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Graco 313882C User's Manual

1. EK PS PSx BCV Z T EN fee Bee 64 8 8 E S eH 3KMx See the ProMix 3KS Repair Parts manual 6 ft 1 83 m fluid 114543 for optional cable lengths hose supplied Fic 2 3KS System shown with G3000 Meters and Color Catalyst Component C Change 12 313882C Overview Table 1 Component Descriptions EasyKey EK Used to set up display operate and monitor the system The EasyKey accepts 85 250 VAC 50 60 Hz line power and converts that power to acceptable low voltage and optical signals used by other system components 3KS Power Accepts 85 250 VAC 50 60 Hz line power and converts that power to acceptable low volt Supply Module age signals used by other system components PSM Booth Control BC Used by the operator for daily painting functions including choosing recipes initiating job complete reading clearing alarms and placing the system in Standby Mix or Purge mode
2. 4 1 1 eeeeee 1 E N cec oo BCC ES R Solenoid Identification Label Solvent Solenoid Overrides Module 2
3. 5 E E Du 595 6 E s 0 5 4 5 gt N 0 atalyst 05 9 9 9 O 9 dd e eeeeee lt 109 e m P Solenoid Identification Label Solvent Solenoid Overrides T112826a FiG 59 Color Change Solenoids 313882C 56 System Operation DVA Fl DVB MA RVA APV TI12556a AT SVA SM SVB SPV Key ProMix 2KS Fluid Station MA Component A Meter SVB Component B Shutoff DVA Component A Dose Valve Valve RVA Component A Sampling MS Solvent Meter Valve SPV Solvent Purge Valve SVA Component A Shutoff Air Purge Valve Valve SM Static Mixer MB Component Meter Fl Fluid Integrator DVB Component Dose Valve AT Air Purge Valve Air Supply RVB Component B Sampling Tube Valve Key ProMix 3KS Fluid Station MC Component C Meter DVC Component Dose Valve RVC Component C Sampling Valve CPV SVC Component C Shutoff Valve CPV Component C Purge Valve SM Static Mixer Fl Fluid Integrator A 3KS fluid inlet Connect fluid supply line from 2KS fluid manifold outlet here A Connect fluid supply line to gun T114382a Fic 60 ProMix 2KS and ProMix 3KS Wall Mount Fluid
4. Ground Screw Main Power 5 Power Access Port to 3KS Panel T114366a T114372a Fic 6 Connections and AC Power Switches 18 313882C EasyKey AC Power Switch Turns system AC power on or off 3KS Power Supply Module AC Power Switch Turns 3KS AC power on or off EasyKey I S Power Power circuit to 2KS Fluid Station 3KS Power Supply Module I S Power Power circuit to 3KS Fluid Station EasyKey Potlife Exceeded Audible Alarm Alerts the user when a Potlife Exceeded alarm occurs Clear by pressing the Alarm Reset 20 313882C EasyKey and 3KS Power Supply Module Connection Ports EasyKey Graco Web Interface Port Used to communicate from a PC to gt Upgrade software View software version gt Download e Job and alarm logs Material usage report e Setup values can also upload Clear job alarm and material usage reports Upload a custom language to view on screen Restore factory defaults Restore setup password See manual 313386 for more information EasyKey Ethernet Connection You can access data on an office or industrial network through the internet with the proper configuration See manual 313386 for more information 19 Run Mode Screens Run Mode Screens NOTE See FIG 9 for a map of the Run screens Detailed screen descriptions follow Splash Screen At power up the Graco logo and software revision will
5. 0 4 Solvent Level Control FiG 11 Totals Screen rand Total Liters Liters Liters Liters Liters Usage This screen shows the job totals grand totals and job number Use the tabs to reset job totals Job Complete reset solvent totals Rst Solvent or go to Level Control Screen page 24 Solvent Totals and the Rst Solvent tab only appear if Meter is selected under Solvent Monitor in Configure Screen 5 on page 31 NOTE Grand totals are not resettable Reset Total Screen Job Complete Are you sure you want to reset job totals Enter new job number or press enter to accept default FiG 12 Reset Total Screen If job is reset job number will increment by one for default 313882C Run Mode Screens Reset Solvent Screen Reset Solvent Are uou sure uou want to reset solvent total Fic 13 Reset Solvent Total Screen The screen will ask if you want to reset solvent total Select Yes or No Alarms Screens ime Alarm Fic 14 Alarms Screen Two screens show the last 10 alarms Use the Up Or Down keys to scroll between the two screens See Table 9 on page 77 for a list of alarm codes 23 Run Mode Screens Level Control Screen Level Control Liters Hlarm Level Current Volume Lolor 1 10 Color 2 Latalyst 1 solvent 10 Reducer 1 10 Level Control 15 Level Control Screen This screen
6. LO CN SE LO CN SF Os SE t _ __ 9 Sd SJE XIWOUd Quvog 1041103 THNVd ai NI O3 019 Ed 03 31872 AN yH NOLLdO 001 De 15 09 A3MASV3 319 XIWOMd ima TOWLNOD T3Nvd 010179 1VWS SnoquvzvH SNOGYVZVH NON 313882C 94 Schematic Diagrams System Electrical Schematic NOTE ProMix 3KS system Some compo EM Iring expansions ble w llustrates all poss IC ical schemati The electr nents shown are not included with all systems Hazardous Area 019 1NV2 T ec lt e I cx in st qu5 0309002 30102 MOTHA SNOILdO 001 9 15 05 9 08 NOILV TOSI NV 019 1 2 LHM NYD 339 GTSIHS 933 19 quo Q3Q02 30102 MOTISA SNOILdO 001 01 0159 MNN EN lt 235und A ovis GION3105 AYM Gay 23509 vi Q 103INVW Nu5 QGT3IHS 915 u313N v19 WOD 838 YMd 319 2 1N3AT0S 4 qs NS
7. NOD 9 io Ef t E wn Hs i 1 E AA NO _ 5 Pet WOD 9 oe NUHLEL 8010 20409 40102 9390240102 3119 159 TEM 10105 t T wo S WoD 9 M am San le L NOS Ae H 68D B WOD 9 SHI TANVd AINT Lee INANOdWOD CN SE XO Os CN SE XO 00 Os 832018 TWNIWYSL Q31NDOW NIG Ei nmw se m st tO 6112 C 0 SP LO CN m st Lo CP sb LO Suv qais WOD 2 da x9 6 IDYNd 2 39804 19 2 3609 N45 ISOA Un G3snNn 1HM 96 3313 X18 WOO 3313 038 9313W 9190 8190 02 mws LID zi EYT Q 103INVW 95 313882C Schematic Diagrams Power Supply Module Electrical Schematic 572019 TWNIWYSL HOLIMS 33208 YAMOd 91 DMY 91 DMY 9
8. 4 Standard Features 5 ACCeSSOLIBS tere ern ear E IN 7 EE IS 8 Glossary of TermS 10 OVerVIOW dva ba eer 12 fats Sa 12 Component Identification and Definition 12 Booth Control ach pa GE E ee dS 16 EasyKey Display and Keyboard 17 Bier ADT 17 Keypad uites dod EAE Bob tatto eios 17 EasyKey and 3KS Power Supply Module Connection Ports 18 EasyKey AC Power Switch 19 3KS Power Supply Module AC Power Switch 19 EasyKey I S Power 19 3KS Power Supply Module 1 5 Power 19 EasyKey Potlife Exceeded Audible Alarm 19 EasyKey Graco Web Interface Port 19 EasyKey Ethernet Connection 19 Run Mode Screens 20 Splash Screen 2 Rx 20 Sidus OCIO Bl 22 Totals Screen 23 Reset Total Screen 23 Reset Solvent Screen 23 Alarms 5 23 Level Control Screen 24 Setup Mod 25 Password Screen 26 Set Up Home Screen 26 System Configuration Screens 28 32 Advanced Setup Screens 34 Recipe S
9. ce DIY 3 Purge Time B Fill Time C Purge Time Air Solvent only one of the purge valves are used 3rd W ater Solvent Water No Gun Flush Boxes Gun Trigger s by Operator Gun Flush Box TET 1 Gun Flush Box Output 2 NENNEN Gun Flush Output 1 Gun Flush Box Output 2 Fic 63 ProMix 3KS Color Change Chart 2 68 313882C Color Change Recipe Change X gt Y No components change 3rd Flush Valve ump ump B olvent B Kee o SSS 3 A Fill Time olvent A olvent C omponent A omponent B omponent C Air IM UN For first purge and final purge Solvent 1 m only one of the purge valves are used Srd Water NM Solvent Water _ Gun Flush Boxes Gun Trigger s by Operator Gun Flush Box Output 1 Gun Flush Box Output 2 Gun Flush Box Output 1 Gun Flush Box Output 2 Two Second Initial Purge Time First Purge Time First Purge C Time Chop Time Final Purge Time Final Purge C Time Mixed Fill Time Fic 64 ProMix 3KS Color Change Chart 3 313882C 69 Color Change Recipe Change X gt Y No components change No 3rd Flush Valve ump A ump B olvent A olvent B olvent C omponent A omponent B
10. ProMix 3KS PART NO SERIES NO MFG YR 1 II f for Class Yow T Group D 50 60 Hz 20 C to 50 C 1441 US T Minneapolis APPROVED Install per 258682 55440 U S A GRACO Um 250 V FMO8ATEX0072 0359 GRACO INC T114375a ATEX Certificate is listed here System Configuration and Part Numbers System Configuration and Part Numbers Configurator Key The configured part number for your equipment is printed on the equipment identification labels See FIG 1 for location of the identification labels The part number includes digits from each of the following categories depending on the configuration of your system 3K Component C Not Not Fluid Meter Component C Change Designated No Meter No Valves single component C 1 G3000 1 Two Valves low pressure 2 G3000HHR 2 Four Valves low pressure 1 8 in Coriolis 3 Two Valves high pressure 4 Solvent Meter Four Valves high pressure ProMix 3KS Intrinsically Safe IS System Install Electronic Proportioner per IS Control Drawing No 258682 EasyKey Interface IS Associated Apparatus for use in non hazardous f location with IS Connection to Smart FMO8ATEX0074 APPROVED Fluid Plate IS Label Location sate Apparatus for use in Label Location on 7 aed Class Division 1 Group C on Fluid Station Power Supply Module
11. 7 avoid splashing slowly open the sampling valves and dispense solvent until the valves and tubes are clean NOTE When performing a calibration purge the solvent valve s close automatically after 2 minutes or when Abort is selected on the screen 313882C System Operation 8 Close sampling valves NOTE Select Abort on Calibration screen to cancel current calibration and close dose or purge valves 9 Fully open both fluid shutoff valves 10 On a single color system reconnect component fluid supply line to flow meter A NOTE After calibration it is necessary to clean out con taminated mix material Do a manual purge and resume the recipe just tested or do Recipe O then go on to the next recipe 61 Meter Calibration Meter Calibration 4 Place the beakers minimum size 250 cc in hold ers Put the sampling tubes into the beakers NOTE If tubes need replacing use 5 32 in or 4mm OD tubing To avoid splashing fluid in the eyes wear eye protec tion The fluid shutoff valves and ratio check valves are retained by mechanical stops that prevent accidental 5 Onthe EasyKey press the Setup g key to access removal of the valve stem while the manifold is pres surized If you cannot turn the valve stems manually relieve the system pressure then disassemble and clean the valve to remove the resistance 6 Press the Right Arrow mp key to select the Calibra setup screens tion Screen Pre
12. N N 05558 1 11 TWNIWHSL 10 394089 XIW WLISIG BENI BEKI BENI BENI 23d 234 238 9 IILE PPPEPETY TETIT HOLIMS 937203 d3MOd 31000 43 435 SNOILdO 000 50 avaHying A 11004 0 sr 4f 01389 GNNOYD YYOMLIN 58758 1HM Y0 8 98554 V 58758 lt Sero 8 NOLLVHD3INI 58754 72018 M9 LHM Y 68754 TWNIWYSL CN SE S3SS3NUVH 9 NOWWOD SOTWNY MO 0 419 NI DOWNY MO14 134 33 1104 980 NOWWOD 078 LAdLNO 13538 WY YTY 4015 31038 038 NOWWOD NI LHM 439914 119 TW TOHLNOD CN SE OD CX sr iO so TAO LO COD st Quvog 1994 8 0 1 L 31038 9 9 935018 TWNIWYAL 1510 43MOd C 92 19 938 S 120ACL SSINYVH Qquvog 40 TER uiua g NadO aasnann _ v SS3NuVH u3MOd VL aasnnn _ a
13. is too large for the mix chamber capacity E 6 the B dose overshoots and forces an A side dose that when combined with B is too large for the mix chamber capacity E 30 the C dose overshoots and when combined with A B is too large for the mix chamber capacity Valve seal or needle seat are leaking Check FIG 11 Repair the valve see valve manual 312782 Totals Screen on page 23 If A B or C are dosing simul taneously sequential dosing only there is a leak Sampling valve is leaking Tighten or replace valve Flow meter fluctuations caused by pressure pulsations Check for pressure pulsations Close all the manifold valves Turn on the circulating pumps and all the booth equipment such as fans and conveyors Check if the ProMix 3KS is reading any fluid flow If the ProMix 3KS shows there is fluid flow and there are no leaks from the gun or any other seals or fit tings the flow meters are probably being affected by pressure pulsations Close the fluid shutoff valve between the fluid supply system and the flow meter The flow indication should stop If necessary install pressure regulators or a surge tank on the fluid inlets to the ProMix 3KS to reduce the fluid supply pressure Contact your Graco distrib utor for information Slow actuation of component A B or C valves See E 3 RATIO HIGH ALARM and E 4 RATIO LOW ALARM pages 79 80 Running a high mix ratio and a high flow rate It may be neces
14. omponent C SSS 3 Purge Time A Fill Time B Purge Time B Fill Time C Purge Time Air Forfirst purge and final purge Solvent only one of the purge valves are used 3rd Water Solvent Water 1 Gun Fluxh Box Gun Flush Box Output 1 Gun Flush Box Output 2 2 Gun Flush Boxes Gun Flush Box Output 1 Gun Flush Box Output 2 65 3KS Color Change Chart 4 70 313882C Color Change Recipe Change X 0 61 gt 0 No more A B C 3rd Flush Valve Time Sequence ump A ump B olvent A olvent B olvent C omponent A omponent B omponent C O O O 001 SSS 3 Purge Time C Purge Time Air Solvent 3rd Water Solvent Water Gun Trigger s by Operator 1 Gun Fluxh Box Gun Flush Box Output 1 Gun Flush Box Output 2 2 Gun Flush Boxes Gun Flush Box Output 1 Gun Flush Box Output 2 Two Second Initial Purge Time Two second initial purge onlty happens if First Purge Time 3rd flush valve is enabled First Purge C Time Chop Time Final Purge Time Final Purge C Time 66 ProMix 3KS Color Change Chart 5 313882C 71 Color Change Recipe Change X 0 61 gt 0 No more A B C No 3rd Flush Valve Time Sequence ump A ump B olvent A olvent B olvent C omponent A omponent B omponent C ce Kee 3 Purge Time B Purge Time C Purge Time Purge A A
15. Flush and Fill Input is set to Recipe in Option Screen 1 page 32 and Special Out puts is set to 1 2 3 or 4 in Configure Screen 5 page 31 The I O board has four programmable outputs 41 Setup Mode Recipe 0 Screens NOTE See FiG 37 on page 38 for a map of the Recipe 0 screens Detailed screen descriptions follow ne 0 is typically used in multiple color systems to purge out material lines without loading a new color e atthe end of a shift to prevent hardening of cata lyzed material NOTE Each screen displays the current screen number and the total number of screens in the group The total number of screens in a group and the fields displayed on each screen may vary depending on selections made in the System Configuration Screens and Option Screens Recipe 0 Screen 1 Recipe aJ First Purge Source Ar Chop Tupe Air Solvent 1 seconds seconds 4 Final Purge Source Air Chop Time solvent Chop Time MESE Calibration Fic 45 Recipe 0 Screen 1 First Purge Source Select Air Solvent or 3rd Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 30 Chop Type Select Air Solvent or Air 3rd Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 30 This refers to the process of mix ing air and solvent or air and 3rd flush fluid together during the flush cycle to help clean the lines and reduce sol
16. It is typically mounted inside the booth or near the painter 2KS Fluid Station Includes air control solenoids flow switches and mountings for the A B and solvent flow 2KS meters and the 2K fluid manifold assembly Its control board manages all proportioning functions 3KS Fluid Station Includes air control solenoids flow switches and mountings for the C and solvent flow 3KS meters and the 3K fluid manifold assembly Its control board manages all proportioning functions 2K Fluid Manifold Pneumatically Operated Dose Valves for component A and B 2KM Purge Valves for solvent and air purge Sampling Valves for calibrating the flow meters and performing ratio checks Shutoff Valves for component A and B to close their fluid passages to the mix mani fold to allow for accurate calibration and ratio checks Mix Manifold which includes the fluid integrator and static mixer Fluid Integrator is the chamber where component A and B align at the selected ratio and begin to mix gt Static Mixer has 24 elements to uniformly blend the materials downstream of the fluid integrator 3K Fluid Manifold Pneumatically Operated Dose Valve for component C 3KM Purge Valve for solvent Sampling Valve for calibrating the flow meter and performing ratio check Shutoff Valve for component C to close the fluid passage to the mix manifold to allow for accurate calibration and ratio check Mix Manifold which includes the fluid integrator and static mix
17. Meter a non intrusive flow meter often used in low flow applications or with light viscosity shear sensi tive or acid catalyzed materials This meter uses vibra tion to measure flow Digital Input and Output a description of data which is transmitted as a sequence of discrete symbols most commonly this means binary data represented using electronic or electromagnetic signals Discrete I O refers to data that constitutes a separate entity and has direct communication to another control Dose Size the amount of resin A catalyst B and reducer C 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 Ethernet a method for directly connecting a computer to a network or equipment in the same physical location Fiber Optic Communication the use of light to trans mit communication signals 10 Fill Time the amount of time that is required to load mix material to the applicator Flow Control Resolution a settable value that allows the flow control system to maximize its performance The value is based on maximum desired flow rates Flow Rate Analog Signal the type of communication signal that can be used on the ProControl module Flow Rate Tolerance the settable percent of accept able variance that the system will allow before a flow rate warning occurs Flow Set Point a predefined flow rate target Grand Total
18. Operation can be stopped at any time by 8 When the target volume is dispensed Dose Valve C closes pressing the Standby r key or shutting off the 9 Components A B and C are pre mixed in the 3KS main power switch integrator then uniformly blended in the 3KS static mixer SM Table 5 Sequential Dosing Operation ee ___ _____ Ratio 2 0 1 Stage 1 A B A B C Stage 1 A B A B C NEN NENNEN MERE 46 313882C System Operation DVA Fl DVB MS MA RVB RVA TI12556a APV AT SVA SM SVB SPV Key ProMix 2KS Fluid Station MA Component A Meter SVB Component B Shutoff DVA Component A Dose Valve Valve RVA Component A Sampling MS Solvent Meter Valve SPV Solvent Purge Valve SVA Component A Shutoff Air Purge Valve Valve SM Static Mixer MB Component Meter Fl Fluid Integrator DVB Component B Dose Valve AT Air Purge Valve Air Supply RVB Component B Sampling Tube Valve Key ProMix 3KS Fluid Station MC Component C Meter DVC Component Dose Valve RVC Component C Sampling Valve CPV SVC Component C Shutoff Valve CPV Component C Purge Valve SM Static Mixer Fl Fluid Integrator N 3KS fluid inlet Connect fluid supply line from 2KS fluid manifold outlet here A Connect fluid supply line to gun TI14382a Fic 50 ProMix 2KS and ProMix 3KS Wall Mount Fluid Stations 313882C 47 System Operation Mix Manifold Valve Settings To open dose or purge valves turn hex nut E counter clockwise T
19. System Upgrade Kit 406800 15V825 Discrete I O Board Kit 313882C Related Manuals Equipment Approvals Equipment approvals appear on the following labels which are attached to the Fluid Station and Power Sup ply Module See FIG 1 on page 4 for label locations Power Supply Module and Fluid Station Label ATEX Certificate is listed here Intrinsically Safe IS System Install per IS Control Drawing No 258682 EasyKey Interface IS Associated Apparatus for use in non hazardous location with 15 Connection to Smart Fluid Plate IS Apparatus for use in Class Division 1 Group D T3 C Hazardous Locations Read Instruction Manual Warning Substitution of components may impair intrinsic safety PARTNO SERIES APPROVED Intrinsically safe equipment for Class I Div 1 Group D T3 C 20 to 50 C 0359 Ex ia IIA T3 MAX AIR WPR 7 100 FLUID WPR SERIAL MFG YR We GRACO INC P O Box 1441 Minneapolis MN GRACO 55440 U S A MPa PSI MAX TEMP 50 C 122 F TI14376a Fluid Station Label FLUID PANEL MAX AIR WPR ProMix 3KS PART NO SERIES SERIAL MFG YR bar A N GRACO INC 1441 SPEROVED 289833 3 x 2G 5 0359 Ex ia eraco 55440 U S A 114374 Te Group D T3 ATEX Certificate is listed here Power Supply Module Label POWER REQUIREMENTS AMPS 2 AMPS MAX
20. The system purges the old material from the dose valves to the gun using only the selected purge media The purge C valve opens during the First Purge C Time and closes when the time expires Chop Cycle Select the Chop Type air solvent or air Srd valve and Chop Times The air purge valve opens only during the air chop cycle and the solvent or 3rd valve opens only during the sol vent chop cycle The number of chop cycles is deter mined by dividing the Total Chop Time by the sum of the Air and Solvent Chop Times 65 Color Change Final Purge Select the Final Purge Source air solvent or 3rd valve and Final Purge Time For most applications solvent is selected The system fills the line with solvent from the dose valves to the gun using only the selected purge media usually solvent The selected purge valve opens during the Final Purge Time and closes when the time expires Final Purge C Select the Final Purge C Source solvent or water and Final Purge C Time For most applications solvent is selected The system fills the line with solvent from the dose valves to the gun using only the selected purge media The purge C valve opens during the Final Purge C Time and closes when the time expires Fill This sequence fills the line from the dose valves to the gun and is also referred to as the mixed material fill The system begins mixing components A B and C until the Fill Time expires Purge Active The
21. fill from the dose valves to the applicator gun 313882C Recipe Setup Screen 5 Recipe A Meter 0 119 cc pulse B Meter 0 119 cc pulse L Meter 0 119 cc pulse solvent Meter 0 119 cc pulse MEE Calibration Fic 42 Recipe Setup Screen 5 This screen appears only if K Factor Input is set to Rec in Option Screen 1 page 32 K factor A Meter Enter the k factor cc pulse for flow meter A This is the amount of material that passes through the flow meter per pulse electrical pulse signal K factor B Meter Enter the k factor cc pulse for flow meter B K factor C Meter Enter the k factor cc pulse for flow meter C K factor Solvent Meter This field only appears if Solvent Monitor in Configure Screen 5 page 31 is set to Meter Enter the k factor cc pulse for the solvent flow meter 313882C Setup Mode Recipe Setup Screen 6 0 cc min min hecipe Flow Rate Monitor Low Flow Limit High Flow Limit Calibration 43 Recipe Setup Screen 6 This screen appears only if Flow Rate Monitor is set to in Option Screen 2 page 33 Flow Rate Monitor Select the desired flow rate monitoring Off Warning or Alarm Low Flow Limit Enter the low flow rate limit 1 to 3999 cc min High Flow Limit Enter the high flow rate limit 1 to 3999 cc min Recipe Setup Screen 7 Fic 44 Recipe Screen 7 This screen appears only if
22. function Color Catalyst Purge This field only appears if the system includes a color change module and Flush and Fill Input is set to Rec ipe in Option Screen 1 page 32 Enter the purge time to 99 seconds It refers to the amount of time required to flush the lines from the color catalyst or component C module to the dose valve or dump valve Color Catalyst Fill This field only appears if the system includes a color change module and Flush and Fill Input is set to Rec ipe in Option Screen 1 page 32 Enter the fill time 0 to 99 seconds It refers to the time required to fill the lines from the color catalyst or component C module to the dose valve or dump valve 39 Setup Mode Recipe Setup Screen 3 Recipe First Purge Source a gt Chop Tupe A Solvent a seconds seconds 4 Final Purge Source Air Chop Time solvent Chop Time MEE Calibration Fic 40 Recipe Setup Screen 3 This screen appears only if Flush and Fill Input is set to Recipe in Option Screen 1 page 32 First Purge Source Select Air Solvent or 3rd Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 30 Chop Type Select Air Solvent or Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 30 This refers to the process of mix ing air and solvent or air and 3rd flush fluid together during the flus
23. gun to relieve pressure If you are using a high pressure gun engage the trig ger lock Remove spray tip and clean tip separately If using an electrostatic gun shut off the electrostatics before flushing the gun 2 Attach solvent supply lines as follows e Single color single catalyst single compo nent C systems disconnect the component A B and C fluid supplies at the flow meter inlets and connect regulated solvent supply lines e Multiple color multiple catalyst multiple component C systems connect the solvent supply lines to the designated solvent valve on the appropriate color catalyst or component C valve stack Do not connect a solvent supply to any flow meter 59 System Operation 60 Adjust the solvent fluid supply pressure Use the lowest possible pressure to avoid splashing Remove the Fluid Station cover to access the sole noid valves See 57 Purge as follows e Single color single catalyst single compo nent C systems Purge component A side Press the manual override on the Dose Valve A solenoid valve and trigger the gun into a grounded metal pail Purge component B side Press the manual override on the Dose Valve B solenoid valve and trigger the gun into a grounded metal pail until clean solvent flows from the gun Purge component C side Press the manual override on the Dose Valve C solenoid valve and trigger the gun into a grounded metal pail until clean solvent flows from t
24. loading a new color e atthe end of a shift to prevent hardening of cata lyzed material To setup Recipe 0 go to Advanced Setup Select the Recipe tab and change the Recipe to 0 The Recipe O Setup Screen appears Set the chop times from 0 999 seconds in increments of 1 second 1 Press the Standby r key on the Booth Control WAS Trigger the gun to relieve pressure If you are using a high pressure gun engage the trig ger lock Remove spray tip and clean tip separately If using an electrostatic gun shut off the electrostatics before flushing the gun 2 If using a gun flush box place the gun into the box and close the lid 3 Select Recipe 0 and press Enter 4 fagun flush box is not used trigger the gun into a grounded metal pail until the purge sequence is com 4 plete 5 The color change LED blinks while Recipe 0 runs and turns solid after purge sequence is complete 6 Ifthe system is not completely clean you can repeat Recipe 0 by pressing Enter A 313882C System Operation Purging Fluid Supply System Follow this procedure before e first time material is loaded into equipment e servicing e shutting down equipment for an extended period of time putting equipment into storage Some steps are not necessary for initial flushing as no material has been loaded into the system yet 1 Press the Standby key on the Booth Control Trigger the
25. of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR 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 performa
26. ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment e Tighten all fluid connections before operating the equipment 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 Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment 313882C 313882C 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 forms from distributor or retailer Check equipment daily Repair or replace worn or damaged parts immediately with genuine manu facturer s replacement parts only Do not alter or modify equipment Use equipment only for its intended purpose Call your distributor for information Houte hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or ov
27. system turns on the Purge Recipe Change Purge Active output during these steps Fill Active The system turns on the Recipe Change Fill Active out put during this step Table 8 ProMix 3KS Color Change Chart Reference Starting Ending A B C 3rd Purge Valve Refer to Fig External Yes Xx o m w ee x o m w fer o m vs Foes _ o m Fes 66 313882C Color Change Recipe Change X gt Y A1 to A2 B1 to B2 C1 to C2 3rd Flush Valve Time Sequence If any component isn t changing that time segment is skipped olvent A olvent B olvent C omponent A omponent B omponent C c o UO 313 oj w A Purge Time A Fill Time Air Solvent 3rd Water Solvent Water Gun Trigger s by Operator Gun Flush Box Output 1 Gun Flush Box Output 2 LEE LL d 2 5 5 To S Gam m __ Gun Flush Box Output 1 Gun Flush Box Output 2 Two Second Initial Purge Time First Purge Time First Purge C Time Chop Time Final Purge Time Final Purge C Time Mixed Fill Time FIG 62 ProMix 3KS Color Change Chart 1 313882C 67 Color Change Recipe Change X gt Y A1 to A2 B1 to B2 C1 to C2 No 3rd Flush Valve Time Sequence ump A If any component isn t changing that time segment is skipped ump B olvent A olvent B olvent C omponent A omponent B omponent C
28. that component A B and C dose valves are operating properly Slow actuation of the component B or C valves This Manually operate the Dispense A and C solenoid can be caused by valves as instructed in the ProMix 3KS Repair Parts manual to check operation e Air pressure to the valve actuators is too low e Increase air pressure Air pressure must be 75 120 psi 0 52 0 84 MPa 5 2 8 4 bar 120 psi is recom mended Something is restricting the solenoid or tubing There may be dirt or moisture in the air supply Filter interrupting valve actuation air appropriately valve is turned in too far e Refer to Table 6 Mix Manifold Valve Settings page 50 for adjustment guidelines e Fluid pressure is high and air pressure is low e Adjust air and fluid pressure See recommended air pressure above 313882C 79 Alarm Troubleshooting Table 10 Alarm Troubleshooting E 4 RATIO_LOW_ALARM Sequential Dosing System The mix ratio is lower than the set tolerance on the previous dose cycle There is too much restriction in the system Check that the system is fully loaded with material Check that the supply pump s cycle rate is set prop erly 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 purging the flow Restrict gun needle t
29. 1 DM GND KlddNS YIMOd 3ovroA 0910 42v18 NOWWOD CI 4 SI ONU5 TBIHS 51 2QA 21 q3snNn qasnNn 5 5 5 81 DW VTA Qavos daludva 313882C 96 Technical Data Maximum fluid working pressure Maximum working air Air supply Air filter inlet size Air filtration for air logic and purge air Graco supplied Air filtration for atomizing air user supplied Mixing ratio On ratio Fluids handled Viscosity range of fluid Fluid filtration Fluid flow rate range G3000 G250 G3000HR G250HR 0005 oa dca e dad 53000 Solvent Meter accessory Fluid inlet sizes Flow Dose Valve Color Valve Adapters Lad get at a Eod og deg Fluid outlet size static External Power Supply Requirements Operating temperature Environmental Conditions Rating Noise Level Sound pressure level Sound power level Wetted Techni
30. 114361 Be Read Instruction Manual T114370a MAX AIR WPR Warning Substitution of components Maximum Fluid 7 7 100 may impair intrinsic safety PARTNO SERIES SERIAL Working Pressure is listed here Configured Part Number bar MAX FLUID WPR GRACO INC P O Box 1441 MPa bar PSI Minneapolis MN MAX TEMP 50 C 122 F GRACO 55440 U S A TI14376a FiG 1 Identification Label 4 313882C System Configuration and Part Numbers Hazardous Location Approval Models using a G3000 G3000HR or intrinsically safe Coriolis meter for A B and C meters are approved for installation in a Hazardous Location Class Div Group D or Zone Group IIA Maximum Working Pressure Maximum working pressure rating is dependent on the fluid component options selected The pressure rating is based on the rating of the lowest rated fluid component Refer to the component pressure ratings below Example Model TK1400 has a maximum working pressure of 3000 psi 21 MPa 210 bar Check the identification label on the EasyKey power supply module or fluid station for the system maxi mum working pressure See FIG 1 ProMix Fluid Components Maximum Working Pressure Base System no meters option 0 no color component C change option 0 3000 psi 21 0 MPa 210 bar Meter Option 1 2 and 4 G3000 or G3000HR Solvent Meter 3000 psi 21 0 MPa 210 bar Meter Option 3 Coriolis Meter 2300 psi 15 86 MPa 158 6 bar Co
31. 78 5 Control Network ID L oantigure 27 Configure Screen 5 Special Outputs Select special outputs 0 4 Each output has two differ ent start times and durations Solvent Monitor Select solvent monitor Off Flow Switch or Meter Web Browser IP The default web browser IP address prefix is 192 168 178 _ Assign a unique number for each EasyKey in your system 1 99 and enter it here Control Network ID Used for the Graco Gateway network system See Graco Gateway manual 312785 for further information 313882C Setup Mode 31 Setup Mode Option Screens NOTE See FIG 21 on page 28 for a map of the Option Screens Detailed screen descriptions follow NOTE Each screen displays the current screen number and the total number of screens in the group Option Screen 1 Flush Volume Check Flush and Fill Input K Factor Input Material Fill Volume stage Fill Volume FIG 28 Option Screen 1 Options Flush Volume Check This field only appears if Solvent Monitor is set to Meter in Configure Screen 5 page 31 If set to Minimum Flush Volume will appear Rec ipe Setup Screen 2 page 39 Flush and Fill Input If set to Global Color Catalyst Purge and Color Cata lyst Fill are added to Advanced Setup Screen 1 page 35 Advanced Setup Screen 2 3 and 5 are added See pages 35 37 set to Recipe Color Catalyst Purge and C
32. Box Output 1 Gun Flush Box Output 2 _ _ Fic 71 ProMix 3KS Color Change Chart 10 Wait for External CC Input Mixed Fill Time 76 313882C Alarms and Warnings NOTICE Do not use the fluid in the line that was dispensed 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 AredLED illuminates steadily or blinks on the Booth Control Booth Control displays an alarm E Code E 1 to E 31 See FIG 72 e Alarm sounds e Status bar on the EasyKey Display shows the alarm E Code with a description see Table 9 Alarm Indicator red Display Recipe Indicator green TI11614A Fic 72 Booth Control System Warnings Table 9 lists the System Warning Codes Warnings do not stop operation or sound an alarm They are saved in the date time stamped log which can be viewed on a PC using the ProMix 2KS Web Interface see manual 313386 313882C Alarms and Warnings To Reset Alarm and Restart NOTE When an alarm occurs be sure to determine the E Code before resetting it See Table 9 If you forget which E Code occurred use the Alarms Screens page 23 to view the last 10 alarms with date and time stamps To reset alarms see Table 10 Many alarms can be e Table 9 System Alarm Warning Codes Ue _ Es Overdose B A Dose Too Short Aarm P
33. MEE Calibration Fic 47 Recipe 0 Screen This screen only appears if Solvent Monitor is set to Meter in Configure Screen 5 page 31 and Flush Vol ume Check is set to On in Option Screen 1 page 32 or 3rd Flush Valve is set to On in Configure Screen 3 on page 30 Minimum Flush Volume This field only appears if Flush Volume Check is set to On in Option Screen 1 on page 32 Enter the mini mum flush volume 0 to 999 cc Exiting Fill Source This field only appears if 3rd Flush Valve is set to in Configure Screen 3 on page 30 Select Off Air Sol vent or 3rd Valve Exiting Fill Time This field only appears if Exiting Fill Source is set to Air Solvent or 3rd Valve Enter the time in seconds 313882C Setup Mode Recipe 0 Screen 4 Fic 48 Recipe 0 Screen 4 This screen appears only if Flush and Fill Input is set to Recipe in Option Screen 1 page 32 and Special Out puts is set to 1 2 3 or 4 in Configure Screen 5 page 31 The I O board has four programmable outputs 43 Setup Mode Calibration Screen Meter A Meter Calibration Measured Actual volume Volume k F actor 0 119 cc pulse Recipe MEINES Fic 49 Calibration Screen Use this screen to calibrate a meter Set to Meter A Meter Meter or Solvent Meter available if Sol vent Monitor in Configure Screen 5 page 31 is set to Meter
34. O LOW ALARM pages 79 80 The supply pump is not turned on Turn on the supply pump There is an air leak downstream from the air flow switch Check the air lines for leaks and repair The air flow switch is stuck open Clean or replace air flow switch System is in Mix mode with 0 volume entered for Min Verify condition of fuse and replace if necessary See Material Fill Volume see Option Screen 1 page 32 Hepair Parts manual and Fuse F1 is blown 82 313882C Alarm Troubleshooting Table 10 Alarm Troubleshooting E 9 MIX IN SETUP ALARM Cause Attempt to operate system while in Setup mode System must be in Standby to change current recipe and cannot be operated E 10 REMOTE STOP ALARM Cause Automation has requested that the system abort all oper Abort operations Troubleshoot automation system ations E 11 PURGE VOLUME ALARM ProMix 3KS solvent flow switch is not activated while Verify that the gun is not shut off and that the solvent flow purging switch is activated while purge is taking place Minimum flush volume is set too high Increase solvent supply or decrease minimum volume setting No meter pulses during Color Catalyst Dump Color change solvent supply not set up or functional Check Color Change setup 313882C 83 Alarm Troubleshooting Table 10 Alarm Troubleshooting E 12 CAN_COMM_ERROR_ALARM Cause Communication between the Color Change Module and Verify that a
35. Operation G 7 GRACO ProMix 3KS 313882C Plural Component Proportioner ED Manual system for proportional mixing of plural component coatings For professional use only Approved for use in explosive atmospheres except the EasyKey and 3KS Power Supply Module Important Safety Instructions Read all warnings and instructions in this manual Save these instructions See page 4 for model information including maximum working pressure Equipment approval labels are on page 3 Some components shown are not included with all systems o ProMix 2KS 688 8KS 0 0 0 5 9 556 0 0 0 0 oni 8 IERI m SHS 7 D Qe 49 114543 C US 0359 APPROVED PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 3 Equipment Approvals 3 System Configuration and Part Numbers 4 Configurator Key
36. S 1 Fiber 1 d Optic LER RAM T dn Not Used Flow Solv Flow C Flow A Flow B Dose A Valve Overrides Dose B OOQOO Dose C gt 3rd Flush Dump Valve A Dump Valve B Optional Solenoid GFB 1 Locations GFB 2 LIII N DEDE pz Dose Valve B Purge Valve A Purge Valve B 7112652 Solenoid Solenoid Solenoid Dose Valve A Solenoid 57 Component A and B Solenoids 54 313882C System Operation Overrides gt AE R14 c10 RIS nin inn ee ssl B ne nnns R24 52 R28 R27 Brio _ cis EE 09 R23 ec T S T gt 5 Q E 5 Dose Valve Solenoid O 128 J4 _ Td cog F te n O 55 T114704a Purge Valve C Solenoid Dump Valve C location optional 58 Component Solenoids 313882C System Operation Module 1 Solenoid Identification Label 112826 Catalyst ER ERE ER ER OOO E
37. SE VALVE PURGE C VALVE DUMP C VALVE OPTIONAL COLOR CHANGE CONTROL N 7 7 ka N 36 SERIES SOLENOID VALVES Schematic Diagrams STACKS 3RD COMP 1 3RD COMP 2 3RD COMP 3 3RD COMP 4 3RD COMP SOLVENT COLOR 13 OPTIONAL COLOR 14 OPTIONAL COLOR 15 OPTIONAL COLOR 16 OPTIONAL COLOR 17 OPTIONAL COLOR 18 OPTIONAL COLOR 19 OPTIONAL COLOR 20 OPTIONAL COLOR 21 OPTIONAL COLOR 22 OPTIONAL COLOR 23 OPTIONAL COLOR 24 OPTIONAL COLOR 25 OPTIONAL 91 Schematic Diagrams System Electrical Schematic NOTE ProMix 3KS system Some compo iring expansions ble w llustrates all possi IC ical schemati The electr nents shown are not included with all systems Non Hazardous Area 38 E NOOV38 Jub Woo BA LNdNIS 1 1QdNI v 1 1QdNI 1 2 LNdNI L NOWWOD NOWWOD LNdNI 83MOd NOWWOD v INdLNO 109345 INdLNO 175345 4 119110 1234 INdLNO 1VID3dS YaMOd NOWWOD 109110 YAMOd NOWWOD 119110 1VLIDIQ Wav Ty 3493 3ALDV 3NLDV AQV3d X LAdLNO 3AUDV X LAdLAO JALOV HD 3dDD38 35Ufld YAMOd NOWWOD LAdLNO 1VLIDIQ 244 93 933 ddd 93 939 933 TYL LAdNI Wdy TY 13538 DHD 910 TVNY31X3 LAdNI 3131907 8Of N N X0l8
38. Stations 313882C 57 System Operation Purging Read Warnings page 8 Follow the Grounding instructions in your system Installation manual To avoid splashing fluid in the eyes wear eye protec tion There are 4 purging procedures in this manual Purging Mixed Material below Purging Using Recipe 0 page 59 Purging Fluid Supply System page 59 Purging Sampling Valves and Tubes page 61 Use the criteria listed in each procedure to determine which procedure to use 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 before servicing the fluid manifold assembly hose or gun In the first stage fluid manifold 2KS solvent purges the component B catalyst right side of the mix manifold and the inner tube of the integrator Air purges the com ponent A resin left side and the outer tube of the inte grator This air solvent chop purges the hose connecting the 2KS static mixer to the 3KS fluid manifold In the second stage fluid manifold 3KS solvent purges the component C right side of the mix manifold and the inner tube of the integrator The air solvent chop from the 2KS purges the left side of the 3KS fluid manifold and the outer tube of the 3KS integrator 1 Press the Standby r key on the Booth Control Trigger the gun to relieve pressure If you are using a high p
39. a non resettable value that shows the total amount of material dispensed through the system Gun Trigger Input Signal used to manage ratio assur ance dose times and flow control processes 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 Job Total a resettable value that shows the amount of material dispensed through the system for one job A job is complete when a color change or complete system flush occurs K factor a value that refers to the amount of material that passes through a meter The assigned value refers to an amount of material per pulse Ki refers to the degree fluid flow over shoots its set point Kp refers to the speed in which the fluid flow reaches its set point 313882C Manual Mode when the proportioning or flow control system is controlling the inputs without any input from an outside control Mix when cross linking of the resin A catalyst B and reducer C occurs Mix Input Signal refers to system mode status where system begins a dose sequence each time the mix sig nal is made High Modbus TCP a type of communication protocol used to communicate Digital I O signals over an ethernet Network Station a means to identify a particular indi vidual proportioning or flow control system Overdose Alarm
40. age 81 ES Dose Time B Aem _ ES Min Setup Aem 12 Network Communication Error Page 84 Alarm High Flow Alarm Page 85 Low Flow Alarm Page 85 cleared by simply pressing the Alarm Reset Page 85 Page 86 Page 87 Material Fill Alarm Page 87 Tank A Low Alarm Page 88 Page Page 88 Page 88 77 Alarm Troubleshooting Alarm Troubleshooting Table 10 Alarm Troubleshooting E 1 COMM_ERROR No power to the EasyKey Connect power to EasyKey No power to Fluid Station The intrinsically safe power Verify that the cable is correctly connected See Installa cable between the EasyKey and Fluid Station is not con tion manual nected No power to Fluid Station The fluid control board fuse is Verify condition of fuse and replace if necessary See blown Repair Parts manual The fiber optic cable between the EasyKey and Fluid Verify that the cable is correctly connected See Installa Station is not connected tion manual The fiber optic cable is cut or bent Verify that the cable has not been cut or bent at a radius smaller than 1 6 in 40 mm Dirty fiber optic cable ends Disconnect fiber optic cable ends and clean with a lint free cloth A communication cable or connector failed Replace cable E 2 POTLIFE_ALARM The potlife time has been exceeded for the mixed mate rial Press the Alarm Reset key to stop the audible al
41. alve RVA Component A Sampling MS Solvent Meter Valve SPV Solvent Purge Valve SVA Component A Shutoff APV Air Purge Valve Valve SM Static Mixer MB Component B Meter FI Fluid Integrator DVB Component B Dose Valve AT Air Purge Valve Air Supply RVB Component B Sampling Tube Valve Key ProMix 3KS Fluid Station MC Component C Meter DVC Component Dose Valve RVC Component C Sampling Valve CPV SVC Component C Shutoff Valve CPV Component C Purge Valve SM Static Mixer Fl Fluid Integrator A 3KS fluid inlet Connect fluid supply line from 2KS fluid manifold outlet here A Connect fluid supply line to gun 114382 Fic 3 ProMix 2KS and ProMix 3KS Wall Mount Fluid Stations 313882C 15 Booth Control Booth Control Used by the operator for daily painting functions includ Table 2 Booth Control Key and Indicator Functions ing changing recipes signalling job complete read see FIG 4 ing clearing alarms and placing the system in Standby Key Indicator Definition and Function Mix or Purge mode It is typically mounted inside the booth or near the painter Down Key Scrolls recipe numbers down Table 2 Booth Control Key and Indicator Functions Wo see FIG 4 Mix Mode Key Starts Mix mode Key Indicator Definition and Function Green LED remains lit while in Mix mode or in Idle mode Display Displays recipe number in Run mode After doing a purge press key If an alarm occurs display
42. anually edit the K Factors in Advanced Setup Screen 4 page 36 or Recipe Setup Screen 5 page 41 Always purge sampling valves after calibrating meters Use one of the following methods Follow the Purging Sampling Valves and Tubes procedure page 61 e Place the sampling valve fluid tubes into a com patible cleaning fluid TSL or solvent or cap them NOTE If fluid hardens in sampling tubes replace them with 5 32 in or 4 mm OD tubing Make sure all sampling valves are closed and all fluid shutoff valves are fully open Before you begin production clear the system of solvent and prime it with material a Goto Mix mode b Trigger the gun into a grounded metal pail until mixed material flows from the gun nozzle C To begin operation see Start Up page 50 63 Color Change Color Change Color Change Procedures Multiple Color Systems 1 2 Shut off air to the gun Place the gun in the gun flush box if used and close the lid owitch to Standby r mode at the Booth Control Use the scroll keys or to select the new color Press Enter to begin the color change sequence If a gun flush box is not used trigger the gun into a grounded metal pail quies until the color change sequence is NS ONY complete PY When the color change indicator light stops flashing on the Booth Control the color change sequence is complete NOTE The color change timer does not start u
43. appears if the component C change option is detected from the cc board meaning that dump valve C is present On is the only setting 3rd Flush Valve Off is default If optional 3rd flush valve is used set to On Configure Screen 4 t SEC Lose size Dose Time Number of buns Flush Box Configure FIG 25 Configure Screen 4 30 Dose Size Select the total dose size cc from the pulldown menu 100 50 25 or 10 NOTE Selection DD is for dynamic dosing which is not used with ProMix 3KS Lose size Dose ime Alarm Number of buns laur Flush S0 t DD 40 sec 20 Fic 26 Dose Size Menu Configure Example To calculate the dose size of each component you must first calculate the A B C dose sizes For example if the total dose size is 50 cc and the A B C ratio is 1 1 the dose size of A B is 25 cc and the dose size of C is also 25 cc Then use the ratio of A B 2 1 in this example to calculate the dose size of A as 16 67 cc 2 3 of 25 and the dose size of B as 8 33 cc 1 3 of 25 Dose Time Alarm Enter the dose time 1 to 99 seconds This is the amount of time allowed for a dose to occur before a dose time alarm occurs Number of Guns Enter the number of spray guns 1 or 2 Gun Flush Box Enter the number of gun flush boxes Off 1 or 2 313882C Configure Screen 5 Special Outputs M t Solvent Monitor 5 Web Browser IP 192 158 1
44. arm Purge the system with solvent fresh mixed mate NOTICE rial or a new color To prevent mixed material from curing in the equip ment do not shut off power Follow one of the solu tions at right e Solvent Purge See Purging Mixed Material on page 58 The system purges until the preset purge time is complete New Mixed Material Purge Go to Mix mode and spray the required volume to restart the timer Color Change Perform a color change page 64 78 313882C Alarm Troubleshooting Table 10 Alarm Troubleshooting E 3 RATIO_HIGH_ALARM Sequential Dosing System The mix ratio is higher than the set tolerance on the previous dose cycle 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 prop erly 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 purging the flow Restrict gun needle travel to slow down the initial fluid rate was probably too high delivery rate until fluid hoses are loaded with material If the alarm occurred after you were spraying for some Adjust component A B and C fluid supply regulator time the pressures from the fluid supplies could be pressures until they are about equal f the pressures are unbalanced already about equal verify
45. asnnn _ c 0 aasnnn L_ 4 NOWWOD Kun NOWWOD N w3MOd OVA0SCS8 JI 2 A3MASV3 SXC XINOYd 3138826 92 Schematic Diagrams System Electrical Schematic NOTE The electrical schematic illustrates all possible wiring expansions in a ProMix 3KS system Some compo nents shown are not included with all systems Non Hazardous Area ef OL NENNEN TANVd INSANOdWOO 9f NI O4 OL __________ LNO 03 OL pe 1 1 TANVd 91173 V3uv SNOQHYYVZVH SNOILdO 001 01 quvog pagava SS3NHYH H3MOd and 05298 12 MINE H N cake 1 OVAOSZ SS 11 H ddMOd 2 SAYNSOTONS Sd daldHdva SME SNOCHYVZVH NON 93 313882C Schematic Diagrams System Electrical Schematic The electrical schematic illustrates all possible wiring expansions in a ProMix 3KS system Some compo nents shown are not included with all systems NOTE Hazardous Area RON Dv18 vig BE 018 3unssauid 43805 4010 3335 LHM 934 WOD 45 34066334 TIO vf 419 WOD C 439 215 TOULNOD SNOLLdO 001 80 038 QIONTIOS AVM LAF Xs TZ 3nm
46. aterials The valves are used to flush with water air and solvent V P refers to the voltage to pressure device in the flow control module 17 Overview Overview Usage The Graco ProMix 3KS Kit adapts a ProMix 2KS system to be an electronic 3 component paint proportioner It can blend most 3 component solvent and waterborne epoxy polyurethane and acid catalyzed paints It is not for use with quick setting paints those with a potlife of less than 15 minutes Can proportion at ratios from 0 1 1 to 50 1 in 0 1 e Color change options are available for low pressure increments with the wall mount fluid station 300 psi 2 1 MPa 21 bar air and high pres e Has user selectable ratio assurance and can main sure 3000 psi 21 MPa 210 bar systems with up tain up to 1 accuracy depending on materials to 25 color change valves and up to 4 catalyst and 4 and operating conditions component C change valves e Models are available to operate air spray or air assisted systems with a capacity of up to 3800 NOTE Optional accessories are available for in field cc min installation to achieve 25 colors or for component C change Component Identification and Definition See FIG 2 and Table 1 for the system components Components marked with a star are available as part of the ProMix 3KS Kit All other components are part of the ProMix 2KS System or are available as accessories
47. cal Data Base system 3000 psi 21 MPa 210 bar Low pressure color change 300 psi 2 1 MPa 21 bar High pressure color change 3000 psi 21 MPa 210 bar Coriolis meter 2300 psi 16 1 MPa 161 bar 100 psi 0 7 MPa 7 bar 75 100 psi 0 5 0 7 MPa 5 2 7 bar 3 8 npt f 5 micron minimum filtration required clean and dry air 30 micron minimum filtration required clean and dry air Stage 1 A B 0 1 1 50 1 Stage 2 A B C 0 1 1 50 1 up to 1 user selectable one or two component solvent and waterborne paints polyurethanes epoxies acid catalyzed varnishes moisture sensitive isocyanates 20 5000 cps 100 mesh minimum 75 3800 cc min 0 02 1 00 gal min 38 1900 cc min 0 01 0 50 gal min 20 3800 cc min 0 005 1 00 gal min 38 1900 cc min 0 01 0 50 gal min 1 4 npt f 1 4 npt f 1 4 npt m 1 4 npt f 85 250 Vac 50 60 Hz 2 amps maximum draw 15 amp maximum circuit breaker required 8 to 14 AWG power supply wire gauge 41 122 F 5 50 C indoor use pollution degree 2 installation category below 70 dBA below 85 dBA 303 304 SST Tungsten carbide with nickel binder perfluoroelastomer PTFE Dependent on flow rate dose size and meter resolution See individual component manuals for additional technical data 313882C 97 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing it
48. d Rec ipe Setup Screen 6 on page 41 will not appear 313882C Setup Mode 33 Setup Mode Advanced Setup Screens NOTE See FiG 31 for a map of the Advanced Setup Screens Detailed screen descriptions follow Gun 1Potlife Volume EEN cc t Color Catalyst Purge seconds 1 Advanced Setup screens 2 3 Color Catalyst Fil seconds 4 and 5 appear depending on selections made in Option screens 1 and 2 Advanced Calibration J First Purge Source Gir Solvents 2 K200017 BC LXX Zil Fia Purge Source Iu P 200012 AK 3K Auto C2 201 Air Chop Time seconde 1042 0198 Solvent Chop Time 20 seconds IP 192 168 178 5 DOPDARRDiS1U Advanced Calibration Meter A Meter Calibration First Purge Time Sec Measured Actual Volume Volume First Purge Time sec Total Chop Time Sec Final Purge Time SEC k Factor 0 119 C Final Purge Time SEC Calibration Fil Time SEC Advanced Calibration A B 67 K Factor 1 B Meter T Ratio Tolerance i B Meter 0 119 cc pulse C Meter 0 119 cc pulse Valves ALY Solvent Meter 0 119 cc pulse Recipe IEE Advanced Calibration J T112786a Fic 31 Advanced Setup Screens 34 313882C NOTE Each screen displays the current screen number and the total number of screens in the group The total number of screens in a group and the fields displayed on each screen
49. d the Dump B valve open during the Purge Time e The catalyst change solvent valve closes when the Purge Time expires Catalyst Fill e This sequence fills the line with the new catalyst all the way to the Dump B valve e The new catalyst valve and the Dump B valve open during the Fill Time e The new catalyst valve and the Dump B valve close when the Fill Time expires Component C Purge Dump e This sequence flushes out component C with sol vent from the component C valve to the Dump C valve e The component C change solvent valve and the Dump C valve open during the Purge Time e The component C change solvent valve closes when the Purge Time expires 313882C Color Change Component C Fill e This sequence fills the line with the new component C all the way to the Dump C valve e The new component C valve and the Dump C valve open during the Fill Time e The new component C valve and the Dump C valve close when the Fill Time expires First Purge Select the First Purge Source air solvent or 3rd valve and First Purge Time For most applications air is selected The system purges the old material from the dose valves to the gun using only the selected purge media usually air The selected purge valve opens during the First Purge Time and closes when the time expires First Purge C Select the First Purge C Source solvent or water and First Purge C Time For most applications solvent is selected
50. display for approximately 5 seconds followed by the Status Screen see page 22 GRACO Control 2 00 0135 Fasukey 2 0 013 FIG 7 Splash Screen The Splash screen will also momentarily display Estab lishing Communication If this display remains for more than one minute check that the fluid station circuit board is powered up LED is on and that the fiber optic cable is properly connected see ProMix 2KS Installation man ual NOTE If the software version of the fluid plate does not match the version of the EasyKey the EasyKey will update the fluid plate and the fluid plate programming screen will appear until the update is completed Programming Fluid Plate Lade Bm 3 Fic 8 Fluid Plate Programming Screen 20 313882C Run Mode Screens Press the Setup a key to enter Setup mode Job Total Grand Total 0 Liters 0 cc 0 Liters 0 Liters 0 cc 0 Liters 0 Liters 0 solvent Level Control ob Complete Reset solvent Level Control Liters Are uou sure you want to Are uou sure uou want to Alarm Level Current Volume reset job totals reset solvent total enter to accept default Level Control Alarms Date Time Alarm TI12783a Fic 9 Run Screens Map 313882C 21 Run Mode Screens Status Screen e Use the Up 4 Down 7 keys to scroll through the Run screens e Press the Setup key to enter the Setup screens from the Status sc
51. e Start start calibration Abort stop calibration e Purge purge sampling valves after calibration See Meter Calibration page 62 for when and how to calibrate a meter 44 313882C System Operation Operation Modes Mix System mixes and dispenses material Standby Stops the system LIN wp Purge Purges the system using air and solvent Sequential Dosing Components A B and C dispense sequentially in the necessary volumes to attain the mix ratio Recipe Color Change The process when the system automatically flushes out the old color and loads a new color See pages 64 76 313882C System Operation General Operating Cycle Sequential Dosing 1 The spray gun operator enters and loads the desired recipe The color change LED blinks while recipe is loading then turns solid when complete 2 The operator presses the Mix key to begin operation The controller sends signals to activate the solenoid valves The solenoid valves activate Dose Valves A B and C Fluid flow begins when the gun is trig gered Stage 1 see Fic 50 ProMix 2KS Detail 4 Components A and B are introduced into the 2KS fluid integrator Fl one at a time as follows a Dose Valve B DVB opens and fluid flows into the integrator b Flow Meter B MB monitors the fluid volume dispensed and sends electrical pulses to the ProMix 2KS controller The controller monitors these pulses and s
52. e button on each color solenoid until flow from dump valve A stops 5 Press and hold the dump valve B solenoid override FIG 57 313882C System Operation See FIG 59 Using the solenoid identification labels as a guide press and hold the override button on each catalyst solenoid until flow from dump valve B stops Press and hold the dump valve C solenoid override FIG 57 See FIG 59 Open the color change module Using the solenoid identification labels as a guide press and hold the override button on each color solenoid until flow from dump valve C stops Press and hold the dump valve A solenoid override FIG 57 Press and hold the A side color solvent solenoid override until clean solvent comes from the dump valve then release Press and hold the dump valve B solenoid override FIG 57 Press and hold the B side catalyst solvent solenoid override until clean solvent comes from the dump valve then release Press and hold the dump valve C solenoid override FIG 57 Press and hold the C side solvent solenoid override until clean solvent comes from the dump valve then release Shutoff the solvent supply to the color catalyst com ponent C change stack solvent valves Press and hold the A B and C solvent solenoid overrides and dump valve overrides until solvent flow from the dump valves stops 53 System Operation AFS 1 AFS 2 SOLV SW 1 PS GFB 2 P
53. ection or cable Communication between the Color Change Module and Verify condition of fuse and replace if necessary See the Fluid Station is interrupted The fluid control board Repair Parts manual fuse is blown Communication between the Booth Control and the Fluid Verify that the cable is correctly connected Station is interrupted 84 313882C Alarm Troubleshooting Table 10 Alarm Troubleshooting E 13 HIGH _FLOW_ALARM or 14 LOW_FLOW_ALARM may also be set as Warnings Cause Fluid system is producing too much or too little flow Troubleshoot fluid system for restrictions leaks exhausted fluid supply incorrect settings etc Increase or decrease flow rate as required E 15 SYSTEM_IDLE_WARNING Mix input is high but the gun has not been triggered for 2 If not painting clear alarm and resume operation minutes If painting shut down and inspect fluid meter and air flow switch E 16 SETUP CHANGE WARNING _ _ _____ __ JN The system setup parameters have been changed No action required See Event Log available through advanced web interface E 17 POWER_ON_WARNING Cause The power to the system has been cycled No action required See Event Log available through advanced web interface E 18 DEFAULTS LOADED WARNING Cause The factory defaults have been installed on the system action required See Event Log available through advanced web interface 313882C 85 Alarm Troublesho
54. een 1 Recipe A B Ratio Tolerance 5 1 1 EL Wales BLA MEE Calibration Fic 38 Recipe Setup Screen 1 Ratio Enter the mix ratio of component A over component B 0 0 1 to 50 1 and the ratio of A B over C 0 0 1 to 50 1 Ratio Tolerance Enter the ratio tolerance 1 to 99 This refers to the percent of acceptable variance that the system will allow before a ratio alarm occurs Component A Color Valve if present This field only appears if the system includes a color change module Enter the component A valve number 1 to 25 Component B Catalyst Valve if present This field only appears if the system includes a color change module Enter the component B valve number 1 to 4 Component C Reducer Valve if present This field only appears if the system includes a color change module Enter the component C valve number 1 to 4 313882C Setup Mode Recipe Setup Screen 2 Recipe Minimum Flush Volume 0 minutes Potlite Time Color Catalyst Purge seconds Color Catalyst Fil seconds Calibration 39 Recipe Setup Screen 2 Minimum Flush Volume This field only appears if Flush Volume Check is set to in Option Screen 1 on page 32 Enter the mini mum flush volume 0 to 999 cc Entering O disables this function Potlife Time Enter the potlife time 0 to 999 minutes Entering dis ables this
55. een appears momentarily if a password is activated 11 9 2009 TI12784a Fic 17 Setup Screens 313882C 25 Setup Mode Password Screen Set Up Home Screen If a password has been activated see Configure Screen 1 page 29 the Password screen will appear Cal Up You must enter the password to access the Set Up Home Screen Entering the wrong password returns the Recipe amp Advanced Setup display to the Status Screen system Configuration NOTE If you forget the password you can reset the password to 0 using the ProMix Web Interface see EK 200 012 LAs 2 01 manual 313386 200 012 AK 3k Buto L2 201 V6 6 0 2 1042 0198 IP 192 166 176 5 MAL 00204AADI1S10 Fic 20 Set Up Home Screen Enter Password This screen displays when you enter Setup mode From it you can go to Recipe and Advanced Setup Screens pages 34 41 or System Configuration Screens pages 28 31 Press the Enter key to go to the selected screen set The screen also displays software versions and internet addresses of various components The values shown in FiG 20 are only examples and may vary on your screen NOTE If a password is activated Setup Locked dis See Table 4 for further information plays momentarily after exiting Setup mode and return Fic 18 Password Screen ing to the Status Screen A lock symbol appears on the Status Screen Setup Locked FIG 19 Setup Loc
56. er Fluid Integrator is the chamber where component C aligns with blended components A B at the selected ratio and begins to mix gt Static Mixer has 24 elements to uniformly blend the materials downstream of the fluid integrator 313882C 13 Overview Table 1 Component Descriptions Component Description Flow Meters MA Four optional flow meters are available from Graco MB xMC MS e 3000 is a general purpose gear meter typically used in flow ranges of 75 3800 cc min 0 02 1 0 gal min pressures up to 4000 psi 28 MPa 276 bar and viscosi ties of 20 3000 centipoise The K factor is approximately 0 119 cc pulse G3000HR is high resolution version of the G3000 meter It is typically used in flow ranges of 38 1900 cc min 0 01 0 5 gal min pressures to 4000 psi 28 MPa 276 bar and viscosities of 20 3000 centipoise The K factor is approximately 0 061 cc pulse 3000 is a gear meter used for solvents in flow ranges of 38 1900 cc min 0 01 0 50 gal min pressures up to 3000 psi 21 MPa 210 bar and viscosities of 20 50 centi poise The K factor is approximately 0 021 cc pulse Coriolis is a specialty meter capable of a wide range of flow rates and viscosities This meter is available with 1 8 in or 3 8 in diameter fluid passages For detailed information on the Coriolis meter see manual 313599 The K factor is user settable at lower flow rates use a lower K factor 1 8 in fluid passag
57. er bend hoses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed e Read 5 5 to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines e Always wear impervious gloves when spraying 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 inhalation of toxic fumes burns and hearing loss This equipment includes but is not limited to e Protective eyewear e Clothing and respirator as recommended by the fluid and solvent manufacturer e Gloves e Hearing protection Glossary of Terms Glossary of Terms Air Chop the process of mixing air and solvent together during the flush cycle to help clean the lines and reduce solvent usage Analog relating to or being a device in which data are represented by continuously variable measurable physical quantities such as length width voltage or pressure Closed Loop Flow Control refers to the process when the flow rate is adjusted automatically to maintain a constant flow Coriolis
58. es set K factor to 020 or 061 3 8 in fluid passages set K factor to 061 or 0 119 Color Change An optional component It is available as a color change valve stack for either low or high Valves ACV and pressure with up to 25 color change valves Each stack includes one additional valve for Color Change solvent to clean the fluid line between color changes Module CCM Catalyst Change An optional component It is available as a catalyst change valve stack for either low or Valves BCV high pressure with up to 4 catalyst change valves Each stack includes one additional valve for solvent to clean the fluid line between catalyst changes Component An optional component It is available as a component C change valve stack for either low Change Valves or high pressure with up to 4 component C change valves Each stack includes one addi CCV tional valve for solvent to clean the fluid line between component C changes Dual Fiber Optic Used to communicate between the EasyKey and Wall Mount Fluid Station Cable FO Fluid Station Used to provide power to the Wall Mount Fluid Station Power Supply Cable PS Applicator Not shown See ProMix 2KS manuals for details Handling use Air Flow Switch AFS or Gun Flush Box GFB 14 313882C Overview DVA Fl DVB MA RVA TI12556a APV AT SVA SM SVB SPV Key ProMix 2KS Fluid Station MA Component A Meter SVB Component B Shutoff DVA Component A Dose Valve V
59. es data overflow 86 313882C Alarm Troubleshooting Table 10 Alarm Troubleshooting E 20 PURGE_INITIATE_ALARM Cause System detects atomizing air to the gun when purge is Shut off gun air selected For systems with a gun flush box gun is not in the box Place gun in gun flush box Verify that gun flush box is when purge is selected operating properly For systems with auto dump on gun is not in the box Place gun in gun flush box Verify that gun flush box is when auto dump is initiated operating properly For systems with a gun flush box Fuse F2 is blown Verify condition of fuse and replace if necessary See Repair Parts manual E 21 MATERIAL FILL ALARM For systems with minimum mixed material fill volume Check for restrictions or leaks in the fluid supply system entered the system detects that fill volume is not achieved during mixed material fill time Check if the fill volume is properly configured e Adjust fill volume e Adjust fill time For systems without color change and with minimum Verify condition of fuse and replace if necessary See mixed material fill volume entered Fuse F1 is blown Repair Parts manual 313882C 87 Alarm Troubleshooting Table 10 Alarm Troubleshooting E 22 TANK A LOW ALARM E 23 TANK B LOW ALARM E 24 TANK S LOW ALARM or E 29 TANK C LOW ALARM The tank volume reaches the low level threshold The EasyKey screen will display the alarm and prompt the use
60. es the language of the screen text Select English default Spanish French German Italian Dutch Jap anese Kanji Korean and Chinese Simplified Password The password is only used to enter Setup mode The default is 0 which means no password is required to enter Setup If a password is desired enter a number from 1 to 9999 NOTE Be sure to write down the password and keep it in a secure location Display Units Select the desired display units e ccl liter default cc gallon 313882C Setup Mode Configure Screen 2 Month Tear Time late Format Configure FIG 23 Configure Screen 2 Month Enter current month Day Enter current day Year Enter current year four digits Time Enter current time in hours 24 hour clock and minutes Seconds are not adjustable Date Format Select mm dd yy or dd mm yy 29 Setup Mode Configure Screen 3 Run Dump Valve Manual 3 Dump Valve B n Dump Valve Un J 3rd Flush Valve Fic 24 Configure Screen Configure Run Mode Indicates that this is a Manual system Dump Valve A This field only appears if the system includes an optional dump valve A If dump valve A is included set to On Dump Valve B This field only appears if the catalyst change option is detected from the cc board meaning that dump valve B is present On is the only setting Dump Valve C This field only
61. etup Screens 38 Recipe 0 Screens 42 Calibration Screen 44 2 System Operation 45 Operation Modes 45 Sequential Dosing 45 Recipe Color Change 45 General Operating Cycle Sequential Dosing 45 Mix Manifold Valve Settings 48 Air Flow Switch AFS Function 49 Dla grep NIE DEDIT 50 wii Cm 52 Pressure Relief Procedure 52 FP COI edere tas dita pond deat det 58 Meter Calibration 62 Color Change 2 bac 64 Color Change Procedures 64 Color Change Sequences 64 Alarms and WarningS 77 System Alarms 77 System Warnings 77 Alarm Troubleshooting 78 Schematic Diagrams 90 System Pneumatic Schematic 90 System Electrical Schematic 92 Power Supply Module Electrical Schematic 96 Technical 2 97 Graco Standard Warranty 98 Graco Information 98 313882C Related Manuals Component Manuals in English Manual Description 313386 Basic Web Interface Advanced Web Inter face 406799 15V256 Automatic
62. g Hu vanna Cat yov1a GIONSTOS aes AT LIS SE Hu vig e Em 031 sanna EZ 03002 90102 438 SNOLLdO 001 01 15 09 aasnNn SNNN SNNN aasnNn aasnNn 019 1NVO LHM NYD 3uvg GTSIHS 933 DOAZ L quo als Ol aasnnn aasnnn SNNN 435 Q3snNn WNIWYAL LLL gd Enp 9 5 1N3A105 Y3 LIW MOT bovis Wo 19195 59313 51 Nu5 q 215 mcm uM m WO 934 l NUD GT3IHS 3LIHM 15 WO a384 4Md 3182 XE 300155394 7949 ___ in H LIMS 34156334 1849 b HOLIMS ININOS 2 no ZHOLMS YY _ OB LHOLIMS joe 3500 m adi GIONSTOS AYN lt 033 X v18 MOTI3A Q3u vao 1 ____ 3498 SISSWHD 45 SS3ud iD MO SE CN SE sio 07 4 EE HB LHM 100
63. h cycle to help clean the lines and reduce solvent usage Final Purge Source Select Air Solvent or 3rd Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 30 Air Chop Time Enter the air chop time 0 0 to 99 9 seconds Solvent Chop Time 3rd Flush Valve Chop Time Enter the solvent or 3rd flush valve chop time 0 0 to 99 9 seconds 40 Recipe Setup Screen 4 Recipe First Purge Time First Purge Time Total Chop Time Final Purge Time Final Purge Time Fill Time Recipe 41 Recipe Setup Screen 4 This screen appears only if Flush and Fill Input is set to Recipe in Option Screen 1 page 32 lf Number of Guns is set to 2 in Configure Screen 4 page 30 a Gun 2 column will appear in this screen First Purge Time Stage 1 Enter the first purge time 0 to 999 seconds for compo nents A and B C First Purge Time Stage 2 Enter the component C first purge time 0 to 999 sec onds Total Chop Time Stage 1 Enter the total chop time 0 to 999 seconds for compo nents A and B Final Purge Time Stage 1 Enter the final purge time 0 to 999 seconds for compo nents A and B C Final Purge Time Stage 2 Enter the component final purge time 0 to 999 sec onds Mixed Material Fill Time Enter the mixed material fill time 0 to 999 seconds It refers to the amount of material that is required to
64. he gun Repeat to thoroughly clean the fluid integrator e Multiple color multiple catalyst multiple component C systems Select Recipe 0 and press Enter to purge the complete system The color change LED blinks while Recipe O runs and turns solid after purge sequence is complete Repeat to thoroughly clean the fluid integrator Reinstall the Fluid Station cover Shut off the solvent fluid supply Disconnect the solvent supply lines and reconnect the component A B and C fluid supplies See page 50 for Start Up procedure 313882C Purging Sampling Valves and Tubes Follow this procedure after meter calibration 1 Press the Standby r key on the Booth Control 2 See 60 Close both fluid shutoff valves and sampling valves 3 Route the sampling tubes into a grounded waste container 4 Onasingle color system attach a solvent supply line to Flow Meter A inlet 5 Onthe EasyKey press the Setup a key and access the Advanced Setup screens 6 Press the Right Arrow mp key to select the Calibra tion screen Press the Down Arrow key and select Purge from the menu Press the Enter Dose A solvent purge valve side component purge valve and color change solvent valves if used will open H Meter Actual __9 0 119 cc pulse Recipe Selig Fic 61 Calibration Screen Meter Calibration Volume
65. iG 21 for map of the System Configura tion Screens Detailed screen descriptions follow Language Enter Password Display Units English uj Fic 21 System Configuration and Option Screens 28 Configure Month Day Year Time Date Format Configure Run Manual t Dump Valve A 3 Dump Valve B On Dump Valve On J 3rd Flush Valve Configure Dose Size t Dose Time Alarm sec 4 Number of Guns Gun Flush Box Configure Ce Solvent Monitor 5 Web Browser IF 192 158 178 5 Control Network ID special Outputs Configure oe aa NOTE Each screen displays the current screen number and the total number of screens in the group Flush Volume Check Flush and Fill Input Global K Factor Input Global Min Material Fil Volume Stage Fill Volume EE Options Warning switching to Global Source Global source recipe for Flush and Fill Input This will overwrite recipe data Are you sure Auto Dump Flow Rate Monitor Options set Up Recipe amp Advanced Setup System Configuration 200 012 BC 1 L1 201 200 012 AK 3k Auto C2 2 01 AP 1042 0195 192 168 178 3 00204AAD1610 112785 3138826 Configure Screen 1 English NU Language Enter Password Display Units Configure FIG 22 Configure Screen 1 Language Defin
66. ignals c When the target volume dispenses Dose Valve B closes NOTE The dispense volume of component A and B is based on the mix ratio and dose size set by the user and calculated by the ProMix 2KS controller d Dose Valve A DVA opens and fluid flows into the 2KS integrator and is aligned proportion ately with component B e Flow Meter A MA monitors the fluid volume dispensed and sends electrical pulses to the ProMix 2KS controller f When the target volume is dispensed Dose Valve A closes 45 System Operation 5 Components A and B are pre mixed in the 2KS inte NOTE To control output from the 3KS static mixer grator then uniformly blended in the 2KS static to the gun install an optional fluid pressure regula mixer SM before flowing through the hose to the tor 3KS Fluid Manifold inlet 10 Components A B and C are alternately fed into the Stage 2 see Fic 50 ProMix 3KS Detail 2KS integrator as long as the gun is triggered 6 Dose Valve C DVC opens and fluid flows into the 11 If the gun is not triggered for two minutes the sys 3KS integrator and is aligned proportionately with tem switches to Idle mode which closes off the mix components A B mixed in Stage 1 manifold dose valves 7 Flow Meter C MC monitors the fluid volume dis 12 When the gun is triggered again the ProMix 3KS pensed and sends electrical pulses to the ProMix continues the process where it left off 3KS controller NOTE
67. ill Time 69 ProMix 3KS Color Change Chart 8 74 313882C Color Change Recipe Change Xx gt Y External Color Change 3rd Flush Valve Valve Time Sequence ump B olvent A olvent B olvent C omponent A omponent B omponent C To o ojl ojlo c c 3 3 O gt B Purge Time B Fill Time C Purge Time Air For first purge and final purge Solvent only one of the purge valves are used 3rd Water Solvent Water Gun Trigger s by Operator Gun Flush Box Output 1 Gun Flush Box Output 2 LE EN LES Gun Flush Box Output 1 Gun Flush Box Output 2 _ E Two Second Initial Purge Time First Purge Time First Purge C Time Chop Time Final Purge Time Final Purge C Time Wait for External CC Input Mixed Fill Time Fic 70 ProMix 3KS Color Change Chart 9 313882C 75 Color Change Recipe Change X gt Y External Color Change No 3rd Flush Valve Valve Time Sequence ump B olvent A olvent B olvent C omponent A omponent B omponent C To o c c 3 3 O gt B Purge Time B Fill Time C Purge Time Air For first purge and final purge Solvent only one of the purge valves are used 3rd Water Solvent Water Gun Trigger s by Operator Gun Flush Box Output 1 Gun Flush Box Output 2 mz HN 2 Gun Flush Boxes ane EE Gun Flush
68. ime seconds Color Catalyst Fill seconds Solvent Chop Time seconds 4 Calibration Calibration Recipe Mt Recipe Color Catalust Purge 5 First Purge Time First Purge Time Total Chap Time Final Purge Time Final Purge Time Sec ias Calibration Recipe Minimum Flush Volume t Exiting Fill Source Exiting Fill Time 0 seconds A ISEE Calibration Recipe Special On Purge Length On Fill Length Calibration FiG 37 Recipe Screens First Purge Source i gt Chop Tupe 18 Final Purge Source Tl Air Chop Time seconds Solvent Chop Time seconds 4 Calibration Recipe First Purge Time First Purge Time Total Chop Time Final Purge Time C Final Purge Time Fil Time Recipe Recipe K Factar A Meter cc pulse B Meter cc pulse C Meter cc pulse Solvent Meter cc pulse ISEE Calibration Recipe Flow Rate Monitor Low Flow Limit D cc min High Flow Limit cemin Recipe Special On Purge Length On Fill Recipe screens 3 4 5 6 and 7 appear depending on selections made in Option screens 1 and 2 T112787a 313882C NOTE Each screen displays the current screen number and the total number of screens in the group The total number of screens in a group and the fields displayed on each screen may vary depending on selections made in the System Configuration Screens and Option Screens Recipe Setup Scr
69. ir purge and final purge Purge B Solvent 1 one of the purge valves are used 3rd Water Solvent Water No Gun Flush Boxes Gun Trigger s by Operator Gun Flush Box Output 1 Gun Flush Box Output 2 _ Gun Flush Box Output 1 Gun Flush Box Output 2 Fic 67 ProMix 3KS Color Change Chart 6 72 313882C Color Change 2 9 2 5 0 61 gt X 2 2 gt Valve Time Sequence olvent A olvent B olvent C omponent A omponent B omponent C e o o gt 3 313 o gt 77 gt lt o B Fill Time C Purge Time Air Solvent 3rd Water Solvent Water Only one of these three valves is used depending on the Exiting Fill Source selected in EasyKey Gun Trigger s by Operator Gun Flush Box Output 2 Gun Flush Box Output 1 Exiting Fill Time Mixed Fill Time Fic 68 ProMix 3KS Color Change Chart 7 313882C 73 Color Change Recipe Change 0 61 gt X New A B C No 3rd Flush Valve Time Sequence olvent A olvent B olvent C omponent A omponent B omponent C c o UO 313 3 oloo gt A Purge Time A Fill Time Air Solvent 3rd Water Solvent Water Gun Trigger s by Operator Gun Flush Box Output 2 Gun Flush Box Output 1 Exiting Fill Time Mixed F
70. ked Screen 26 313882C Setup Mode Table 4 Component Software Versions Display may vary from examples Component shown Description EK EasyKey 2 00 012 EasyKey software version FP Fluid Plate 2 00 012 Fluid Plate software version 313882C BC Booth Control Booth Control not installed not detected or not oper ational Booth Control software version 1 00 or 1 01 Booth Control software version 2 C1 C2 Color Change Color Change Module 1 2 not installed not detected Modules 1 and 2 or not operational Color Change Module software version 1 00 or 1 01 Color Change Module software version 2 XX AK Autokey 2K Manual No AutoKey installed or detected System operates in 2K Manual Mode only 2K Auto 2K AutoKey detected System can operate in 2K Man ual Semi automatic or Automatic Mode 3K Auto 3K AutoKey detected System can operate in 3K Man ual Semi automatic or Automatic Mode XP XPORT V6 6 0 2 Example of XPORT network module software version Other versions are acceptable MC Micro Controller 1042 0198 Example of fluid plate micro controller version Other versions are acceptable Internet Address 192 168 178 5 Example of the address EasyKey is set to for basic and advanced web interface reporting MAC MAC address 00204AAD1810 Example of internet MAC address Each EasyKey will have a different value in this format 27 Setup Mode System Configuration Screens NOTE See F
71. ll cables are connected securely and that the Fluid Station is interrupted the Color Change and Booth Control power LEDs turn on If the power LED does not turn on the prob lem is probably caused by a bad connection The nut on the connector must make at least 5 complete turns to ensure a good connection If the power LED still does not light the cable or board is bad e Check the color change board DIP switch settings See the ProMix 3KS installation manual e Check the fluid plate board DIP switch setting An incorrect setting will not cause E 12 alarms but a correct setting will help prevent E 12 caused by elec trical noise See the ProMix 3KS installation manual e Check EasyKey software version displayed at power up for all versions and when the lock key is pressed for version 2 02 000 and above If older than 1 06 002 upgrade Be sure to save settings through BWI or AWI before upgrading as they will be erased e The sticker on the color change board shows the software part number and version for example 151270 1 01 If the version is older than 1 01 replace the board e If all software versions and DIP switch settings are correct and you still have E 12 alarms then the sys tem has a bad connection bad cable or bad circuit board Use a multimeter on the CAN connectors to test whether there is a good connection between systems If there is you have a bad circuit board If there is not you have a bad connector conn
72. lor Change Option 1 and 2 low pressure valves 300 psi 2 07 MPa 20 6 bar Color Change Option 3 and 4 high pressure valves 3000 psi 21 MPa 210 bar Flow Meter Fluid Flow Rate Range 75 3800 cc min 0 02 1 0 gal min 38 1900 cc min 0 01 0 50 gal min Coriolis Meter 20 3800 cc min 0 005 1 00 gal min 53000 Solvent Meter accessory 38 1900 cc min 0 01 0 50 gal min Standard Features Feature 3 Third Component Network Cable yellow color coded 6 ft 1 83 m C Side Dump Valve if color valve s selected 313882C 5 System Configuration and Part Numbers 6 313882C Accessories Accessories 15V256 Automatic Mode Upgrade Kit 313882C 7 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 symbol refers to procedure specific risk Refer back to these warnings Additional product specific warnings may be found 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 sol
73. may vary depending on selections made in the System Configuration Screens and Option Screens Advanced Setup Screen 1 Em t seconds 1 seconds Lun 1 Potlte Volume Color Catalyst Purge Color Catalyst Fill Advanced Calibration Fic 32 Advanced Setup Screen 1 Gun 1 Gun2 Potlife Volume Enter the potlife volume 1 to 1999 cc for each gun This is the amount of material required to move through the mix manifold hose and applicator gun before the potlife timer is reset Use the following information to determine approximate pot life volume PLV in cc Hose ID inches Volume cc foot Integrator manifold and mixer volume 75 cc Spray Gun Volume 20 cc Hose x Feet of Hose 75 20 Color Catalyst Purge This field only appears if the system includes a color change module and Flush and Fill Input is set to Global in Option Screen 1 page 32 Enter the purge time 0 to 99 seconds It refers to the amount of time required to flush the lines from the color catalyst compo nent C module to the dose valve or dump valve 313882C Setup Mode Color Catalyst Fill This field only appears if the system includes a color change module and Flush and Fill Input is set to Global in Option Screen 1 page 32 Enter the fill time 0 to 99 seconds It refers to the time required to fill the lines from the color catalyst component C module to the dose valve or dump valve Advanced Se
74. must be inserted in the GFBs during the entire color change cycle purge and fill The system will turn each GFB trigger output on and off based on the preset time for each gun e For Special Outputs options the system will turn each output on and off based on the preset times Each Special Output has two different start times and durations e For systems without dump valves the First Purge begins after the Color Catalyst Component C Change steps are completed e Dump Valve B is required for a Catalyst Change system e Dump Valve C is required for a Component C Change system e When going from Recipe X to Recipe 0 only the purge cycle data from Recipe 0 is used e When going from Recipe to Recipe X only the fill cycle data from Recipe X is used 313882C Color Purge Dump e This sequence flushes out the color with solvent from the color valve to the Dump A valve e The color change solvent valve and the Dump A valve open during the Purge Time e The color change solvent valve closes when the Purge Time expires Color Fill e This sequence fills the line with the new color all the way to the Dump A valve e The new color valve and the Dump A valve open during the Fill Time e The new color valve and the Dump A valve close when the Fill Time expires Purge Dump This sequence flushes out the catalyst with solvent from the catalyst valve to the Dump B valve e The catalyst change solvent valve an
75. nce or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com 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 313882 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 2010 Graco Inc is registered to ISO 9001 WWW graco com Revised June 2012
76. ng up the system purge it as instructed in Purging Fluid Supply System page 59 The equipment was tested with lightweight oil which should be flushed out to avoid contaminat I ing your material 5 Make sure that the Booth Control is in Standby r mode T112656a 1114372 Fic 53 Power Switch 50 313882C System Operation 6 Adjust component A B and C fluid sup Watch the fluid flow rate displayed on the Status plies as needed for your application Use Q screen while the gun is fully open Verify that the lowest pressure possible flow rate of components A and are within 10 of each other 7 Do not exceed the maximum rated work ing pressure shown on the system identification If the fluid flow rate is too low increase air pres label or the lowest rated component in the system sure to component A B and C fluid supplies or increase the regulated fluid pressure 8 Open the fluid supply valves to the system If the fluid flow rate is too high reduce the air pressure close the fluid manifold dose valves fur ther or adjust the fluid pressure regulator 9 Adjust the air pressure Most appli cations 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 NOTE Pressure adjustments of each component will vary with fluid viscosity Start with the same fluid pres sure for component A B and C then adjus
77. ntil the gun is triggered and fluid flow is detected If no flow is detected within 2 minutes the color change operation aborts The Booth Control enters Standby mode at the previous color When you are ready to spray remove the gun from the gun flush box if used and close its door NOTE The gun flush box door must be closed for the atomizing air valve to open Press the Mix key to start spraying Single Color Systems 1 2 3 64 Follow procedure for Purging Fluid Supply Sys tem page 59 Load the new color See Start Up page 50 Press the Mix gt key to start spraying Color Change Sequences 62 through 71 illustrate various color change sequences See Table 8 to determine which figure to ref erence based on the recipe change and system config uration The time sequences are detailed in the following paragraphs NOTE See Setup Mode on page 25 to select purge sources and set desired purge chop and fill times NOTES e The system uses old recipe data for the purge cycle However it opens the new color catalyst valve based on the new recipe data e The system uses the new recipe data for the fill cycle e For the one gun flush box GFB option the spray gun must be inserted in the GFB during the entire color change cycle purge and fill The GFB trigger output will be on during the recipe change cycle e the two gun flush box option both spray guns
78. o close turn clockwise See Table 6 and FIG 51 pue L TI11581a FiG 51 Valve Adjustment Table 6 Mix Manifold Valve Settings Hex nut E 1 1 4 Limits maximum fluid flow rate into integrator and turns out from fully minimizes valve response time closed Hex nut E 1 1 4 Limits maximum fluid flow rate into integrator and turns out from fully minimizes valve response time closed Shutoff Fully open during Closes component A B and C ports to integrator SVA and Run Mix operation during ratio check or meter calibration Open ports SVB 60 during Run Mix operation Sampling Fully closed during Open to dispense component A B and C while cali RVA RVB Run Mix operation brating meters Do not open sampling valves unless and RVC fluid shutoff valves are closed FIG 60 48 313882C 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 controller when the gun is triggered The AFS functions with the flow meters to ensure that system components are functioning correctly For example if a flow meter fails or clogs pure resin or catalyst could spray indefinitely if the ProMix does not detect the condition and intervene which is why the AFS is so important If the ProMix detects through the AFS signal that the gun is triggered yet there is no fluid flow through the meter a Dose Time Alarm E 7 or E 8 occu
79. olor Cata lyst Fill are added to Recipe Setup Screen 2 page 39 Recipe Setup Screen 3 4 and 7 are added See pages 40 41 K Factor Input If set to Global Advanced Setup Screen 4 36 is added set to Recipe Recipe Setup Screen 5 page 41 is added Minimum Material Fill Volume Enter 0 9999 cc 32 Stage Fill Volume This field refers to the amount of material that is required to fill the mixed material line from the A B fluid panel to the C fluid panel before adding component C This value must be the same as the selected dose size Default is 50 cc Verification Screen Warning switching ta source Llobal source recipe for Flush and Fill Input This will overwrite recipe data Are you sure Fic 29 Verification Screen Verification This screen appears if Flush and Fill Input or K Factor Input are changed from Recipe to Global in Option Screen 1 313882C Option Screen 2 Auto Dump Flow Rate Monitor 30 Option Screen 2 Auto Dump If the auto dump feature is being used set to On Once the auto dump is enabled the gun flush box is enabled and the potlife alarm is active for 2 minutes the system will automatically flush out the old material Flow Rate Monitor If set to On Recipe Setup Screen 6 on page 41 is added enabling setting of high and low flow limits If set to Off flow rate monitoring is disabled an
80. on and Establishing Communication will display followed by Status screen See page 20 Checklist gt At power up the system defaults to Recipe 61 which is not a valid recipe number Initiate a System grounded color change to Recipe 0 or a valid recipe num ber 1 60 In bottom left corner the system status displays which can be Standby Mix Purge or an alarm All connections tight and correct notification Table 7 Pre Operation Checklist Verify all grounding connections were made See the ProMix 3KS Installation manual Verify all electrical fluid air and system connec tions are tight and installed according to the Installation manual 11 9 7009 Fluid supply containers filled Check component A B and C and solvent supply containers Mix manifold valves set Check that mix manifold valves are set correctly Start with the settings recommended in Mix Mani fold Valve Settings page 48 then adjust as Fluid supply valves open and pressure set Fic 54 Status Screen Component A B and C fluid supply pressures should be equal unless one component is more viscous and requires a higher pressure setting 3 Make sure that the Booth Control is working The active recipe number should display and the Solenoid pressure set 75 100 psi inlet air supply 0 5 0 7 MPa 5 2 7 bar Standby LED Ore should be lit 2 Turn the AC Power Switch on the EasyKey and on 4 this is the first time starti
81. on file originally made on a 2KS machine Config Error Occurs if a configuration file sent to the EasyKey specifies a different hardware setup than what exists For example the configuration file specifies 2 color change boards but only 1 is present Range Error Occurs if a valve used in a recipe is not present in the current hardware setup For example a recipe calls for valve 30 but the system has only 12 valves Level Control LC Error Occurs if level control data is received by the EasyKey and the current Autokey setting 2K or 3K has changed since the level control data was originally initialized Level Control LC Range Error Occurs if level control data includes a valve range exceeding the capability of the machine Flush the system or perform a color change If possible identify the origin of the reboot or power cycle Reinstall the Autokey or verify that the Autokey is set properly Verify that the source data is from a valid recipe 1 60 Verify that the Autokey is set properly or that the configu ration file is valid Verify that the configuration file is valid Verify that the configuration file specifications and the hardware conform Verify that the recipe specifications and the hardware conform Verify that the Autokey is set properly Set level control data correctly Modbus MB Overflow Occurs if the Modbus connec Verify the Modbus protocol to the EasyKey tion to a PLC experienc
82. oting Table 10 Alarm Troubleshooting E 19 ALARM The Mix and Purge digital inputs are on at the same time Ensure that only one input is on at a time At least 1 sec delay is required when switching from Mix to Purge or vice versa NOTE The I O alarm incorporates several sub alarms relating to internal data issues as detailed below These alarms may not apply to all software versions Fluid Plate Reboot FP Reboot Occurs if the system detects a fluid plate control board reboot or power cycle not triggered from the EasyKey The system reverts to Recipe 61 and mixed material may be in the lines Autokey Lost Occurs if the Autokey is lost or changed after having been detected A short term loss of the Autokey will not be registered Some system functions may become unavailable For example an automatic system will not respond to PLC or robot control Illegal Source Occurs if a recipe outside of the range 1 60 is detected as the source data for global recipe data copies This is possible if an invalid configuration file is sent to the EasyKey 2K 3K Error Occurs if the recipe data is incompatible with the current Autokey setting 2K or 3K This is possi ble if the Autokey is changed or an invalid configuration file is sent to the EasyKey Init Error Occurs if the recipe data codes specifying the type of machine they were made on are not what is expected For example a 3KS machine receives con figurati
83. page 32 lf Number of Guns is set to 2 in Configure Screen 4 page 30 a Gun 2 column will appear in this screen First Purge Time Stage 1 Enter the first purge time 0 to 999 seconds for compo nents A and B C First Purge Time Stage 2 Enter the component C first purge time 0 to 999 sec onds Total Chop Time Stage 1 Enter the total chop time 0 to 999 seconds for compo nents A and B Final Purge Time Stage 1 Enter the final purge time 0 to 999 seconds for compo nents A and B C Final Purge Time Stage 2 Enter the component C final purge time 0 to 999 sec onds Mixed Fill Time Enter the mixed fill time 0 to 999 seconds It refers to the amount of material that is required to fill from the dose valves to the applicator gun 36 Advanced Setup Screen 4 E Factar A Meter CC pulse B Meter 0 119 cc pulse Meter 0 119 cc pulse solvent Meter 0 1149 cc pulse Advanced Calibration Fic 35 Advanced Setup Screen 4 This screen appears only if K Factor Input is set to Global in Option Screen 1 page 32 K factor A Meter Enter the k factor cc pulse for flow meter A This is the amount of material that passes through the flow meter per pulse electrical pulse signal K factor B Meter Enter the k factor cc pulse for flow meter B K factor C Meter Enter the k factor cc pulse for flow meter C K factor Solvent Meter This field only appears if Solvent Monitor in Config
84. r to do one of the following tank volume to clear the alarm e Resume mixing by selecting Spray 25 of remain ing volume If this selection is chosen a second alarm will occur after 25 of the remaining volume is mixed Refill tank volume to clear the alarm 25 AUTO DUMP COMPLETE ALARM A potlife alarm is active for more than 2 minutes the gun Be sure to spray all mixed material before potlife expires flush box is enabled and gun is in the gun flush box and an auto dump flush sequence is complete E 26 COLOR CATALYST PURGE ALARM System detects no meter pulses or a disruption in meter Check that meter cable is connected pulses lasting longer than 1 second throughout the Color Catalyst purge time duration Clean or repair meter E 27 COLOR CATALYST_FILL_ALARM System detects no meter pulses or system must detect Check that meter cable is connected at least 10cc of material from each side throughout the Color Catalyst fill time duration Clean or repair meter Gun dump valve or correct color catalyst valve not Open the valve open Exhausted fluid supply Check fluid level and refill if necessary Fuse F1 F2 or both are blown Verify condition of fuses and replace if necessary See Repair Parts manual E 29 TANK_C_LOW_ALARM see above E 30 OVERDOSE_C_ALARM see page 81 E 31 DOSE_TIME_C_ALARM see page 82 88 313882C Alarm Troubleshooting 313882C 89 Schema
85. ravel to slow down the initial fluid rate was probably too high delivery rate until fluid hoses are loaded with material If the alarm occurred after you were spraying for some Adjust component A B and C fluid supply regulator time the pressures from the fluid supplies could be pressures until they are about equal f the pressures are unbalanced already about equal verify that component A B and C dose valves are operating properly Slow actuation of the component A B or C valves This Manually operate the Dispense A and C solenoid can be caused by valves as instructed in the ProMix 3KS Repair Parts manual to check operation Air pressure to the valve actuators is too low e Increase air pressure Air pressure must be 75 120 psi 0 52 0 84 MPa 5 2 8 4 bar 120 psi is recom mended e Something is restricting the solenoid or tubing There may be dirt or moisture in the air supply Filter interrupting valve actuation air appropriately A dose valve is turned in too far e Refer to Table 6 Mix Manifold Valve Settings page 50 for adjustment guidelines e Fluid pressure is high and air pressure is low e Adjust air and fluid pressure See recommended air pressure above 80 313882C Alarm Troubleshooting Table 10 Alarm Troubleshooting E 5 OVERDOSE_A B_DOSE_TOO_SHORT_ALARM E 6 OVERDOSE B A DOSE TOO SHORT ALARM and E 30 OVERDOSE C ALARM E 5 the A dose overshoots and when combined with B
86. reen e The other keys have no function in this Status screen 11 3 2009 16 39 Fic 10 Status Screen Key to Fic 10 D Active Recipe shows the active recipe NOTE At power up the system defaults to Recipe 61 which is not a valid recipe number 2 Stage 1 Target Ratio A B for the active recipe The ratio can be from 0 0 1 50 0 1 in 0 1 incre ments 3 Stage 1 Actual Ratio A B in hundredths calcu lated after each dose of A and B 4 Stage 2 Target Ratio A B C for the active recipe The ratio can be from 0 0 1 50 0 1 in 0 1 incre ments 5 Stage 2 Actual Ratio A B C in hundredths cal culated after each dose of C 22 6 Potlife Timer shows remaining potlife time in min utes Two times are shown if there are two guns 7 Status Bar shows current alarm or operation mode standby mix purge recipe change or the current alarm Current Flow Rate in cc min 9 Animation when the gun is triggered the gun appears to spray and the component A B or C hose lights up showing which component dose valve is open Current Date and Time 41 Screen Number and Screen Arrows displays the current screen number and the total number of screens in a group The Up and Down arrows on the right edge of the screen indicate the scroll feature The total number of screens in some groups may vary depending on system configuration selections 313882C Totals Screen Job Total
87. ressure gun engage the trigger lock Remove spray tip and clean tip separately 58 If using an electrostatic gun shut off the electrostatics before flushing the gun 2 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 the Purge Sg key on the Booth Control The purge sequence automatically Starts If the gun flush box is not used trig ger the gun into a grounded metal EK pail until the purge sequence is com lt WY plete N When done purging the Booth Control automati cally switches to Standby mode NOTE After doing a purge press the Mix gt key once The system will do a mixed material fill sequence then go to Standby Press again to start Mix mode 4 the system is not completely clean repeat step NOTE If necessary adjust purge sequence so only one cycle is required Trigger the gun to relieve pressure Engage trigger lock 5 If spray tip was removed reinstall it 6 Adjust the solvent supply regulator back to its nor mal operating pressure 313882C Purging Using Recipe 0 0 is typically used in multiple color systems to purge out material lines without
88. rs after 40 seconds and the system shuts down N AFS lt d 92 113350 Fic 52 Air Flow Switches 313882C System Operation Operating Without Air Flow Switch It is not recommended to run without an air flow switch If a switch fails replace it as soon as possible Airless Gun It is not recommended to use an airless gun with the ProMix 3KS Two issues can arise from operating with out an air flow switch e Without a gun trigger air flow switch input the Pro 3KS does not know it is spraying and will not generate a Dose Time Alarm E 7 or E 8 This means there is no way to detect a failed meter You could spray pure resin or catalyst for 2 minutes with out knowing e Since the ProMix 3KS does not know it is spraying because there is no gun trigger air flow switch input it will go into System Idle E 15 every 2 minutes when in Mix mode System Idle Warning E 15 This warning occurs if the ProMix is set to Mix gt and 2 minutes have elapsed since the system received a flow meter pulse 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 Standby r then Mix gt then trigger the gun 49 System Operation Start Up 1 through the Pre Operation Checklist in Table 7 gt Graco logo software revisi
89. s name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty 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
90. s the once The system will do a mixed alarm code E1 to E31 and red material fill sequence then go to Alarm indicator blinks Standby Press again to start Mix Recipe number displays after mode alarm is reset Standby Mode Starts Standby mode Recipe Green LED stays lit while a recipe Green LED remains lit while in Indicator is in use Key Standby mode LED shuts off when Up or Ore Down keys are pressed or if Purge Mode Starts Purge mode alarm occurs Green LED remains lit while in Key LED blinks while a new recipe is Purge mode loading and turns solid after load ing is complete LED blinks when purging Select a new recipe by pressing Up or Down keys then Alarm Indicator red pressing Enter Alarm Reset Red LED blinks when an alarm Key and occurs Indicator Press key to reset alarm LED Ogo shuts off after alarm is reset Job Complete Signals that job is complete and Key and resets A B and C totalizers Indicator Green LED blinks once after key is pressed Enters selected recipe and starts color change sequence Display Recipe Indicator green TI11614A Scrolls recipe numbers up Fic 4 Booth Control see Table 2 16 313882C EasyKey Display and Keyboard EasyKey Display and Keyboard LCD Display a Navigation Keys Fic 5 EasyKey Display and Keypad Display Shows graphical and text information related to setup and spray opera
91. sary to restrict the flow rate through the component B or C dose valve by adjusting its hex nut E See page 48 313882C 81 Alarm Troubleshooting Table 10 Alarm Troubleshooting E 7 DOSE TIME A ALARM E 8 DOSE TIME B ALARM and E 31 DOSE TIME C ALARM E 7 gun trigger input is active AFS or Integration and no A meter pulses are detected during the dose time selected E 8 gun trigger input is active AFS or Integration and no B meter pulses are detected during the dose time selected E 31 gun trigger input is active AFS or Integration and no C meter pulses are detected during the dose time selected Fully trigger the gun System is in Mix gt mode and gun is only partially triggered allowing air but no fluid to pass through gun Fluid flow rate is too low Increase flow rate Dose time setting is too short for the current flow rate Increase the dose time setting Flow meter or cable failed or flow meter clogged To check meter sensor operation remove meter cap to expose sensor Pass a ferrous metal tool in front of the sensor TI12792a If there is a meter or cable failure you will see a large dif ference between the amount of fluid dispensed and the flow meter volume displayed by the EasyKey Clean or repair meter as necessary Also see meter manual 308778 Follow Meter Calibration procedure page 62 Slow actuation of component A B or C valves See E 3 RATIO HIGH ALARM and E 4 RATI
92. shows the current volume for each fluid Adjust the actual volumes on this screen or use the tab to go to Usage Totals Screen page 23 See 16 If the tank volume reaches the low level threshold the EasyKey screen will display the Tank Level Low alarm and prompt the user to do one of the following 1 Refill tank volume to clear the alarm 2 Resume mixing by selecting Spray 25 of Remain der If this selection is chosen a second alarm will occur after 25 of the remaining volume is mixed Hefill tank volume to clear the alarm Warning Tank Level Lou Alarm Color 1 10 Liters Alarm Level Liters Current Volume 1 Tank Volume 2 eprau 4o4 of Remainder Selection J FiG 16 Tank Level Low Screen Tank A Shown 24 313882C Setup Mode Setup Mode NOTE See FiG 17 for map of the Setup screens Press the Setup key to enter Setup mode Detailed screen descriptions follow Press the Setup key to enter Setup mode Enter Password This screen appears only if a password is activated To access Advanced Setup Screens page Vance 3l System Configuration 34 and Recipe Setup Screens page 38 2 00012 BC 1 44 C1 2 01 ee To access System Configuration Screens YB 6 0 2 MC 1042 0198 IP 192 168 1785 002048801810 page 28 Press the Setup a key to exit Setup mode and return to the Status screen setup Locked This scr
93. ss the Enter key to select Calibrate the meter either Dose Valve A B C or Solvent Press the e The first time the system is operated Down Arrow key and select Start from the menu Start only one at a time e Whenever new materials are used in the system especially if the materials have viscosities that differ significantly d Meter e At least once per month as part of regular mainte Meter Meter nance Calibration Whenever a flow meter is serviced or replaced Measured Actual Volume Volume NOTE CC K Factors on the Calibration Screen are updated automatically after the calibration pro 0 119 cc pulse d leted cedure Is Comp Advanced Recipe Eee Home e K Factor values on the screen are viewable only If needed you can manually edit the K Factors in Advanced Setup Screen 4 page 36 or Recipe Setup Screen 5 page 41 7 Dispense component A B C or Solvent into bea ker e All values on this screen are in cc independent of the units set in Configure Screen 1 e The controller will use the active recipe K factors for meter calibration The active recipe To avoid splashing slowly open sampling must be recipe 1 to recipe 60 Recipes 0 and 61 valves do not have K factor values b Formore accurate calibration adjust the valve 1 Before calibrating meter A B or C prime the sys to dispense at a flow rate similar to your produc tem
94. t as needed 10 If using a gun flush box place the gun into the box NOTICE and close the lid Press the Purge key on the Do not use the first 4 5 oz 120 150 cc of material as Booth Control The purge sequence automatically it may not be thoroughly mixed due to alarms while starts priming the system If the gun flush box is not used trig 12 Turn on atomizing air to the gun Check the spra ger the gun into a grounded metal g 9 pattern as instructed in your spray gun manual pail until the purge sequence is com C plete 4 NOTICE When done purging the Booth Control automati Do not allow a fluid supply tank to run empty It is pos cally switches to Standby mode sible for air flow in the supply line to turn gear meters in the same manner as fluid This can lead to the pro 11 Adjust the flow rate portioning of fluid and air that meets the ratio and tol erance settings of the equipment This can further The fluid flow rate shown on the EasyKey Status result in spraying uncatalyzed or poorly catalyzed screen is for either component A B and C depend material ing on which dose valve is open The fluid supply lines on the screen highlight to show which dose valve is open 11 9 2009 Fic 55 Status Screen Flow Rate Display 313882C 51 System Operation Shutdown Overnight Shutdown 1 Leave the power on 2 Run Recipe 1 purge solvent through meters and gun Service Shutdo
95. t pressure is reduced to O NOTE If a Purge Volume alarm E 11 occurs clear the alarm 313882C Systems with Color Change and without Dump Valves NOTE This procedure relieves pressure through the sampling valve 1 Complete all steps under Single Color Systems page 52 Close the A side shutoff valve SVA Fic 60 Open the A side sampling valve RVA Direct the A side sampling tube into a waste con tainer See FIG 59 Open the color change module Using the solenoid identification labels as a guide press and hold the override button on each color solenoid until flow from the sampling valve stops Press and hold the solvent solenoid override until clean solvent comes from the sampling valve then release Shutoff the solvent supply to the color change stack solvent valve Press and hold the solvent solenoid override until solvent flow from the sampling valve stops Open the A side shutoff valve SVA 60 Close the A side sampling valve RVA Systems with Color Catalyst Component C Change and Dump Valves NOTE This procedure relieves pressure through the dump valves Complete all steps under Single Color Systems page 52 2 Shut off all color catalyst component C supplies to the valve stacks 3 Press and hold the dump valve A solenoid override FIG 57 4 See FIG 59 Open the color change module Using the solenoid identification labels as a guide press and hold the overrid
96. tic Diagrams Schematic Diagrams System Pneumatic Schematic 1 4 TUBE TO MANIFOLD 3 8 AIR FILTER MANUAL DRAIN 5 MICRON WALL MOUNT ONLY lt l O Z O AIR INPUT c lt AIR INPUT MANIFOLD 90 AIR EXHAUST MUFFLER 12 VDC a 4 WAY SOLENOID na 12 VDC B 4 WAY SOLENOID mx P PURGEA VALVE 12 VDC E 4 WAY SOLENOID lt ES 12 VDC 4 WAY SOLENOID mx PURGE x PURGE C VALVE FLO OPTIONAL e AIR EXHAUST MUFFLER 12 VDC 3 WAY SOLENOID SEP DUMP A sS OPTIONAL i LT Wd 12 VDC 3 WAY SOLENOID Pd DUMP B PA eal AE e T 12 VDC E 8 WAY SOLENOID lt lt GFB 1 d OPTIONAL Hg 9 12 VDC SOLENOID S ye 4 2 d OPTIONAL 2 lt 9 FLUSH AIR TO FLUID INLET 1 4 TUBE COLOR CHANGE CONTROL E St Z gt 36 SERIES SOLENOID VALVES STACKS COLOR 1 COLOR 2 COLOR 3 COLOR 4 COLOR 5 COLOR 6 COLOR 7 COLOR 8 COLOR SOLVENT COLOR 9 COLOR 10 COLOR 11 COLOR 12 CATALYST 1 CATALYST 2 CATALYST 3 CATALYST 4 CATALYST SOLVENT 313882C System Pneumatic Schematic 313882C MANIFOLD 1 4 TUBE TO MANIFOLD AIR EXHAUST MUFFLER 12 VDC 3 WAY SOLENOID DO
97. tions Back light will turn off after 10 minutes without any key press Press any key to turn back on Keypad Used to input numerical data enter setup screens scroll through screens and select setup values In addition to the numbered keys on the EasyKey key pad which are used to enter values in setup there are keys to navigate within a screen and between screens and to save entered values See Table 3 313882C Keypad 9 Q T111630A Alarm Reset Key Table 3 EasyKey Keypad Functions see FiG 5 _______ ra Setup press to enter or exit Setup mode Enter if cursor is in menu box press Enter key to view menu Press Enter to save a value either keyed in from the numerical keypad or selected from a menu Up Arrow move to previous field or menu item or to previous screen within a group Down Arrow move to next field or menu item or to next screen within a group Left Arrow move to previous screen group Right Arrow move to next screen group Alarm Reset resets alarms 17 EasyKey and 3KS Power Supply Module Connection Ports EasyKey and 3KS Power Supply Module Connection Ports EasyKey AC Power Fiber Optic Strain Audible Alarm Switch Relief Port Main Power Access Port Ground Screw I S Power Graco Web Discrete I O Cable to 2KS Interface Connector Ports Panel TI12638a TI12657a 3KS Power Supply Module AC Power Switch
98. tup Screen 2 First Purge Source Chop Air Solvent 2 sec e sec Final Purge Source Air Chop Time solvent Chop Time Advanced Calibration Fic 33 Advanced Setup Screen 2 This screen appears only if Flush and Fill Input is set to Global in Option Screen 1 page 32 First Purge Source Select Air Solvent or Ord Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 30 Chop Type Select Air Solvent or Air 3rd Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 30 This refers to the process of mix ing air and solvent or air and 3rd flush fluid together during the flush cycle to help clean the lines and reduce solvent usage Final Purge Source Select Air Solvent or 3rd Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 30 Air Chop Time Enter the air chop time 0 0 to 99 9 seconds Solvent Chop Time 3rd Flush Valve Chop Time Enter the solvent or 3rd flush valve chop time 0 0 to 99 9 seconds 35 Setup Mode Advanced Setup Screen 3 First Purge Time First Purge Time Total Chop Time SEC SEC SBL SEC SEC Final Purge Time Final Purge Time Mised Fill Time 10 Advanced Calibration Fic 34 Advanced Setup Screen This screen appears only if Flush and Fill Input is set to Global in Option Screen 1
99. ure Screen 5 page 31 is set to Meter Enter the k factor cc pulse for the solvent flow meter 313882C Advanced Setup Screen 5 Special Un Fill Length Advanced Calibration Fic 36 Advanced Setup Screen 5 1 z EU 0 Length 0 0 0 This screen appears only if Flush and Fill Input is set to Global in Option Screen 1 page 32 and Special Out puts is set to 1 2 3 or 4 in Configure Screen 5 page 31 The I O board has four programmable outputs 313882C Setup Mode 37 Setup Mode Recipe Setup Screens NOTE See FIG 37 for a map of the Recipe screens Detailed screen descriptions follow Recipe Ratio 18 1 Ratio Tolerance 5 5 Valves mpi ELI ISEE Calibration Set Up Home Recipe amp fidvanced Setup Gun iPotlife Voume t system Configuration Color Catalyst Purge seconds 1 a Color Catalyst Fill seconds E 200012 LES 1201 FP 2 00 0412 3k Ruto Ce 2 01 0 1042 0196 192 166 178 5 002048 01810 Advanced Calibration Meter A Meter Calibration Measured Actual volume Recipe 0 Screens Occ 0 K Factar 0 119 Recipe 01090 Recipe Recipe First Purge Source Minimum Flush Volume Chop Type Rir Solvent 1 Fotlife Time minutes Final Purge Source 4 Color DCatalust Purge seconds Air Chop T
100. vent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground all equipment in the work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding setup or usage of the system can cause electric shock Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment Connect only to grounded power source All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations INTRINSIC SAFETY Only models with G3000 G250 G3000HR G250HR or intrinsically safe Coriolis meter for A B and C meters are approved for installation in a Hazardous Location Class Div Group D or Zone Group IIA T3 To help prevent fire and explosion Do not install equipment approved only for a non hazardous location in a hazardous area See the ID label for the intrinsic safety rating of your model Do not substitute or modify system components as this may impair intrinsic safety SKIN INJECTION HAZARD High pressure fluid from gun hose leaks or
101. vent usage Final Purge Source Select Air Solvent or 3rd Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 30 42 Air Chop Time Enter the air chop time 0 0 to 99 9 seconds Solvent Chop Time 3rd Flush Valve Chop Time Enter the solvent or 3rd flush valve chop time 0 0 to 99 9 seconds Recipe 0 Screen 2 Recipe Ii Color Catalust Purge 5 First Purge Time 10 First Purge Time 10 Total Chop Time Final Purge Time C Final Purge Time 10 Recipe Fic 46 Recipe 0 Screen 2 lf Number of Guns is set to 2 in Configure Screen 4 page 30 a Gun 2 column will appear in this screen Color Catalyst Purge Time This field only appears if the system includes a color change module Enter the purge time 0 to 999 sec onds First Purge Time Stage 1 Enter the first purge time 0 to 999 seconds for compo nents A and B C First Purge Time Stage 2 Enter the component C first purge time 0 to 999 sec onds Total Chop Time Enter the total chop time 0 to 999 seconds for compo nents A and B Final Purge Time Stage 1 Enter the final purge time 0 to 999 seconds for compo nents A and B C Final Purge Time Stage 2 Enter the component C final purge time 0 to 999 sec onds 313882C Recipe 0 Screen 3 0 seconds Recipe Minimum Flush Valume Exiting Fill Source Exiting Fill Dime
102. when either the resin A catalyst B or reducer C component dispenses too much material and the system cannot compensate for the additional material Potlife Time the amount of time before a material becomes unsprayable Potlife Volume the amount of material that is required to move through the mix manifold hose and applicator before the potlife timer is reset Color Catalyst Dump refers to the time required to flush the lines from the color or catalyst change module to the mix manifold during a color or catalyst change Color Catalyst Fill refers to the time required to fill the lines from the color or catalyst change module to the mix manifold 313882C Glossary of Terms Purge when all mixed material is flushed from the sys tem Purge Time the amount of time required to flush all mixed material from the system Ratio Tolerance the settable percent of acceptable variance that the system will allow before a ratio alarm occurs Sequential Color Change the process when a color change is initiated and the system automatically flushes the old color and loads a new color Sequential Dosing Components A B and C dispense sequentially in the necessary volumes to attain the mix ratio Solvent Fill the time required to fill the mixed material line with solvent Standby refers to the status of the system Third Purge Valve refers to the use of three purge valves used to flush some waterborne m
103. with material For a color catalyst component C tion spray flow rate change system make sure the color catalyst com ponent C valve is open c Dispense a minimum of 250 cc make sure enough material is dispensed to accurately read the volume with your beaker The volumes do not have to be equal or at any particular ratio 2 Shut off all spray or dispense devices connected to the ProMix 3 Close all fluid shutoff valves and sampling valves d Close sampling valve tightly 62 313882C 8 10 The volume that the ProMix measured displays on the EasyKey Compare the amounts on the EasyKey to the amount in the beakers NOTE For maximum accuracy use a gravimetric mass method to determine the actual volumes dis pensed If the screen and actual volumes are different enter the actual dispensed volume in cc for A B C or Solvent Volume field and press the Enter key If the value was substantially different repeat the calibration process NOTE If the screen and actual volume is the same or if for any reason you want to cancel the calibra tion procedure scroll to Abort on the Calibration Screen menu and press the Enter ii key 313882C 11 12 Meter Calibration After the volume for A B C or Solvent is entered the ProMix 3KS controller calculates the new flow meter K Factor and shows it on the Calibration Screen NOTE K Factor values on the screen are viewable only If needed you can m
104. wn 1 Follow Pressure Relief Procedure on page 52 2 Close main air shutoff valve on air supply line and on ProMix 3 Shut OFF the Power Switch on the EasyKey and on the Power Supply Module 0 position FiG 56 4 If servicing the EasyKey or Power Supply Module also shut off power at main circuit breaker 0 OFF 114372 112657 Fic 56 Power Switch 52 Pressure Relief Procedure NOTE The following procedures relieve all fluid and air pressure in the ProMix 3KS system Use the procedure appropriate for your system configuration Relieve pressure when you stop spraying before changing spray tips and before cleaning checking or servicing equipment Single Color Systems 1 While in Mix mode gun triggered shut off the A B and C fluid supply pumps pressure pots Close all fluid shutoff valves at the pump outlets 2 With the gun triggered push the manual override on the A B and C dose valve solenoids to relieve pres sure See FIG 57 NOTE Dose Time alarm E 7 E 8 occurs clear the alarm 3 Doa complete system purge following the instruc tions under Purging Using Recipe 0 page 59 4 Shut off the fluid supply to the solvent purge valve SPV and the air supply to the air purge valve APV FiG 60 5 With the gun triggered push the manual override on the A B and C purge valve solenoids to relieve air and solvent pressure See 57 Verify that sol ven

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