cee gt BLACK RED at L BLACK 3X CABLE PWR RED FLOW METER A COM BLACK SIG WHITE SHIELD GRN 14 PWR RED
39. a gun flush box the gun is fresh mixed material detect a gun in the gun flush not in the box when purge is active box during purge color Solvent Purge See Purging change or auto dump Mixed Material on page 33 The system purges until the preset To prevent mixed material from purge time is complete curing in the equipment do not shut off power Follow one of New Mixed Material Purge Go the solutions at right to Mix mode and spray the required volume to restart the potlife timer SAD1 or SAD2 Atomizing air is stuck on Replace air flow switch Atomizing Air During Purge GinienotinCun Flush Box Insert the gun into the Gun Flush Box Atomizing air to Gun 1 SAD1 or Gun 2 SAD2 is detected Gun Flush Box air shutoff is not working Test using Troubleshooting Screens when purge is selected or dur See page 46 Repair replace air shut ing purge sequence off valve as needed Air leak in atomizing air line Inspect air line for kinks damage or loose connections Repair or replace as needed 54 3A0868G System Errors SFA1 or SFB1 Gun line or valve is plugged or stuck components and clean repair PreMix Error or replace as necessary In systems with a gun flush Pump s not working or out of fluid Refill fluid supply Check and repair box insufficient quantity of pump See pump manual for repair resin color SFA1 or catalyst procedures and replacement parts 22 c Air lin
40. al 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 39 41 for further screen information if needed N Vg 1 Calibrate the pumps as described in Pump Calibra tion page 31 Pump 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 46 Adjust the flow rate 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 loaded recipe 3 Adjust the 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 25 10 1345 4 23 ei 1 0 0 00 ou rate B m Fic 18 Flow Rate Display 32 If the fluid flow rate is too low increase air 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 y
41. ce needle seat on dispense DFB1 does not stall up dur valve ing the pump calibration and stall test Keeps moving up when dosing valve is closed DGA1 or DGB1 Displacement pump is not seating properly Rebuild displacement pump and Stall Down Error replace packings balls and seats Pump A DGA1 or Pump B DGB1 does not stall down during the pump calibration and stall test Keeps moving down when dosing valve is closed No Stall Error replace packings balls and seats Pump DHA1 or Pump B Dispense valve not seating sealing Replace needle seat on dispense DHB1 does not stall in either valve direction during the pump cali bration and stall test keeps moving when dosing valve is closed Dispense valve not seating sealing Replace needle seat on dispense valve 3A0868G 59 Dynamic Dosing Restrictor Selection Graphs Dynamic Dosing Restrictor Selection Graphs Use the graphs on pages 61 65 as a guide to determine the correct restrictor size for your desired flow and mate rial viscosity Table 4 lists the available restrictor sizes Example 60 Application air spray system with a 5 1 mix ratio Fluid Supply 1 1 pumps at 100 psi 7 bar 0 7 MPa Flow Rate 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
42. creen 28 44 Recipe 1 2 Screen 29 44 Maintenance 1 3 Screens 24 26 45 Maintenance Recommendations 45 Calibration 1 and 2 Screens 22 and 23 46 Troubleshooting Screens 35 37 46 Dynamic Dosing 48 System Errors USES ER VE 50 System Alarms 223 0204 de So bed dex weeds 50 System Advisory Record Codes 50 To Clear Error and Restart 50 Air Flow Switch AFS Function 50 System Idle Warning IDLE 51 GOUGS os doe Roe a es XE 52 Alarm Troubleshooting 53 Dynamic Dosing Restrictor Selection Graphs 60 Schemali6S 66 Dimensions and Mounting 72 Technical Data 73 Graco Standard Warranty 74 3A0868G 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 USB psi MPa bar Port Approvals A 31 Merkur AandB 300 24 20 _ 4 Merkur A uii Merkur Bellows B 300 2 1 21 lt em gt Merkur A APPROVED 24F107 23 1 2300 15 8 158 Intrinsically safe and pu
43. e before e the first time material is loaded into equipment e Servicing e shutting down equipment for an extended period of time e putting equipment into storage 1 Press on Run Mix Spray Screen 2 or from any screen to put the system in Standby 2 Trigger the gun to relieve pressure 3 If you are using a high pressure gun engage the trigger lock Remove spray tip and clean tip sepa rately 4 If using an electrostatic gun shut off the electrostat ics before flushing the gun 5 Disconnect the component A and B fluid supplies at the pump inlets and connect solvent supply lines 6 Adjust the solvent fluid supply pressure Use the lowest possible pressure to avoid splashing 7 Remove the Control Box cover to access the sole noid valves See FIG 19 33 Basic Operation 8 Purge as follows 9 Reinstall the Control Box cover e Purge component A side Press the manual 10 Shut off the solvent fluid supply override on the Dose Valve A solenoid valve and trigger the gun into a grounded metal pail 11 Disconnect the solvent supply lines and reconnect l the component A and B fluid supplies e Purge component B side Press the manual override on the Dose Valve B solenoid valve NOTE The system remains full of solvent and trigger the gun into a grounded metal pail until clean solvent flows from the gun e Repeat to thoroughly clean the mix manifold Manual overrides O mO ut Sol
44. e 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 MN plete R When done purging the system automatically switches to Standby mode If the system is not completely clean repeat step 6 NOTE If necessary adjust purge sequence times so only one cycle is required 3A0868G Basic Operation 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 Verify that clean solvent flows from each gun If not repeat purge or clear clog blockage in sys tem Purging Fluid Supply System Follow this procedur
45. equired 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 Standby refers to the status of the system 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 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 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 A and B as well as solvent valves Pumps Display Module Used to set up display operate and monitor the system Used for daily painting functions including choosin
46. eration completed N A System performed an autodump after N A a potlife EQU1 USB Drive connected while in Standby 3A0868G System Errors Alarm Troubleshooting CA The CAN cable between the Display Mod Verify that the cable is correctly Communication Error ule and the Advanced Fluid Control Module connected The Display Module is not is not connected communicating with the The CAN cable is cut or bent Verify that the cable has not been cut Advanced Fluid Control or bent at a radius smaller than 1 6 in Module 40 mm The cable or connector failed Replace cable Alternator Powered Systems For any module that does not have power disconnect and Check that the Advance Fluid Control Mod check the voltage on the cable ule AFCM Display Module DM and produced by the alternator mod USB Module have power green LED and ule See Alternator Module Power are communicating amber LED blinking Output If the proper voltage is not detected troubleshoot 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 Heplace 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 AF
47. es or solenoids are plumbed incor Check air line path See System 4 rectly or solenoids not working Pneumatic Schematic page 66 or 67 Verify that solenoid is working Flow rate is too low Increase fluid pressure SHA1 or SHB1 PreFill Error Total PreFill sequence volume is not reached for color SHA1 or catalyst SHB1 during the 5 minute PreFill sequence SM Gun Flush Box is not triggering gun Verify trigger is being pulled Adjust MixFill Start Error as needed In systems with a gun flush Line or gun is plugged or restricted Clean line tip or filter Increase fluid pressure or decrease mixed material is detected Flow rate 1 too low ae restriction during the 10 second mixed fill sequence Valve is stuck Clean valve or verify that solenoid is triggering valve properly 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 keep Purge the mixed material line See Potlife Error fresh mixed fluid in the mix manifold hose 33 Potlife has been exceeded for and gun the mixed material for Gun 1 Check that hose length and diameter QPD1 or Gun 2 QPD2 have been entered correctly See Configure 2 Screen 19 page 43 Spray the required volume to restart the potlife timer 3A0868G 55 System Errors R1 Ratio Low Error The mix ratio is lower
48. eshooting active press to display Troubleshooting System Inputs Screen 35 An X displays in the box to indicate if Pump B is up or down if Pump A is up or down if Air Flow Switch 1 or 2 is on and if the gun is in the Gun Flush Box This screen also displays the pressure of Pump A and Pump B The fields relating to meter func tion can be ignored Air Flow Gun in Gun Flush Box Fic 46 Troubleshooting System Inputs Screen 35 e Press EA then again to move to Trouble shooting System Outputs Screen 37 Press to move to the Membrane Test Screen 36 Membrane Test Screen 36 From Setup Home Screen 17 with Troubleshooting active press gt then again Membrane Test Screen 36 displays You could also press 5 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 08125 10 1619358837 51 Fic 47 Membrane Test Screen 36 e Press three times to return to Setup Home Screen 17 Direct access to any other screen is not possible 3A0868G Setup Mode Details Troubleshooting System Outputs Screen 37 From Setup Home Screen 17 with Troubleshooting active press to display Troubleshooting System Outputs Screen 37 An X displays in the box to show an electrical state of On
49. eys won Description _ Mix Spray Purge Reset Counter Start Stop Standby 3A0868G 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 29 For further detail on individual screens see Run Mode Details page 39 or Setup Mode Details page 42 Run Mode The run mode has three 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 controls dispense of a set vol ume e Totals Screen 4 displays grand and batch totals for materials A 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 Pump Control Screen 15 e Manually start or stop a pump e Park pumps for brief shutdowns 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 gun flush box enable and number of guns 1 or 2 Configure 2 Screen 19 controls hose length and diameter for one or two guns flow rate region setting and air flow switch enable or disable e Configure 3 Screen 20 controls language for optional USB Module
50. fter 40 seconds and the system goes into Standby NOTE Systems with a 45 1 pump ratio are designed for use with an airless gun These systems contain no air flow switch and are set up so that they do not trigger a System Idle Warning NOTE For airless applications with other pump ratios the air flow switch can be disabled on Configure 2 Screen 19 3A0868G System Idle Warning IDLE This warning occurs if the ProMix is set to Mix m and 2 minutes have elapsed since the system last received the air flow switch signal gun trigger The Gun Idle icon ii is displayed This warning is not active in systems with a 45 1 pump ratio using an airless gun In applications using the AFS triggering the gun clears the warning and you can start spraying again Without the AFS triggering the gun does not clear the alarm To start spraying again you must press EU then m then trigger the gun 3A0868G System Errors 51 System Errors Error Codes Table 3 System Alarm Advisory Record Codes ems Alarm Codes Alarm sounds system stops icon dis plays until problem is solved and alarm is cleared SAD1 Atomizing Air During Purge Gun 1 SAD2 Atomizing Air During Purge Gun 2 SFA1 PreMix Error Color 55 SFB1 PreMix Error Catalyst SHA1 PreFill Error Color SHB1 PreFill Error Catalyst MixFill Start Error 54 _ MixFill Complete Error QPD1 Potlife Error Gu
51. g recipes reading clearing errors and placing the system in Spray Standby or Purge mode Installation General Information e Reference numbers and letters in parentheses in the text refer to numbers and letters in the illustra tions e Be sure all accessories are adequately sized and pressure rated to meet system requirements To protect the Display Module screens from paints and solvents clear plastic protective shields are available in packs of 10 Part No 24G821 Clean the screens with a dry cloth if necessary 10 3A0868G Installation Intrinsically Safe Installation Requirements Do not substitute or modify system components as this may impair intrinsic safety For installation maintenance or operation instructions read instruction manuals Do not install equipment approved only for non hazardous location hazardous location See the identification label for the intrinsic safety rating for your model 1 The installation must meet the requirements of the National Electric Code NFPA 70 Article 504 Resp Article 505 and ANSI ISA 12 06 01 2 Multiple earthing of components is allowed only if high integrity equipotential system realized between the points of bonding For ATEX install per EN 60079 14 and applicable local and national codes Hazardous Classified Locations Class 1 Div 1 Group D T3 US and Canada Class 1 Zone 1 Group IIA T3 ATEX only USER
52. h Screen 3 Run Mix Totals Screen 4 and Run Job Number Screen 38 Press to access Run Home Screen 1 Run Home Screen 1 Screen number oazo Ted 17 EI Fic 27 Run Home Screen 1 3A0868G Run Mode Details Press a soft key button to select one of the main Run Mode screen sections Mix m Errors or Pump Control d Press to enter the Setup screens Run Mix Batch Screen 3 Run Mix Batch Screen 3 displays if is selected from the Run Mix Spray Screen Use the Mix Batch screen to dispense set volumes Target volume can be set from 1 to 9999 cc 05 250 1355 24 16 Target ratio Actual ratio Target volume Actual volume Start Stop Home Fic 28 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 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 39 Run Mode Details Run Mix Totals Screen 4 Run Mix Totals Screen 4 displays if is selected from the Run Mix Batch Screen Use this screen to view grand and batch totals for material A and material B and to clear batch totals if desired 08250 16 03 3 12 gt Pied Batch total Grand total Home Clear batch totals increment job Fic 29 Run Mix Totals Screen 4 FEEEE e Press to clear all batch totals A verification screen
53. hird flush as user defined thotidlschawitls thesAipardashalfertexatnptzoenter 0 seconds for A 30 seconds for 30 seconds for the third flush time and select A for the third flush source The system wil Third flush time uses material set in next field First flush time A purge Second flush time B purge Fic 41 Recipe 1 2 Screen 29 e Press to 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 toggle between the Recipe screens e Press N to return to Setup Home Screen 17 3A0868G Maintenance 1 3 Screens 24 26 Maintenance 1 Screen 24 displays if zB is selected on Setup Home Screen 17 The Maintenance Screens display actual and target maintenance timers for pumps and solvent valves Maintenance 1 Screen 24 dose valves Maintenance 2 Screen 25 and fluid filters and air filters Maintenance 3 Screen 26 Maintenance tim ers for pumps and valves are settable from O to 9999999 Timers for filters are settable from O to 9999 days Solvent valves Pumps a Maintenance actual and target Maintenance 1 Clear Totals Dose valves Fluid filters p EET E 0 x X 0000 P Maintenance 3 FIG 42 Setup Maintenance 1 3 Screens 24 26 Press to move through the three mainte nance screens ELH Press m m to clear the maintenance total that i
54. i 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 3A0868G Basic Operation Non IS Systems Wall Power Supplied Turn the AC Power Switch ON I ON 0 OFF AB 6122 2 pP 09 0 I GL zer 2 22 22 1 Ae gt 2 7 3 4 20 i HH L HE 2 355 ii ii H 82 i pb 718 ji sii eU i 85 FIG 15 Power Switch Power Switch 16336 2 Graco logo will display after five seconds followed by Run Mix Spray Screen 2 082570 13 39 4 3 R BG 1 oo 0 00 10 min 16 Run Mix Spray Screen 2 cc min Initial System Setup 1 Change optional setup selections to desired param eters as described in Configure 1 4 Screens 18 21 page 43 2 Set recipe and flush information as described in Recipe 1 1 Screen 28 and Recipe 1 2 Screen 29 page 44 Set maintenance timers for pumps valves fluid fil ters and air filters as described in Maintenance 1 3 Screens 24 26 page 45 29 Basic Operation Prime the System NOTE See Run Mode Details pages 39 41 for further screen information if needed 1
55. ids are operational Dose Valve B is turned in too far e Refer to Valve Settings page Dose Valve A is open too far 35 for adjustment guidelines e Fluid pressure is high and air pressure Adjust air and fluid pressure See is low recommended air pressure above 56 3A0868G 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 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 If the alarm occurs during start up after Restrict gun needle travel to slow purging the flow rate was probably too down the initial fluid delivery rate until high fluid hoses are loaded with material If the alarm occurred after you were spray Adjust component A and B fluid sup ing for some time the pressures from the regulator pressures until they are fluid supplies could be unbalanced about equal f the pressures are already about equal verify that com ponent A and B dose valves are oper ating properly Slow actuation of the component A or B Manually operate the Dose Valve A valves This can be caused by and B solenoid valves to check oper ation e Air pressure to the
56. igation keys Flow rate A Enter key Error Reset key 116319 Keys are used to input numerical data enter setup screens navigate within a screen scroll through screens and select setup values NOTICE To prevent damage to the soft key buttons do not press the buttons with sharp objects such as pens plastic cards or fingernails Up Down Arrows Use to move among fields on a screen items on a dropdown menu or digits in a settable field Error Reset Use to clear alarm SO cause can be fixed Also use to cancel a data entry field Standby Stops the current operation and puts the system into standby Soft keys Press to select the specific screen or operation shown on the display directly above each key 21 Display Module Icon Key The following tables present a printable version of the information on the ProMix 2KE icon card See Table 3 page 52 for a printable version of the error code information on the reverse side of the card General Icons Ratio Volume 22 Spray Gun States icon Description Mix Mix Spray In Flush Box Purge Purge in Flush Box Operation Modes Description EN MEE Purge Ei Color Change Dispense Batch Calibrate emm Screen Shortcuts ieon Description _ Home A gt Spray me 02 Alarm Log Mee System Configuration o 106 Maintenance zd Calibrate Softk
57. ion 1 22 Pump A or Pump B Factor 5 to 50 cc in 50cc 10 cc in 75cc 15 cc in 100 cc 20 cc in Maintenance 3 125 25 cc in 150 30 cc in 46 Calibration 2 23 Actual Dispensed Volume 1 to 9999 cc 2 gt system will attempt to hold whatever accuracy is entered For some ratios and applications testing shows that actual sys tem accuracy may be 2 or 5 See Technical Data page 73 4 3A0868G Display Module 041405 gor before Fel 51000 5 00000 IshEET 516101 ung Fic 11 Run Mode Screen Map 25 3A0868G Display Module 2 OO 59 GA uilpz 0000 8 620 202 59 up 248 ub 014 99S LOLOL COOOL SA 200101 SA ZOOLOL s 7 e 1 pa oso dN 19S 62 seo 74 0 3 5 pJOMSSed 12 Setup Mode Screen page 1 3A0868G 26 Display Module 2310000 N e 0000 g 42 0075 ES um 00381 a El pz e 0000 ob 14 995 COU 20010 SA ify ZOOLOL SA 195 13 Setup Mode Screen page 2 27 3A0868G Display Module Password 08 2570 160 Set Password to 9909 See Configure 3 Screen 20 then enter it here P
58. le only for 1 gun systems For all pump systems the type of dosing is dynamic and the number of colors is 1 See Dynamic DosingDy namic Dosing page 48 for more information 08 25 10 16 27 2119 p flush A FRE 2x System AR type y Number of guns Home Fic 36 Configure 1 Screen 18 Press to highlight the desired field Press Co display the dropdown menu for that field Press to choose from the menu options and set Press to move to the next field Press to move through Configure 2 Screen 19 Configure 3 Screen 20 and Configure 4 Screen 21 NOTE If you change system type pump to meter or number of guns a verification screen appears Use to highlight and press on the to make the change or on the 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 3A0868G Setup Mode Details 08 25 10 16 244 2119 Fic 37 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 sys
59. lvent Valve B 3R 3R 0 156 4 0 4 0 Fud Pump Bio Valve StackB a J Fud PumpAto Valve a Fluid Valve Stack Ato MixManifold A6 Fui VaveSkBioMxManfod A7 A7 J 0 38 Ar Red Dose Valve B Off 0 156 4 0 5 Used only on IS models E I 2 S WM 22 I o9 59 wer ELLE 14 2G 3G 4G GFB1 C D He i ES w 5 ti13861a 1 D m d GFB1 P x Pressurized air line A9 1 ti16771a GFB1 C GFB1 S 113863 16 3A0868G GFB1 A 1R 1G aN See Manual 312784 for full setup instructions for a gun flush box Si A6 3A0868G Installation 116772 CI DES AAA 3R 3G as nr m E B Side ti16766a 4 1 nz P EA L cet d S a A7 Side 1 16764a 17 Installation Electrical Power Connection non IS units only All electrical wiring must be completed by qualified electrician and comply with all local codes and regulations 10 gt f
60. n Repeat for Pump B 3A0868G Pump Calibration NOTE See Calibration 1 and 2 Screens 22 and 23 page 46 for further screen information if needed Calibrate the pump 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 Atleast once per month as part of regular mainte nance e Whenever a pump is serviced or replaced NOTE e Pump 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 in regardless of the units set in Configure 4 Screen 21 e During each calibration the dispense valve will close during an up stroke and a down stroke in either order This test is to verify that the pump ball checks are seating properly and not leak ing If leaking occurs the system will alarm after the calibration for that particular valve 1 Before calibrating pump A or B prime the system with material See Prime the System page 30 2 Ifthe display is on a Run Mode screen press to access setup screens 3 Press kz to display Calibration1 Screen 22 Pump calibration factors are shown for Pump A and Pump B 4 Press to move to Calibration 2 Screen 23 5 Press to highlight the pump you wish to cali brate Pre
61. n 1 55 QPD2 Potlife Error Gun 2 Ratio Low Error Ratio High Error 1 Overdose Dose too Short 57 QDB1 Overdose B A Dose too Short QTA1 Dose Time A Error 58 QTB1 Dose Time B Error QLAX Leak Error A 58 QLBX Leak Error DJA1 Linear Sensor Error Pump 58 DJB1 Linear Sensor Error Pump B DKA1 Reed Switch Error Pump 58 DKB1 Reed Switch Error Pump B P4A1 Pressure High Error Pump A 58 P4B1 Pressure High Error Pump B P6A1 Pressure Transducer Error Pump 58 P6B1 Pressure Transducer Error Pump B DDA1 Diving Cavitation Error Pump A 59 DDB1 Diving Cavitation Error Pump B EFA1 Park Error Pump A 59 EFB1 Park Error Pump B DFA1 Stall Up Error Pump A 59 DFB1 Stall Up Error Pump B DGA1 Stall Down Error Pump A DGB1 Stall Down Error Pump B DHA1 No Stall Error Pump DHB1 No Stall Error Pump B 52 Table 3 System Alarm Advisory Record Codes om Advisory Codes No alarm system continues operat ing icon displays on active screen until cleared MAA1 Pump A maintenance due MAB1 Pump B maintenance due MEA1 Mix valve A maintenance due MEB1 Mix valve B maintenance due MESA Solvent valve A 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 Pump park op
62. nded 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 is 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 cos
63. nt parts only Do not alter or modify equipment Use equipment only for its intended purpose Call your distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations MOVING PARTS HAZARD Moving parts can pinch cut or amputate fingers and other body parts Keep clear of moving parts Do not operate equipment with protective guards or covers removed e Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure and disconnect all power sources TOXIC FLUID OR FUMES 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 fluid 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
64. o dispense _ xvii dispense volume T 15 00 E 15 00 cc in Actual dispense em g volume Start Pump Cancel Pump Home Calibration Calibration Fic 44 Calibration 2 Screen 23 46 e Press to highlight the pump you wish to cali brate Press e An X displays in the box e Press gt to start the calibration on the highlighted pump A or B Press e to cancel the calibration NOTE If you press b but calibration does not begin check to be sure that you have selected Pump A or Pump B e Press to highlight the actual dispense vol ume field Press to set the volume from O to 9999 cc Press PB 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 44 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 0842570 161631435 1 v5 101002 T WS 101002 VS 107 002 VC 101 001 FIG 45 Setup Home with Troubleshooting 3A0868G Troubleshooting System Inputs Screen 35 From Setup Home Screen 17 with Troubl
65. ord Codes TABLE 3 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 50 Record no icon Alarm icon Advisory icon Fic 54 Error Log Icons To Clear Error and Restart NOTE When 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 40 to view the last 50 errors with date and time stamps To reset alarms see Table 3 and Alarm Troubleshoot ing page 53 Many errors can be cleared by simply pressing 20 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 gun icon on the Display Module shows spray when the AFS is activated If a pump fails pure resin or catalyst could spray indefi nitely 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 one or both of the pumps are not running a Dose Time Alarm QTA1 or QTB1 occurs a
66. our spray gun manual NOTE e Pressure adjustments of each component will vary with fluid viscosity Start with the same fluid pressure for component A and B then adjust as needed Do not use the first 4 5 oz 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 Purging NOTE See Run Mode Details pages 39 41 for further screen information if needed 9 E 69 2 There 2 purging procedures in this manual e Purging Mixed Material Purging Fluid Supply System Use the criteria listed for each procedure to determine which procedure to use 3A0868G Purging Mixed Material There are times when you only want to purge the fluid manifold such as end of potlife breaks in spraying that exceed the potlife overnight shutdown or end of shift before servicing the fluid manifold assembly hose or gun Press on Run Mix Spray Screen 2 or from any screen to put the system in Standby Trigger the gun to relieve pressure If you are using a high pressur
67. 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 a working fire extinguisher in the work area N 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 e The aluminum adapter plate may spark upon impact or contact with moving parts which may cause fire or explosion Take precautions to avoid such impact or contact ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding setup or usage of the system can cause electric shock Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment gt Connect only to grounded power source All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations 3A0868G 5 Warnings M 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
68. ponent A or B valves See Ratio Low Error and Ratio High on and valves are open air flow switch repair The air flow switch is stuck open Clean or replace air flow switch QLAX or QLBX A or B dose valve leak Replace valve needle and seat Leak Error Pump QLAX or Pump A or pump is not seating and continues Replace pump packings balls and to move creep seats QLBX is running with all valves closed DJA1 or DJB1 Linear Sensor Error System does not detect the pump A DJA1 or pump B DJB1 linear position sensor Sensor not recognized by system Verify that sensor is plugged in Verify that sensor and AFCM are opera tional Verify cable connections Replace any malfunctioning compo nent or has an invalid position read Magnet fell off Replace magnet and holder on top Ing side of air motor piston Sensor readings are out of range Verify that the sensor is threaded down completely DKA1 or DKB1 Reed switch installed backward Flip reed switch 180 degrees to align Reed Switch Error with magnet in air valve System does not detect h Reed switches are stuck or both reed Verify cable is connected on both pump A DKA1 or Pump B switches are on at once ends Verify that reed switch cable DKB1 reed switch sensor or and AFCM are operational Replace detects an invalid state any malfunctioning component Magnet in air valve not functioning prop Verify that magnet is installed prop
69. re 4 Home Fic 39 Configure 3 Screen 20 and Configure 4 Screen 21 Recipe 1 1 Screen 28 Note about Settings of 0 If Ratio is set to 0 the sys tem will dispense the A material only If Potlife Time is set to 0 the potlife alarm is disabled Recipe 1 1 Screen 28 displays if E is selected on Setup Home Screen 17 The Recipe Screens allow the user to set up the basic recipe Recipe 1 1 Screen 28 includes the ratio of Material A to Material B 0 to 30 ratio tolerance 1 to 99 percent and potlife time 0 to 240 minutes aes D Potlife timer E TENES KB Fic 40 Recipe 1 1 Screen 28 44 Recipe 1 2 Screen 29 Note about Settings of 0 If a Flush time is set to 0 that valve will not flush Recipe 1 2 Screen 29 includes timers for first second and third flush 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 or 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 0 seconds to 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 t
70. regulations A N and the following safety requirements e Only models with model numbers 24F102 24F115 utilizing the air driven alternator are approved for db 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 To help prevent fire and explosion OSHA 1910 107 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 Do not install equipment approved only for a non hazardous location in a hazardous location See model ID label for the intrinsic safety rating of your model Do not substitute system components as this may impair intrinsic safety Equipment that comes in contact with the intrinsically safe terminals must be rated for Intrinsic Safety This includes DC voltage meters ohmmeters cables and connections Remove the unit from the hazardous area when troubleshooting The equipment is intrinsically safe when no external electrical components are connected to 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 res
71. rements 1 Tighten all ProMix 2KE system air and fluid line con nections as they may have loosened during ship ment Connect the main air supply line to the main air inlet This air line supplies the solenoids valves and pumps See 3 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 airless high pressure 50 cc pumps only air spray or air assisted systems with a capacity of up to 3800 cc min Main Air Inlet e Fluid supply pressure tanks feed pumps or circu lating systems can be used 115708 e Materials can be transferred from their original con Fic 3 Air Supply Inlet tainers or from a central paint recirculating line NOTE The fluid supply must be free of pressure spikes which are commonly caused by pump stroke change over If necessary install pressure regulators or a surge tank on the ProMix 2KE fluid inlets to reduce pulsation Contact your Graco distributor for additional information For each gun in the system connect a separate clean air supply line to the air inlet of the air flow switch This air supplies gun atomizing air The air flow switch detects air flow to the gun and
72. ress 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 gt w Screen Screen gg 8250 Ee 08 25 70 1 082570 16164 iz VS 101002 TU Bac n T WS 101002 WS 107 002 vC 101001 O z ESA Push to enter forced mode System Outputs 2 System Outputs 2 To Membrane Test To Setup Home NEE Jim 1X BU BU 20 Ej X EH 14 Troubleshooting Screen 28 3A0868G Basic Operation Pre Operation Tasks Go through the Pre Operation Checklist in Table 1 Table 1 Pre Operation Checklist Checklist System grounded Verify all grounding connections were made See Grounding page 19 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 component A and B and solvent supply containers Dose valves set Check that dose valves are set correctly Start with the settings recommended in Valve Set tings page 35 then adjust as needed Fluid supply valves open and pressure set Component and fluid supply pressures should be equal unless one component is more viscous and requires a higher pressure setting Solenoid pressure set 75 100 ps
73. rged equipment for Merkur Bellows B Merkur A ee 1 Group D T3 24F 108 Merkur Bellows B 3500 24 1 241 m 3 1 23 1 30 1 45 1 3 1 23 1 35 1 A 24F109 Merkur A and B 300 2 1 21 24F110 C 24 111 sss 24F112 24F113 24F114 Merkur A and 2300 15 8 158 Merkur A and 3000 20 6 206 Merkur A for Safe Use in Merkur Bellows B 300 2 1 21 Warnings page 5 Merkur A Merkur Bellows B 2300 15 8 158 Merkur A dibus bd Merkur Bellows ae 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 33 293 301 45 1 Merkur Aand B 4500 31 0 310 __ see Special Conditions See page 4 for models approved for non hazardous locations 3A0868G 3 Models Models continued Approved for Non Hazardous Location Maximum Working Pressure USB psi MPa bar Port Approvals 24088 31 Merkur AandB 30001 24089 291 Merkur 2300 15 8 158 _ 247091 Merkur A and 4500 31 0 310 Merkur A Merkur A Merkur A 24F094 ERE Merkur A 3500 24 1 241 Um 242095 31 Merkur AandB 300 21 20 v Merkur A Merkur Bellows 209 4 Merkur A 4 Merkur A 24F101
74. s highlighted A verification screen appears Use to highlight and press Am the 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 3A0868G Setup Mode Details Maintenance Recommendations The following table shows recommended starting values for maintenance Maintenance needs will vary based on individual applications and material differences Recommended Maintenance Component Frequency Solvent Valves 1 000 000 cycles 45 Setup Mode Details Calibration 1 and 2 Screens 22 and 23 NOTE See Pump Calibration page 31 for detailed instructions Calibration 1 Screen 22 displays if i is selected on Setup Home Screen 17 This screen displays the pump factor for Pump A and Pump B The factor is the pump displacement per inch The system starts at the default factor for the pump size chosen on Configure 1 Screen 18 page 43 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 5 to 50 cc in Pump Factor Home Fic 43 Calibration 1 Screen 22 Press to display Calibration 2 Screen 23 This screen allows the user to perform a calibration It dis plays Pump A and Pump B factors the target dispense volume the actual dispense volume 0 to 9999 cc and the material to dispense Material t
75. ss e An X displays in the box 3A0868G Basic Operation 6 Press to start the calibration on the checked pump A or B Press 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 as it will cancel the calibra tion 8 The volume that the ProMix measured displays on the Display Module Volume measured by system displays here T 15 00 E 15 00 ccin 0 Es UL ccn ue Occ e 0000 Enter dispensed volume here Fic 17 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 Ifthe screen and actual volumes are different press to highlight the dispense volume field Press EB Press move between digits Press to change a digit Press ES nen field is correct NOTE If the value is substantially different repeat the calibration process until the dispensed volume and mea sured volume match 31 Basic Operation 10 After the volume for A or B 1 entered the ProMix 2KE controller calculates the new pump factor and shows it on Calibration 1 Screen 22 and Calibra tion 2 Screen 23 11 Before you begin production clear the system of solvent and prime it with materi
76. tem 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 Users also can configure the flow rate region and the air flow switch The flow rate region High Low determines the sensitivity of the overdose alarm e Select the High setting if your flow rate is 250 cc min or higher The High setting has a 100cc over dose volume e Select the Low setting if your flow rate is less than 250 cc min The Low setting has a 50 cc over dose volume The air flow switch can be disabled here for airless applications Select to enable or to disable A change in any of these fields will trigger the lock See NOTE in previous paragraph Gun 1 Gun 2 hose 06 05 13 015241820 5 1 D hose lenath length am Gun 1 Gun 2 hose 0 25 diameter diameter Air Flow flow region switch Home Fic 38 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 0 to 99 of inactivity required before the backlight turns off Configure 4 Screen 21 allows users to set pre ferred units for distance volume and pressure 43 Setup Mode Details USB log language Date format Password Date Backlight timer Time Distance units Pressure units Configu
77. than the set tolerance for an A to B component volume compari son There is too much restriction in the Check that the system is fully system 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 clogged Check that the fluid regulator is set properly If the alarm occurs during start up after Restrict gun needle travel to slow purging the flow rate was probably too down the initial fluid delivery rate until high fluid hoses are loaded with material If the alarm occurred after you were spray Adjust component A and B fluid sup ing for some time the pressures from the ply regulator pressures until they are fluid supplies could be unbalanced about equal f the pressures are already about equal verify that com ponent A and B dose valves are oper ating properly Slow actuation of the component A or B Manually operate the Dose Valve A valves This can be caused by and B solenoid valves as instructed in the ProMix 2KE Repair Parts manual to check operation e Air pressure to the valve actuators is e Increase air pressure Air pres too low sure must be 75 120 psi 0 52 0 84 MPa 5 2 8 4 bar 120 psi is recommended Something is restricting the solenoid or e There may be dirt or moisture in tubing and interrupting valve actuation the air supply Filter appropri air ately Verify that soleno
78. ting 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 50 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 B Pressure 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 pressure readings for each pump on Run Pump Control Screen 15 og 25no tm 15 1 gt O Fic 49 Monitor Pump Pressures Warning messages also provide information on system performance Adjust pressures accordingly See Table 2 on page 49 3A0868G Setup Mode Details e and cont xO ma Too Low oo B Pressure b Too Low B Pressure Too High B Pressure A Press
79. ts Go 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 solvent 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 3A0868G Glossary of Terms Dose Size the amount of resin A and catalyst
80. ts 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 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 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
81. ult 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 2 MPa bar PSI 6 3A0868G 3A0868G Warnings 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 replaceme
82. ure B Pressure and car RE Fic 50 Control Range with Properly Sized Restrictor NOTE If the restrictor is too small it may be necessary to supply more differential pressure than is available in your system Fic 51 A B Control Range with Too Large a Restrictor To Static Component A continuous flow Proportioned Material Mixer Component B pulsed injection Fic 52 Schematic Diagram of Dynamic Dosing Operation Table 2 Dynamic Dosing Troubleshooting Guide for complete system troubleshooting see Table 3 beginning on page 52 Error Message Solution Ratio Low Error R1 Increase A pressure or decrease B pressure Use a smaller restrictor Ratio High Error R4 Increase B pressure Clean restrictor or use a larger size Verify B valve is opening properly 3A0868G 49 System Errors 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 and 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 code e Alarm is saved in the date time stamped log Error Code Indicator Josnono Bie Bbm 18 vs 0 02001 T vs 0 02001 107 001 102 000 ga A D Fic 53 Display Module Alarm Codes System Advisory Rec
83. valve actuators is e Increase air pressure Air pres too low sure must be 75 120 psi 0 52 0 84 MPa 5 2 8 4 bar 120 psi is recommended e Something is restricting the solenoid or e There may be dirt or moisture in tubing and interrupting valve actuation the air supply Filter appropri air ately Dose Valve B is turned in too far e Refer to Valve Settings page Dose Valve A is open too far 35 for adjustment guidelines e Fluid pressure is high and air pressure Adjust air and fluid pressure See is low recommended air pressure above QDA1 Valve seal or needle seat are leaking Repair the valve Overdose A Slow actuation of component A or B valves See Ratio Low Error and Ratio High The A dose has overshot and Error pages 56 57 when combined with B is too Running a high mix ratio and a high flow _ It may be necessary to restrict the large for the mix manifold rate flow rate through the component B capacity dose valve by adjusting its hex nut QDB1 Overdose B The B dose has overshot forcing an A dose that when combined with B is too large for the mix manifold capacity 3A0868G 57 System Errors System is in Mix mode and gun is only par Fully trigger the gun tially triggered allowing air but no fluid to QTA1 or QTB1 Dose Time Error The gun trigger is active but pass through gun A pump or B pump QTB1 movement is detected Siow actuation of com
84. vent Valve A Solenoid Dose Valve A Gun Flush Box Solenoid ti15730a Solenoid location if used Solvent Valve B Dose Valve B Solenoid Solenoid Fic 19 Solenoid Valves in Control Box 34 3A0868G Pressure Relief Procedure To reduce the risk of skin injection relieve pressure when you stop spraying before changing spray tips and before cleaning checking or servicing equipment NOTE The following procedure relieves all fluid and air pressure in the ProMix 2KE system 1 Press Run Spray Screen 2 from any screen to put the system in Standby 2 Follow procedure for Purging Fluid Supply Sys tem page 33 if desired or necessary 3 Shut off air supply to A and B pumps and solvent supply pumps 4 With the gun triggered push the manual override on the A and B dose and solvent valve solenoids to relieve pressure See FIG 19 Verify that fluid pres sure is reduced to O 5 Reinstall the Control Box cover Lock Mode NOTE Do not change system type number of guns hose length or hose diameter when material is loaded in the system Change these inputs only if system hard ware is changed If you change one of these inputs the system locks so that you cannot spray or mix If you have changed to a meter system the system also locks if you change the dosing type or the number of colors The lock icons dis play 08 2510 13 49 4 510 A B 1 0 A Omin 45

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