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Graco 312780F User's Manual

1. C N m om 4 o o Solenoid 2 4 8 Solenoid Identification ia E Identification Ge n 8 e e esc 1959 68 o o oy 5 0 2 TT Ice 91 0 1 3 12826 Solvent Solenoid Overrides Fic 3 Color Change Solenoids Key DVA FI DVB MA Component A Meter MB DVA Component A Dose Valve RVA Component A MS sampling Valve MA SVA Component A Shutoff Valve MB Component B Meter RVB DVB Component B Ui Dose Valve 2 i RVB Component B 27 LAA Sampling Valve lt B SVB Component B d Ya lt lt TL Shutoff Valve 194 MS Solvent Meter AT accessory i SPV Solvent Purge Valve P APV Air Purge Valve 11125560 static Mixer Fl Fluid Integrator AT Air Purge Valve Air RVA SVA SM SVB Fic 4 Wall Mount Fluid Station 14 SPV Supply Tube 312780F Troubleshooting Troubleshooting Table 1 System Alarm Codes Communication Error Alarm Potlife Alarm 2 Ratio High Alarm Follow Pressure Relief Procedure page 12 before cleaning checking or servicing equipment NOTE Do not use the fluid in the line that was dis et O pensed off ratio as it may not cure properly E 5 Overdose A B Dose Too Short Alarm Overdose B A Dose Too Short Alarm Alarm Codes Dose Time A Alarm Dose Time Alarm Table 1 lists the system
2. CQ 21111 Connectors on Fluid Station Control Board Fic 24 Meter Cable Schematic 48 312780F Servicing Fluid Manifold We Removal 1 Follow Servicing Flow Meters Mounted on Wall Panel Removal steps 1 5 page 48 2 Disconnect air and fluid lines from the manifold 4 3 Holding onto the fluid manifold 4 loosen the three screws 341 holding the bracket 325 to the fluid station Lift the fluid manifold 4 and pull it away from the panel Service as instructed in the Fluid Mix Manifold manual 312781 Installation 1 Secure the fluid manifold 4 and mounting plate 325 with three screws 341 2 Install meters See Installation steps 1 3 page 48 3 Connect air and fluid lines 4 Calibrate meters as instructed in ProMix Operation manual 312780F Service 12654 Fic 25 Fluid Manifold Servicing Color Change Module Color Catalyst Valves and Dump Valves r I hh ye 1 Follow Before Servicing page 38 2 See manual 312787 for the color change module 3 See manual 312783 for the color catalyst valve stacks 4 See manual 312786 for the dump valve kits 5 See manual 312782 to service an individual valve 49 Service RoboMix Fluid Station Preparation 2 Remove the RoboMix cover 410 Fic 26 r 1 1 Follow Before Servicing page 3
3. To replace a single solenoid 1 Follow Preparation page 44 and shut off power at main circuit breaker 2 Disconnect 2 solenoid wires from control board 302 See FiG 21 and System Electrical Sche matic page 33 3 Unscrew 2 screws P and remove solenoid 313 FIG 22 4 Install new solenoid 313 5 Connect 2 wires to control board 302 Solenoid wires are polarized red black Refer to Sys tem Electrical Schematic page 33 6 Replace the cover 322 Replacing Control Board Fuse Replacing a fuse F1 or F2 with a non Graco fuse voids the IS system safety approval Description F1 F2 123690 Fuse 125 mA intrinsically safe 1 Follow Preparation page 44 2 Locate fuse F1 or F2 on the control board See FIG 22 Remove the screw and metal strap 3 Pull the fuse away from the board 4 Install the new fuse 343 5 Replace the cover 322 312780F Service Table 7 Wall Panel Solenoids Dose Valve A 3 3 DweVawB m APugVe m a Solvent Purge Valve 8 marshy e _ 7 6 Dumpvaver fe _ GmFuhBoi e 77 F _ 302 343 11126520 313 Fic 22 Replacing Solenoids and Fuse 47 Service Servicing FIOW Meters Mou nted 2 Secure meter M and plate MP to fluid station with screws MS on Wall Panel NOTE You must assemble the meter sensor to the meter body before connecting
4. 9 Replacing Air Filter Element 44 Important Two Component Material Wall Mount Fluid Station 44 11 Servicing Flow Meters Mounted on Isocyanate Conditions 11 Wall 48 Material Self ignition 11 Servicing Fluid Manifold 49 Keep Components A and B Separate 11 Servicing Color Change Module Color Catalyst Moisture Sensitivity of Isocyanates 11 Valves and Dump Valves 49 Changing Materials 11 RoboMix Fluid Station 50 Grounding 12 servicing Flow 57 Check Resistance 12 dol Cain Ta oda t sa p ee o 59 Pressure Relief Procedure 12 ProMix 2KS Automatic Wall Panel System 59 Troubleshooting 15 ProMix 2KS Automatic RoboMix Panel Alarm Codes 15 system 63 Solenoid Troubleshooting 16 EasyKey Controls 66 Wall Mount Fluid Manifold Troubleshooting 18 Available Cables 67 EasyKey Barrier Board Diagnostics 19 Wall Mount Fluid Station 68 EasyKey Display Board Diagnostics ae eae 20 RoboMix Fluid Station
5. 2 E AL ol Si LI Dj B5 AT 113858 13857 1113856 13859 312780F 36 Schematic Diagrams Table 6 Tubing Chart Color Description Starting Point Point mm Tube Ref No ao 5924 5 M Included in optional Green Dump B Dump Valve Kit 15V821 Wall Panel or 15V822 RoboMix Dose A Off 33 Dose B Off 337 Purge B Off 337 Natural Solenoid Air Supply 334 Natural Flow Control Air Supply User supplied Con nects air manifold to flow control regulator Natural Purge Air Supply Use as a separate line connected directly to the main shop air line Do not connect to the unit s main air supply or to the air manifold 335 Rea Red _ 312780F 37 Service Service Before Servicing 3 Shut off ProMix 2KS power 0 position Fic 14 4 If servicing EasyKey also shut off power at main cir cuit breaker To avoid electric shock turn off EasyKey power before servicing Servicing EasyKey display exposes you to high voltage Shut off power at main circuit breaker before opening enclosure All electrical wiring must be done by a qualified electrician and comply with all local codes and reg 0 OFF ulations Do not substitute or modify system components as this may impair intrinsic safety Read Warnings page 9 112657 A FIG 14 Power Off NOTICE To av
6. ONHWHT m _ NANIEOLD 1 t 1 eaaet ay 8 19 i CLR 10 CLR6 Cat xoc L s 211 lan 3 Sg ge GRD BLK 3 com 6 1 12VDC eae 35 ars ED s qe m w pare CLR3 I 2 COM Tu a 16 1 1206 Tun pe Se p A CLR 2 _ ZH H 22 6 BLACK SUL 2 ED RSS MEE 5 RED a ats FP 1 4 BLACK 1 4 5 2 3 Eee um Ng mE GFB 42 5 6 STD 6 BLACK 14523 4 ee BOARD 2 3 080 VOR COLORS 2 EN 13 THRU 30 1 L RED PURGE C e 6 B ACK 71 Males 5 RED PURGE xc pu 2 5 2 12VDC EN TA PURGE A aum pack Havoc 3 COM 21 C1R23 uj 12VDC 2 BLACK uo CLR 19 4 aoc 2 24 NOT USED Lf COM L 6 1 a 1 RED gt x 2VDC jc xoc 6 0 BLACK L4 com 32 T 5 RED w USED CLR 17 12VDC 3 Te 4 BLACK TE 2 1 T Hi pee a 2 BLACK 6 mur uH
7. C37 R65 ax W Js AE jal zi s i mn Jo ai IDE jad Solenoid Output 014 OUTPUTISSOLENOID 8 SOLENOID OUTPUT 2007 Dose Valves J14 Solenoid Output Air Purge Valve and Solvent Flush Valve 21 255765 Fluid Station Control Board 46 M43MOd Ns LLO 15 dOL M vO hs EC En ge J11 b i t 5 1 1 gem IE R78 R28 sj m mum 8 HHH p C1 PRGRM HDR S psd 7 m E E N m ENS EN R66 R61 R62 R59 883 R86 Noii Mtt OUTPUT J8 J6 F O Input black J10 Power Input EUH o giis LE mn ge lt 2 411 g Color Change Module SSY EPERE J7 E Not Used PN 45 R82 R84 i Bl e Flow Control m CL q J5 e 620684 92 a M cca 6202 No Solenoid Output Dump Valve B J15 Solenoid Output 3rd Flush Valve Dump Valve A 312780F Replacing Solenoids The Wall Mount Fluid Station has a minimum of 4 sole noids If you have options installed you have additional optional solenoids for each See Table 7 and Sche matic Diagrams page 30
8. 100 mesh minimum Fluid flow rate range G3000 G250 75 3800 cc min 0 02 1 00 gal min G3000HR G250HR Meter 38 1900 cc min 0 01 0 50 gal min Coriolis 20 3800 cc min 0 005 1 00 gal min 53000 Solvent Meter accessory 38 1900 cc min 0 01 0 50 gal min Fluid inlet sizes Flow 1 4 npt f Dose Valve Color Valve Adapters 1 4 npt f Fluid outlet size static 1 4 npt f External Power Supply Requirements 85 250 Vac 50 60 Hz 2 amps maximum draw 15 amp maximum circuit breaker required 8 to 14 AWG power supply wire gauge Operating temperature 41 122 F 5 50 C Environmental Conditions Rating indoor use pollution degree 2 installation category 11 Noise Level Sound pressure below 70 dBA Sound power below 85 dBA Wetted 303 304 SST Tungsten carbide with nickel binder perfluoroelastomer PTFE Dependent on programmed K factor and application The maximum allowable flow meter pulse frequency is 425 Hz pulses sec For more detailed information on viscosities flow rates or mixing ratios consult your Graco dis tributor See individual component manuals for additiona
9. 615 No Part No Description Qty 601 102980 NUT full hex 4 40 1 613 604 60227 n a O RING chemically resistant 1 fluoroelastomer 603 112698 ELBOW 1 8 npt m x 1 4 in 1 6 mm OD tube 604 n a O RING chemically resistant 1 fluoroelastomer 605 n a SCREW cap socket hd 12 10 32 x 1 2 in 13 mm 606 n a PLATE fluid regulator 1 607 15F799 PLATE air regulator 1 609 SEAT regulator 1 610 n a RETAINER seat 1 611 n a HOUSING flow control 1 612 n a SPACER regulator 1 613 NEEDLE regulator 1 614 BRACKET flow control 1 615 15F806 PLUG regulator 1 616 168881 GASKET acetal 1 617 178321 DIAPHRAGM regulator 1 618 249179 BOARD circuit assembly 1 619 120013 VALVE proportional V P 1 includes items 619a and 619b 619 SCREW socket hd 2 M3 x 0 5 x 44 mm 6190 106560 O RING mounting 007 2 6201 SENSOR pressure control 1 621 107295 SCREW machine pan hd 4 4 40 x 3 16 in 5 mm 622 104765 PLUG pipe 1 8 1 623 192387 PIN dowel 2 624 15G613 WIRE HARNESS flow control 1 Parts included in Regulator Service Kit 154843 Purchase separately Parts included in Sensor Service Kit 15G867 Purchase separately Parts labeled n a are not available separately T112506a Torque to 8 10 in lbs 0 9 1 1 Nem A Torque to 30 40 in Ibs 3 4 4 5 Nem Torque to 5 7 in lbs 0 6 0 8 Nem 76 312780F Parts Color Change Accessory Kits Low Pressur
10. NO Fa Ds za a FB15 U20 U25 E 5 Lure e I N 7 I N N76 N72 H7 E Ni N N e 111111 RNS U21 Sp m Miso se NODE o 125A 34 43 044 Pin 1 039 032 038 16 1 037 045 046 910 Pin 1 D9 D10 F1 Fuse 13 256172 Color Change Board 28 312780F Troubleshooting Table 5 Color Change Board Diagnostics LED and Pin Nos Description Communication yellow 2 Replaceable n a Fuse Der NN Ds A gt oO 312780F Board 2 Signal Description Board OK Communication yellow Power Color 16 Color 14 Color 19 Color 15 Color 20 Color 26 Color 21 Color 22 Color 17 Color 13 Color 28 Color 27 Color 25 Color 18 Color 23 Color 24 Color 29 Color 30 n a Blinks heartbeat during normal operation Turns on when board is communicating with Pro Mix 2KS Turns on when power is supplied to the board D27 through D46 turn on when ProMix 2KS sends a signal to actuate the related solenoid valve Check fuse condition if there is no power to the board or if communication is interrupted between the fluid station and the color change module 29 Schematic Diagrams Schematic Diagrams System Pneumatic Schematic
11. a AMOER qu a as s att 8881 52 4 9 w 55 mm aris EL asihe ee we 50 cggou o 221 5 D LL cs 8 ge p G 2 at TI NM CL lt P 5 8 11 F 52 00 N O O o e 5 3 n 5 8 5 e 8 PS 8 Sim a e t e Ji 8 803 C7 Lael Lad U7 MMMM X U1 F e 1 J4 im seen 12924 BK885 CR1220 Battery mie i U O U 3V 12 5 mm lithium coin EB m 11111111 XE 011 7 6555 5 555555555 5 gt 2 R5 TP2 R5 FiG 8 255767 EasyKey Display Board 20 312780F Troubleshooting Table 3 EasyKey Display Board Diagnostics Indicator Description U Graphic Display Backight 000 8 RibbonCabeioMembane 18 inputs and Outputs 96 00 Fiber Optic Cable Input black JB Fiber Optic Cable Output blue J1 J4 J5 J6 J7 J8 312780F Connector Indicator Description 24 Vdc Power Input Alarm Output RS485 Communication Terminals D7 green LED turns on when power is supplied to board D11 yellow LED blinks heartbeat when board is operating 1 Ethernet Por H5 Display Cont
12. 2 DOSE A 1 RED pc L1 COM ae 2 27 27 4 AIR FLOW SWITCH 1 com 4 HADE 3 SG 6 m 201 CLR30 4 0 __ AIR FLOW SWITCH 2 i 2141 1100 SOLVENT FLOW SWITCH 26 2 GFB 1 PRESSURE SWITCH 9 SIG 10 COM 7 GFB 2 PRESSURE SWITCH 33 Schematic Diagrams RoboMix Panel Board Schematic 12 0 1 5 lt a lt COM RW SHIELD gt TO FLOW U REGULATOR a GRD Bu I2VDC RED TOCOLOR SHIELD BARE T CANH WHT NOT USED NOT USED 3 NOT USED MANIFOLD 4 NOT USED NOTUSED RED 2 SOLVENT FLOW SWITCH BLACK 7 NOT USED DOSEB RED 8 NOT USED BLACK 9 NOT USED 1 NOT USED PURGE B L BLACK PWR RED E RED COM BLACK FLOW METER A BLACK SIG WHITE HIELD GRN NOT USED BLACK RED OM BLACK FLOW METERB SIG WHITE ro DUMPA BLACK PWR RED RED COM BLACK FLOW METER NOTUSED BLACK SOLVENT MEM Img BLACK i RED OT USED OT USED DUMPB E GROUND TERMINAL NOT USED UNUSED BLACK UNUSED NOT USED 2 RED UNUSED UNUSED 34 312780F 312780F Schematic Diagrams 35 Schematic Diagrams Tubing Schematic 13 gt F B1 14
13. 70 Discrete I O Board Diagnostics 22 256654 RoboMix Manifold 74 Fluid Station Control Board Diagnostics 25 249849 Flow Control Regulator 76 Color Change Board Diagnostics 28 Color Change Accessory Kits 77 Schematic Diagrams 30 TECHNICAL es ohare ew kusqa wees 79 System Pneumatic Schematic 30 Graco Standard Warranty 80 EasyKey Electrical Schematic 31 Graco Information 80 2 312780F Related Manuals Component Manuals in English Description 312778 ProMix 2KS Automatic System Installation 312779 ProMix 2KS Automatic System Operation 312784 310745 312786 Dump Valve and Third Purge Valve Kits 312785 Network Communication Kits 308778 G3000 G3000HR G250 G250HR Flow Meter 313386 Basic Web Interface Advanced Web Interface 406800 15V825 Discrete I O Board Kit 312780F Related Manuals Equipment Approvals Equipment approvals appear on the following labels which are attached to the Fluid Station and EasyKey See FIG 1 on page 4 and FIG 2 on page 6 for label loca tions EasyKey and Fluid Station Label ATEX Certificate is listed here ProMix 2KS Electronic Byoportioner lt APPROVED Intrinsically Safe IS System Install per IS Control Drawing No 289833 EasyKey Interface IS Associated Apparatus for use in non
14. AIR INPUT 30 PURGE AIR 3 8 AIR FILTER MANUAL DRAIN 5 MICRON WALL MOUNT ONLY AIR INPUT MANIFOL gt TO MANIFOLD 1 4 TUBE CONTROL AIR AIR EXHAUST MUFFLER MANIFOLD 12 VDC _ 4 WAY SOLENOID x 4 WAY p 4 WAY mio x x x 4 WAY SOLENOID AIR EXHAUST MUFFLER 12VDC 3 WAY SOLENOID x 12VDC B 3 WAY SOLENOID 5 lt Ko M LAM ue 3 WAY SOLENOID 7 so vee DOSE A VALVE PURGE A VALVE PURGE C VALVE OPTIONAL lt H h DUMP A LET OPTIONAL J Jan PUMP B LET OPTIONAL W GFB 1 VALVE a OPTIONAL 2 VALVE LIT OPTIONAL LLI ca D st Q E st FLUSH AIRTO FLUID INLET COLOR CHANGE CONTROL Annn nnm LIII COLOR VALVE 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 COLOR 13 COLOR 14 COLOR 15 COLOR 16 COLOR 17 COLOR 18 COLOR 19 COLOR 20 COLOR 21 COLOR 22 COLOR 23 COLOR 24 COLOR 25 COLOR 26 COLOR 27 COLOR 28 COLOR 29 COLOR 30 36 SERIES SOLENOID VALVES 312780F Schematic Diagrams EasyKey Electrical Schematic 8 svfd R
15. Description HOSE component A dump 1 4 npt mbe ptfe 15 5 in 394 mm Panel with no dump valve Panel with one dump valve Panel with two dump valves HOSE component B dump 1 4 npt mbe ptfe 10 5 in 267 mm Panel with no dump valve Panel with one dump valve Panel with two dump valves WASHER plain no 10 SCREW thumb 8 32 VALVE dispense includes item 422 see 312782 Panel with air and solvent purge valves no dump valve Panel with air and solvent purge valves one dump valve Panel with air and solvent purge valves two dump valves O RING ptfe Panel with no dump valve Panel with one dump valve Panel with two dump valves NIPPLE 1 4 npt Panel with no dump valve Panel with one dump valve Panel with two dump valves PLUG pipe 1 4 npt sst SUPPORT board RoboMix BOARD circuit COVER board RoboMix Qty O O gt 312780F Ref No 428 429 431 432 433 434 435 436 437 438 439 440 441 442 443 458 463 464 465 466 474 477 Part No 107295 15U725 109193 108382 120053 111328 113933 111987 120030 150726 150727 117018 116899 117028 114446 501867 119257 801012 150730 150928 949122 256654 312780F Description SCREW machine pan hd 4 40 x 3 16 in 5 mm MANIFOLD solenoid Robo Mix ELBOW tube 10 32 x 5 32 in 4 mm OD tube FITTING seal o ring 10
16. 2019 TWNIWYAL 83111 u3MOd 91 NMOU8 DMY 91 039 DMY 91 E ON 91 034 DMY 91 Wavv 31 Stf gt d quvogAvldslq Syry lt H 08808 3448 NOWWOD iE dasnNnn q3snNn q3snNn aasnwn aasnNnn 81 034 GND DMY 81 2 18 JDVLIOA LAdLNO 81 039 024 GAvC 81 2 18 6 81 034 DMY 81 4219 Qe 3 DMY CC 3LIHWPIDV 18 038 2 DMY AAMA 18 N3385 QD Quvoa 1 51 312780F Schematic Diagrams System Electrical Schematic NOTE The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS system Some compo nents shown are not included with all systems Non Hazardous Area 32 DISPLAY NO Ow Un NO OPERATOR INTERFACE L1 LINE UNUSED OPEN UNUSED EN E HARNESS 1 2 3 4 5 1 2 3 BARRIER BOARD 424VDC OPEN 1 2 3L COMMON DISPLAY BOARD POWER DIST TERMINAL BLOCKS OO REMOTE 0 INTEGRATION BOARD FLOW CONTROL CAL BLK GUN TRIGGER WHT DIGITAL IN COMMON RED
17. 150 ft 45 7 m for A purge air supply RoboMix logic air supply and flow control air JJ Bi N regulator supply 4 S TN o Parts EasyKey Controls 277869 EasyKey with Display Detail of Display Interface Kit 210 210c not part of kit 12554 1124170 201 214d 214f 212 203 218 2141 ae I 214m KNS 214e 244j 207 205 206 209 204 215 221 211 71124966 213 223 206 66 312780 277869 EasyKey with Display Ref No 201 202 203 203a 204 205 206 207 208 209 210 210a 210b 210c 210d 210e 211 212A 213 214 214a 214b 214c 214d 214e 214f 214g 214h 214j 214k Part No n a 116320 n a 117818 111987 110911 111307 n a C19293 194337 15X779 n a n a 255767 n a n a 15D568 15W776 223547 n a 255 86 n a 117526 119257 114095 121314 n a n a n a n a 312780F Description CONTROL BOX with display SWITCH power LATCH includes item 3a e KEY CONNECTOR cord strain relief NUT hex M5 x 0 8 WASHER lock external tooth M5 HOLDER tie NUT hex WIRE grounding door KIT display interface includes items 210a 210b 210d and 210e does not include 210c MEMBRANE GRAPHIC display BOARD EasyKey display not part of kit e
18. 49 412 J13 914 415 from con trol board 302 Fic 21 Hemove 4 screws 303 Remove connector jam nuts on the outside of the enclosure 301 Remove control board 302 FIG 20 Install new control board 302 with 4 screws 303 Connect cables to control board 302 FIG 21 Insert fiber optic cable connectors J4 J6 into board connectors E matching blue with blue black with black and hand tighten connectors Do not pinch or kink the fiber optic cables the cables require a 2 in 51 mm bend radius Replace the cover 322 Turn EasyKey power on to test operation F1 343 F O Output blue e CIN 22 L E m OCH e m 4 4 Te Digital Input m c o 5 2 79 egulvH LEY 6 CY ZEY LH le e g mu aza EN je AE g af 9 imma 19 ENS _ 22 8 9 Bm E J13 525 Not Used ae Ko c26 28 R5 Toe C3 A g 2 9 mw R79 ERR 9 2 2 Solvent Meter Input 5 4a SHI mm OU m 82 ely ES e OLY LZ 184 DADA N GO G J3 Meter A and B Input
19. Apparatus for use in Class Division 1 Group D T3 Label Location Div 1 Group D T3 Fluid Station C 4 Ta 20 C E 50 C Hazardous Locations on Easy Key 0359 Read Instruction Manual 12423 AIR WPR Warning Substitution of components 1112418 Maximum Fluid Working Pressure is listed here 312780F MAX TEMP 50 C 122 F may impair intrinsic safety PARTNO SERIES GRACO INC P O Box 1441 Minneapolis MN GRACO 55440 U S A SERIAL MFG YR 6 Digit Configured Part No 59 Parts Part No ADOOON to AD742Y includes EasyKey with LCD display A Items 310 and 329 are part of the Wall Mount Fluid Station See the parts list beginning on page 69 for descriptions 2 gt TI12553a Detail of Automatic Upgrade Kit 26 9 T I 8 E Ee ag 5 26 26a T112496a 60 312780F Parts Part No ADOOON to AD742Y includes EasyKey with LCD display see page 59 or part usage Description Qty CONT
20. International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2008 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Hevision F June 2014
21. and J5 FIG 18 4 Using the security tool provided Part No 122239 remove 2 screws 214k and the cover 214b See FIG 17 5 Noting their location remove 5 screws 214g 214h from the barrier board 214a Do not remove the screw noted in Fic 18 Remove board 6 Apply thermal compound to the heatsink Z on the back of the new barrier board 214a FiG 18 7 Install the new barrier board with the 5 screws 214g 214h 214k FiG 17 Replacing Barrier Board 42 8 Install the cover 214b with 2 screws 214k using the security tool 9 Connect cables to J1 J4 and J5 10 Close and lock EasyKey door with key 11 Turn on power at main circuit breaker 12 Turn EasyKey power on to test operation Replacing Barrier Board Fuses A 1 2 114788 Power In Fuses 2 amp time lag F4 150979 Power Out Fuses 0 4 amp quick acting 1 Follow Replacing Barrier Board steps 1 4 2 Remove the fuse F1 F2 F3 or F4 from its fuse holder FiG 18 3 Snap new fuse into holder 4 Follow Replacing Barrier Board steps 8 12 11126490 214h 21404 214 312780F J4 Power to Display Board 2144 F3 214h 4 Do not remove this screw 214h J1 Power In Apply thermal compound to surface of heatsink Z Back of Barrier Board showing Heatsink Z Fic 18 Barrier Board Connectors and Fu
22. 32 ELBOW tube 10 32 x 1 4 in 6 mm OD tube CONNECTOR male 10 32 x 5 32 in 4 mm OD tube ELBOW 45 1 4 npt m x f CONNECTOR cord strain relief PLATE blank solenoid Panel with no dump valve Panel with one dump valve Panel with two dump valves METER mount RoboMix SPACER meter RoboMix WASHER SCREW cap socket hd M6 x 1 10 mm sst SCREW cap socket hd M6 x 1 0 16 mm ELBOW swivel 90 1 4 npt m 1 4 npsm f sst Panel with no dump valve Panel with one dump valve Panel with two dump valves VALVE check 1 4 npt mbe CONNECTOR bar ground GROMMET SPACER valve mount Robo Mix CABLE 90 for G250 and G250HR meters see page 34 for connection points KIT flexible mixer see page 64 MANIFOLD RoboMix see page 74 Qty mo A N O Ref No 478 479 480 483 484 485A 486 488 489 490 492 493 494 495 496 4979 Part No C19810 15X764 116343 15D320 15U533 15G809 121795 104176 223547 116658 n a 15V267 15G795 15V409 15V888 123690 Description SCREW cap socket hd 1 4 20 x 1 in 25 mm SEAT valve Panel with no dump valve Panel with one dump valve Panel with two dump valves SCREW ground M5 x 0 8 CABLE fiber optic twin 50 ft 15 25 m see page 64 for location CABLE CAN intrinsically safe 50 ft 15 25 m see page 64 for location LABEL safety VALVE solenoid
23. Change D29 115224 Set switch 51 to down if system has Booth Control OR Color Change or neither 25 Troubleshooting 885029 9 LL Mika 2 BE o_o reo FB17 rg1g mm R25 R26 D32 B 7 TOP SILK D37 1 8 IN m U8 959 949 m 2 11 a V D 12 PRGRM HDR usnid PJs E EN ESE E E N E N E Uld 2 K dur eod e L IBN isu 14 106 a Gp Ea RN2 eA eA ie a en E R m H R81 rsa BL V eBung C2 N R70 BB 15 m D16 EP Fein HE H E R5 ai m 014 is 2 4 4 ma O am mi 3 ml H oo oo o o o Oo Oo NH ll TTTTTTTTT T TTTT J1 DIGITAL INPUT J13METER INPUT a 9 55 5 T co oO o 0 gt Q 29 gt gt LL LL 03 m m m C C o 9 lt 2 P 5 2 Z gt lt 2 8 8 2 8 o LL LL Q Q 0 Oo m 312780F J15 J8 J14 FiG 12 255765 Fluid Station Control Board Input Output Connections 26 Troublesho
24. J15 3rd Purge Valve Dump Valve A and B and GFB 1 and 2 solenoids 17 Troubleshooting Wall Mount Fluid Manifold Troubleshooting See FIG 6 To remove the fluid manifold see page 49 See manual 312781 for complete information on the fluid manifold ASL ACV DVA OFF MA DVA DVA ON 2 akya pd ALL APV ON lt 6 AS DVB OFF Fl DVB ON APV OFF SVA SVB RVA SM RVB Key Component A Side Component B Side MA Component A Meter MB Component B Meter DVA Component A Dose Valve DVB Component B Dose Valve RVA Component A Sampling Valve RVB Component B Sampling Valve SVA Component A Shutoff Valve SVB Component B Shutoff Valve APV Air Purge Valve BSL Component B Supply Line AT Air Purge Valve Air Supply Tube BCV Meter B Check Valve ASL Component A Supply Line SPV Solvent Purge Valve ACV Meter A Check Valve SSL Solvent Supply Line MS Solvent Meter accessory SCV Solvent Meter Check Valve Fic 6 Wall Mount Fluid Manifold 18 BCV BSL SSL MB SCV MS DVB H SPV ON SPV SPV OFF 125560 Mixed Material SM Static Mixer Fl Fluid Integrator 312780F Troubleshooting EasyKey Barrier Board Diagnostics See Fic 7 and Table 2 to troubleshoot the EasyKey barrier board Also see the EasyKey Electrical Schematic on page 31 and the System Electrical Schematic on pages 32 and 33 J4 Pin 1 J1 Pin 1 mo FT la
25. N Ref No 325 327 328 329 330 331 332 334 335 336 337 338 339A 340A 341 342 3439 Part No 15U510 n a 121072 15D320 104644 121628 223547 n a 15U679 n a n a 16J457 186620 15W775 C19798 104640 123690 Parts Description Qty BRACKET mounting mix man 1 ifold COVER fluid station 1 MUFFLER 2 CABLE fiber optic twin 50 ft 1 15 25 m see page 60 for location PLUG screw 10 32 x 5 32 in 2 4 mm SCREW machine self seal 8 ing 4 40 x 1 4 in 6 mm WIRE ground 25 ft 7 6 m 1 TUBE nylon to connect air A R manifold 335 to elbow 311 at solenoid manifold 308 1 4 in 6 mm OD 2 5 ft 0 76 m MANIFOLD air 3 8 npt m x 1 six 1 4 in 6 mm OD tube ports TUBE nylon green for control air to turn valves on 5 32 in 4 mm OD four 2 ft 0 6 m lengths TUBE nylon red for control to turn valves off 5 32 in 4 mm OD four 2 ft 0 6 m lengths TUBE nylon for purge air sup 1 ply 1 4 in 6 mm OD 25 ft 7 6 m includes caution label 626413 LABEL symbol ground 1 LABEL warning 1 SCREW cap socket hd 3 1 4 20 x 3 8 in 10 mm GASKET 3 FUSE 125 mA 2 A Heplacement Danger and Warning labels tags and cards are available at no cost Heplacing the fuse with a non Graco fuse voids the IS system safety approval Parts labeled n a are not available separately 69
26. PLATE e SCREW 4 40 x 1 in 25 mm ALARM LABEL warning GROUND WIRE 25 ft 7 6 m PLATE application includes items 214a 214m BOARD barrier IS includes fuses 15D979 and 114788 see page 43 for fuse location COVER e SPACER BAR ground e BLOCK terminal e POWER SUPPLY 24 Vdc 2A e SCREW machine pan hd 6 32 x 3 8 in 10 mm e SCREW machine pan hd 6 32 x 1 1 2 in 38 mm e SCREW machine pan hd 8 32 x 3 4 in 19 mm e SCREW machine pan hd 10 24 x 3 8 in 10 mm Qty I 214 214m 215 216 218 220 221 223 224 Part No 123823 123824 15V280 15G569 15R642 n a 198165 116343 15G869 Description e FILTER line single phase 110 250 V 3A BRACKET line filter HARNESS connection LABEL EasyKey inputs HARNESS wire SOFTWARE application CONNECTOR RJ45 with bulkhead fitting SCREW ground M5 x 0 8 CABLE ethernet CAT5 6 ft 1 8 m to make web interface connection to a computer Parts Qty A Heplacement Danger and Warning labels tags and cards are available at no cost Parts labeled n a are not available separately Available Cables CAN Cables 15U531 15U532 15V205 15V206 15V207 15V208 15U533 15V213 ft m 5 5 2 5 05 Fiber Optic Cables 15D320 50 15 25 Standard Length 67 Parts Wall Mount Fluid Station 314 31
27. Parts ProMix 2KS Automatic Wall Panel System Configurator Key The configured part number for your equipment is printed on the equipment identification labels See the illustrations below for location of the identification labels The part number includes one digit from each of the following six categories depending on the configuration of your system The digits in this table do not correspond to ref nos in the parts lists or parts drawings Flow Control Auto Color Valves matic Sys tem Control and Display A and B Meter Catalyst Valves 0 No Valves single catalyst No Valves single color EasyKey with LCD Display 0 No Meters 23000 A B 3000 A and B 1 8 in Coriolis A and 23000 B 33000 A and 1 8 in Coriolis B 1 8 in Coriolis A and G3000HR B G3000HR A and 1 8 in Coriolis B 1 8 in Coriolis A and B 1 Two Valves low pressure 1 Two Valves low pressure 2 Four Valves low pressure 2 Four Valves low pressure Seven Valves low pressure 4 Twelve Valves low pressure Label Location on ProMix 2KS Electronic Proportioner lt APPROVED Intrinsically safe equipment for Class I FM08ATEX0074 Ex ia Intrinsically Safe IS System Install per IS Control Drawing No 289833 EasyKey Interface IS Associated Apparatus for use in non hazardous location with IS Connection to Smart Fluid Plate IS
28. 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 one digit from each of the following six categories depending on the configuration of your system Automatic Control and Display A and B Meter Color Valves Catalyst Valves Flow System Control D EasyKey with LCD Display 0 No Meters Label Location on Fluid Station 12423 Maximum Fluid Working Pressure is listed here 1 8 in Coriolis A and 2 5 Electronic Proportioner FMO8ATEX0074 Ex ia 0359 AIR WPR equipment for Class I Div 1 Group D T3 0 No Valves G3000 A and B single color G3000HR AandB Two Valves low pressure 2 Four Valves low pressure G3000 A and 1 8 in Coriolis B 1 8 in Coriolis A and G3000HR B G3000HR A and 1 8 in Coriolis B 1 8 in Coriolis A and B 3 Seven Valves low pressure 4 Twelve Valves low pressure Intrinsically Safe IS System Install per IS Control Drawing No 289833 EasyKey Interface IS Associated Apparatus for use in non hazardous location with IS Connection to Smart Fluid Plate IS Apparatus for use in Class Division 1 Group D T3 Hazardous Locations Read Instruction Manual Warning Substitution of components may impair intrinsic safety PART NO APPROVED Intrinsica
29. m o o o B ES A D5 e Lr er y F1 F2 F4 e LA 3 2 e O e F3 e e e 7 TOP SILK 15D303E DA all E a x 06 D1 19 R9 R12 G GRACO bse M e 1191 6 Ri4e 6 D2 e e b e 19 e R5 R6 150303 J5 x Ta eae e Fic 7 255786 EasyKey Barrier Board Table 2 EasyKey Barrier Board Diagnostics AC Power Input n a 24 Vdc Power Input to D5 turns on EasyKey Display Board Fluid Station Board or Graco Part No 150979 are blown or there is no input power at J4 If there is no input power D5 does not light fuses F1 and F2 Graco Part No 114788 may be blown 12 Power Output to D4 turns on if barrier board is functioning If D4 does not turn on fuses 312780F 19 Troubleshooting EasyKey Display Board Diagnostics See FIG 8 and Table to troubleshoot the EasyKey display board Also see the EasyKey Electrical Schematic on page 31 and the System Electrical Schematic on pages 32 and 33 Multiple Station 2 O M lt J10 8111 RS485 T ERI QO m lt 2 Integration Control 12923 Output Common General Alarm J10 Analog In Signal 22 Analog In Common I O J9 D7 J5 um o V
30. the ISO will begin to gel increasing in vis cosity If used this partially cured ISO will reduce perfor mance and the life of all wetted parts NOTE The amount of film formation and rate of crystal lization varies depending on the blend of ISO the humidity and the temperature To prevent exposing ISO to moisture e Always use a sealed container with a desiccant dryer in the vent or a nitrogen atmosphere Never store ISO in an open container e Use moisture proof hoses specifically designed for ISO such as those supplied with your system e Never use reclaimed solvents which may contain moisture Always keep solvent containers closed when not in use e Never use solvent on one side if it has been con taminated from the other side e Always lubricate threaded parts with ISO pump oil or grease when reassembling Changing Materials e When changing materials flush the equipment mul tiple times to ensure it is thoroughly clean e Always clean the fluid inlet strainers after flushing e Check with your material manufacturer for chemical compatibility Most materials use ISO on the A side but some use ISO on the B side 11 Grounding Grounding Your system must be grounded See the Grounding instructions in your ProMix 2KS Installation manual Check Resistance To ensure proper grounding resistance between Pro Mix components and true earth ground must be less than 1 ohm Have a
31. 1 and 2 low pressure valves Flow Control Option Y Yes Flow Meter Fluid Flow Rate Range Coriolis Meter S3000 Solvent Meter accessory Standard Features EasyKey with LCD Fiber Optic and Power Cables 50 ft 15 25 m Wall Mount Fluid Station 50 cc Integrator and Static Mixer Discrete I O Board A Side Dump Valve if color valve s selected B Side Dump Valve if catalyst valve s selected Flow Control with 15 ft 4 57 m Cable if selected Basic Web Interface 312780F 4000 psi 27 58 MPa 275 8 bar 4000 psi 27 58 MPa 275 8 bar 2300 psi 15 86 MPa 158 6 bar 300 psi 2 07 MPa 20 6 bar 190 psi 1 31 MPa 13 1 bar 75 3800 cc min 0 02 1 0 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 System Configuration and Part Numbers RoboMix Fluid Station Configurator Key The configured part number for your equipment is printed on the equipment identification labels See Fic 2 for location of the identification labels The part number includes one digit from each of the following six categories depending on the configuration of your system RoboMix Control and Display A and B Meter Color Valves Catalyst Valves Flow System Control EasyKey with LCD Display 0 No Meters 0 No Valves 0 No Valves 1 G250 A and single color single catalyst 2 G250HR A and 1 Two Valves 1 Two Valves i low pressure low pressur
32. 14 to the housing 611 FIG 37 3 Carefully separate the bracket from the housing and disconnect the three cables from J1 J2 and J4 on the circuit board 618 Fic 36 4 Remove the screws 621 Replace the old board with the new board 5 Reconnect the three cables to J1 J2 and J4 on the circuit board 618 Fic 36 6 Reattach the bracket 614 to the housing 611 Torque the screws 605 to 30 40 in Ib 3 4 4 5 Nem 57 Service Servicing the V P Valve 1 2 Follow Before Servicing page 38 Remove the four screws 605 holding the bracket 614 to the housing 611 FIG 37 Carefully separate the bracket from the housing and disconnect the V P valve cable from J2 on the circuit board 618 FIG 36 Remove the two screws 619a and o rings 619b Install the new valve 619 with new screws and O rings Reconnect the V P valve cable to J2 on the circuit board 618 FIG 36 Reattach the bracket 614 to the housing 611 Torque the screws 605 to 30 40 in Ib 3 4 4 5 Nem J2 V P Valve R3 n4C12 L1 LE m mj Daag r U1 J4 Pressure Sensor J1 Power Input 36 249179 Flow Control Board 58 615 613 O _ 604 S Flow 610 i A Torque to 8 10 in Ib 0 9 1 1 Nem Torque to 30 40 in Ib 3 4 4 5 Nem A Torque to 5 7 in lb 0 6 0 8 Nem 37 Flow Control 12506 312780F Parts
33. 4 way Panel with no dump valve Panel with one dump valve Panel with two dump valves BULKHEAD tube 1 4 in 6 mm OD both ends WIRE ground 25 ft 7 6 m FITTING tube 1 4 npt m x 1 4 in 6 mm OD tube TUBE air polyethylene 1 4 in 6 mm OD 1 1 2 ft 0 46 m KIT ratio check RoboMix CONNECTOR plug 6 position CONNECTOR plug 10 posi tion RETAINER seat valve Panel with no dump valve Panel with one dump valve Panel with two dump valves FUSE 125 mA Parts Qty A OOo P N A Replacement Danger and Warning labels tags and cards are available at no cost Replacing the fuse with a non Graco fuse voids the IS system safety approval Available as kit Part No 24V862 Parts labeled n a are not available separately 71 Parts ion id Stat IX Flu RoboM Detail of Circuit Board Assembly RoboMix Panel two dump valves shown 410 427 e LO CN T Detail of Flow Meter Assembly 404 for description A See page 65 112507 401 See page 73 for detail 112509 312780F 72 Parts RoboMix Fluid Station Detail of Ratio Check Kit 493 Detail of Connection Ports 490 Air Purge Inlet 112514 458 Solvent 477 Inlet A Dump He ae Gee page 74 Outlet TI12511a for detail 480 489 415 492 416 N 112510 312780F 73 Parts 256654 RoboMix Manifold Re
34. 5057 Remove the seal screw 506 from the integrator housing 501 Replace the o ring 505 Remove the check valves 519 from each valve adapter 517 and from the elbow 528 on the A side of the manifold Replace all three check valves The arrow on the check valves must face toward the manifold Remove the pipe plugs 522 from each valve adapter 517 Replace the plugs Reassemble in reverse order following all assembly notes in FIG 35 82 _ UN 511 517 504 as 504 509 A 508 522 N Apply pipe sealant to tapered threads A Lubricate all o rings Apply thread sealant OO 519 529 12513 312780F Servicing Flow Control Preparation I 1 Follow Before Servicing page 38 2 Disconnect all air and fluid lines from the flow con trol regulator 3 Disconnect the flow control cable from connector 624 FIG 37 4 Remove the four screws 605 holding the air plate 607 to the housing 611 Carefully lift the plate off the housing and disconnect the three cables from J2 and J4 on the circuit board 618 FIG 36 Servicing the Regulator and Pressure Sensor Regulator Service Kit 15G843 is available Kit parts are marked with an asterisk for example 602 For best results use all parts in the kit Sensor Service Kit 15G867 is available to service the pressure sensor only Kit par
35. 6 Separate graphic display 210b from display board 210c connector J2 on back of board 7 assemble the new parts align connector J2 on the display board 210c with the socket on the graphic display 210b Press them together See FIG 15 8 Reconnect the graphic display power cable J1 to the display board 210c 9 Mount display board assembly with screws 2106 10 Plug all connectors into display board 210c FIG 15 Confirm that the cables do not pinch when open ing or closing the door 11 Locate the battery on the board see FIG 8 on page 20 Pull the strip to remove the protective isolator and activate the battery 12 Close and lock EasyKey door with key 13 Turn EasyKey power on to test display board Replacing Power Supply 1 Follow Before Servicing page 38 2 Unlock and open EasyKey door with its key 3 Note position of power supply input and output wires See EasyKey Electrical Schematic page 31 Disconnect wires from power supply 214f See 16 4 Remove power supply from din rail 5 Install new power supply 214f Reconnect input and output wires in positions noted in step 3 6 Close and lock EasyKey door with key 7 Turn on power at main circuit breaker 8 Turn EasyKey power on to test operation 39 Service Replacing Line Filter 1 Follow Before Servicing page 38 2 Unlock and ope
36. 8 3 Note the position of all RoboMix hoses then discon nect them 410 Air Logic Inlet A Inlet Air Purge Inlet Solvent Inlet B Dump Outlet A Dump Outlet 112512 Fic 26 RoboMix Fluid Station 50 312780F Service Replacing Control Board 4 Remove 4 screws 428 Remove control board 1 Follow Preparation page 50 2 Remove the control board cover 427 FIG 27 427 12579 Fic 27 Remove Control Board Cover 3 Disconnect fiber optic wires J4 J6 and all cables 41 43 45 47 48 49 412 J13 914 415 from con trol board 426 FIG 29 112648 Fic 28 Remove Control Board 5 Install new control board 426 with 4 screws 428 6 Connect cables to control board 426 FiG 29 Insert fiber optic cable connectors J4 J6 into board connectors E matching blue with blue black with black and hand tighten connectors E Do not pinch or kink the fiber optic cables the cables require a 2 in 51 mm bend radius 7 Reinstall covers 427 410 8 Reconnect all hoses FIG 26 9 Turn EasyKey power on to test operation 312780F 51 Service Replacing Control Board Fuse 1 Follow Preparation page 44 2 Locate fuse F1 on the control board See FIG 29 Remove the screw and metal strap Replacing the fuse with a non Graco fuse voids the Pull the fuse away from the board IS system safety approv
37. 8 332 1112425 341 325 321 335 Control Board Fuses 343 317 Solenoid Manifold Detail 324 331 312 112426 1126520 68 312780F Wall Mount Fluid Station NOTE Parts are shown on page 68 unless noted Ref No 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 317a 318 319 320 321 322 323 324 Part No 256529 255765 n a 119257 119162 116773 113783 15R668 06061 150533 112781 114263 121374 111987 114669 n a 114124 114228 116343 100985 101345 120685 15U507 100139 552183 312780F Description ENCLOSURE BOARD circuit SCREW machine pan hd 4 40 x 3 16 in 5 mm CONNECTOR bar ground CONNECTOR plug 6 position CONNECTOR plug 10 posi tion SCREW machine pan hd 1 4 20 x 1 2 in 13 mm MANIFOLD solenoid 5 station MUFFLER CABLE CAN intrinsically safe 50 ft 15 25 m see page 60 for location ELBOW swivel 90 1 8 npt m x 1 4 in 6 mm OD tube FITTING tube 1 8 npt m x 5 32 in 4 mm OD tube VALVE solenoid 4 way intrin sically safe 12 Vdc CONNECTOR cord strain relief SCREW machine phillips pan hd M5 x 0 8 10 mm PLATE mounting FILTER air 3 8 npt includes 317a e ELEMENT filter 5 micron SCREW ground WASHER lock external tooth 1 4 NUT hex jam 1 4 20 GROMMET COVER enclosure PLUG pipe 1 8 npt PLATE blanking Qty N
38. FLOW METER C 312780F Servicing RoboMix Manifold Manifold Service Kit 15V480 is available Kit parts are marked with an asterisk for example 502 For best results use all parts in the kit Lubricate all o rings dur ing assembly 1 Follow Preparation page 50 Service Disconnect all fluid and air lines from the manifold 477 Unscrew the flexible mixer 474 from the integrator cap 511 Remove the screws 403 478 and the spacer 465 on the B side Remove the manifold assembly 477 from the RoboMix fluid station FiG 34 Fic 34 RoboMix Manifold 312780F 112651 55 Service 5 Unscrew the integrator cap 511 and housing 8 510 Inspect the mixer 508 and mix cap 509 Replace the o rings 504 Fic 35 9 6 Unscrew the integrator manifold plug 507 Remove the integrator base 503 Replace both o rings 502 5047 10 NOTICE 11 Keep A side and B side parts separate when disas sembling to prevent contamination during reassem bly 7 Unscrew the A and B dose valves 521 from the 40 valve adapters 517 Replace the o rings 518 NOTE To repair the dose valves 521 see manual 13 312782 521 Fic 35 Manifold Repair 56 O Remove the screws 520 and adapters 517 Inspect the seat 516 Replace the o rings 515 Remove the screws 513 and the A and B valve mounts 512 Replace the o rings
39. OWER 24 YEL ORG BRN RED H 04 00 COM BLACK SHIELD 312780F System Electrical Schematic NOTE The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS system Some compo nents shown are not included with all systems Hazardous Area FO OUT BLU FOIN 312780F BLK FLUID PANEL CONTROL BOX FLUID PANEL CONTROL 3 BOARD gl 43 Schematic Diagrams HAZARDOUS AREA 3X CABLE PWR RED BLACK FLOW METER A gig WHITE 1 1 TL PWRIRED COM BLACK FLOW METER B 1 5 METERS SIG WHITE r SHIELD GRN 4 BLACK FLOWMETERSOLVENT 20 0 T G WHITE SHIELD GRN n 1 SIG RED GROUND V P ANALOG OUT WHT 2 COM BLK TERMINAL PRESS GRN UNUSED 12 L UNUSED GND BLK J4 LUNUSED CHASSIS BARE PRESSURE GRN UNUSED 2 COM RED L UNUSED 3 WHT l UNUSED E PRESSURE BLK SHIELD BARE L _ JJ LLLLEII 1 45 2 3 COLOR BOARD 1 6 STD 3 100 OPTIONS NE o Se RED CATA TST 5 SHIELD BARE 1 THRU 4 4 E
40. Parts RoboMix Fluid Station NOTE Parts are shown on pages 72 and 73 unless noted RoboMix Panel no dump valve RoboMix Panel one dump valve RoboMix Panel two dump valves Ref No 401 402 403 404 406 407 408 409 410 411 412 413 414 415 70 Part No 15U712 C19979 C19798 114339 111307 110911 15U713 15U714 150716 150853 104371 150717 150718 150719 Description PANEL RoboMix SCREW cap socket hd 10 24 x 3 8 in 10 mm Panel with no dump valve Panel with one dump valve Panel with two dump valves SCREW cap socket hd 1 4 20 x 3 8 in 10 mm UNION swivel 1 4 npt m x 1 4 npsm f sst Panel with no dump valve Panel with one dump valve Panel with two dump valves WASHER lock external tooth M5 NUT hex M5 x 0 8 VALVE adapter RoboMix Panel with no dump valve Panel with one dump valve Panel with two dump valves VALVE adapter RoboMix COVER panel RoboMix FITTING bulkhead 1 4 npt x M20 SCREW cap socket hd 10 32 x 3 8 in 10 mm HOSE component B supply 1 4 npt mbe ptfe 7 5 in 191 mm HOSE component A supply 1 4 npt mbe ptfe 8 in 203 mm HOSE solvent 1 4 npt mbe ptfe 12 in 305 mm Qty A NON N GQ N Ref No 416 417 419 420 421 422 423 424 425 426 427 Part No 15U720 150721 104116 700332 15 304 166421 101970 150723 255765 150724
41. REMOTE STOP GRN ALARM RESET BRN I ALARM OUTPUT BLU DIGITAL OUTPUT COMMON ORG POT LIFE YEL FLOW RATE ANALOG IN PUR 0 L FLOW RATE ANALOG COMMON GRAY O OC CO gt SERRE I O HARNESSES TERMINAL RS485 INTEGRATION A WHT BLU BLOCKS RS485 INTEGRATION BLU WHT RS485 INTEGRATION GROUND SHIELD RS485 NETWORK A WHT ORG RS485 NETWORK B ORG WHT 85485 NETWORK GROUND SHIELD Ov Q J7 FO IN BLK 8 FOOUT BLU WEB SERVER MODULE NON HAZARDOUS AREA POWER ROCKER SWITCH DC OK 1 L1 85 250 VAC mc we COMMON COMMON H GND LUG POWER HARNESS UNUSED UNUSED oy CABLE 50 STD 100 OPTION CABLE MIX INPUT PURGE INPUT JOB COMPLETE INPUT EXTERNAL CLR CHG READY RESET ALARM INPUT DIGITAL INPUT COMMON DIGITAL INPUT COMMON RECIPE BIT 0 INPUT RECIPE BIT 1 INPUT RECIPE BIT 2 INPUT RECIPE BIT 3 INPUT RECIPE BIT 4 INPUT RECIPE BIT 5 INPUT RECIPE CHANGE INPUT DIGITAL OUTPUT COMMON POWER PURGE RECIPE CHG ACTIVE OUTPUT MIX ACTIVE OUTPUT MIX READY OUTPUT FILL ACTIVE FLOW CAL ACTIVE FLOW RATE ALARM OUTPUT DIGITAL OUTPUT COMMON POWER DIGITAL OUTPUT COMMON POWER SPECIAL OUTPUT 1 SPECIAL OUTPUT 2 SPECIAL OUTPUT 3 SPECIAL OUTPUT 4 DIGITAL OUTPUT COMMON P
42. ROL DISPLAY EasyKey used on ADOOON to AD742Y see page 66 68 pe je 5 5 15 67 G3000HR flow meter see manual 308778 1 _ pe 00 6 15 96 Coriolis flow meter see manual 313899 1 77 Tf 77 Tf 77 Tf 4 REGULATOR flow contra CABLE flow control connects flow control regulator to fluid control only station 40 ft 12 2 m CABLE CAN intrinsically safe connects color change control change only module to fluid station 3 ft 1 m 26a 15V825 e board discrete part of item 26 C S Parts 62 312780F Parts ProMix 2KS Automatic RoboMix Panel System Configurator Key The configured part number for your equipment is printed on the equipment identification labels See the illustrations below for location of the identification labels The part number includes one digit from each of the following six categories depending on the configuration of your system The digits in this table do not correspond to ref nos in the parts lists or parts drawings Auto Control and Display A and B Meter Color Valves Catalyst Valves Flow matic Sys Control tem EasyKey with LCD Display 0 No Meters 0 No Valves 0 No Valves 1 G250 and single color single catalyst 2 G250HR A and 1 Two Valves 1 Two Valves low pressure low pressure 2 Four Valves 2 Four Valves low pressure low pressure 3 Seven Valves low pressu
43. Repair Parts lt gt 7 GRACO ProMix 2KS 312780F Plural Component Proportioner EN Automatic systems for proportional mixing of plural component coatings with Wall Mount Fluid Station or RoboMix Fluid Station For professional use only For use in explosive atmospheres except the EasyKey See pages 4 7 for model information including maxi Important Safety Instructions mum working pressure Equipment approval labels are Read all warnings and instructions in this on page 3 Some components shown are not included manual Save these instructions with all systems Automatic System with RoboMix Fluid Station Automatic System with Wall Mount Fluid Station 12552 12553 C 0359 APPROVED Ex G PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 3 System Electrical Schematic 32 Equipment Approvals 3 RoboMix Panel Board Schematic 34 System Configuration and Part Numbers 4 Tubing SCHEMAUC ER RU ERE eis 36 Wall Mount Fluid Station Configurator Key 4 voce tee nur das 38 RoboMix Fluid Station Configurator Key 6 Before Servicing 38 Standard Features 7 After Servicing 38 5 165 8 Servicing 39
44. ailer 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 over bend hoses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed Read MSDS s 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 chemically impermeable 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 10 312780F Important Two Component Material Information Important Two Component Material Informatio
45. al 4 Install the new fuse 497 5 Reinstall covers 427 410 Fus Parte _ 123690 Fuse 125 mA intrinsically safe J4 F1 497 F O Output J6 F O Input black L Cp e ri NS 9 e J1 EL 9 38 J10 Digital Input 544 a Power Input 9 je a gt 9 211 LL Thai ind E e e 7 e I mm sea mm G H 46 aS 229 911 PT TI m 5 J13 ird 200 JE Color Change Module meme 5 Not Used SN we 5 x E C26 mu 5 Epa O sam misa U 3 8 9 ms R79 aN HEB s J12 ware mm MITT R78 R28 FEET aes Solvent Meter Input 17 LL pm mmi 28 ES F pene EE Not Used NES MI n EN J3 J5 Meter A and B Input SN R66 R61 R62 R59 Flow Control 7 8 i i Me E i ms Road J8 Solenoid Output OLEYOID OUTPUUTSSOLENOID OUTPUT JB SOLENOID OUTPUT Dose Valves A and Solenoid Output Dump Valve B J14 J15 Solenoid Output Solenoid Output Air Purge Valve and Solvent Flush Valve 3rd Flush Valve Dump Valv
46. alarm codes See the system Mix in Setup Alarm operation manual for complete information on alarm Setup Change Warning Power On Warning troubleshooting Material Fill Alarm 312780F 15 Troubleshooting Solenoid Troubleshooting RoboMix Fluid Station Dose Valve B Override Button Dose Valve A Override Button 12655 Wall Mount Fluid Station 1 Power d Fiber 1 Optic CAN 13 CAN a i em ooo oou Valve Dose A fs IN 99999 2 20000 0 5999090 oooooo 2555s TIT 2996566 4696666 14 ER J8 Dump Valve A Dump Valve B Tose PME Optional Solenoid 1 GFB 1 Locations k J GFB 2 I gt PII IW L Dose Valve A 3rd Purge Valve Solenoid Solenoid Dose Valve B Purge Valve A Purge Valve B Solenoid Solenoid Solenoid 1112652 Fic 5 Fluid Station Board and Solenoids 16 312780F Troubleshooting NOTE Refer to the Schematic Diagrams page 30 If the dispense or purge valves are not turning on or off correctly it could be caused by one of the following 1 Air regulator pressure set too high or too low Check air pressure 80 90 psi 550 630 kPa 5 5 6 3 bar is commonly used Do not go below 70 psi 490 kPa 4 9 bar or above 120 psi 0 8 MPa 8 bar 2 Airor electrical lines damaged or Visua
47. arettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground all equipment in the work area See Grounding instructions in your system installation man ual 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 Intrinsically safe equipment that is installed improperly or connected to non intrinsically safe equipment will create a hazardous condition and can cause fire explosion or electric shock Follow local regulations and the following safety requirements e Only models with G3000 2250 G3000HH 250 or intrinsically safe Coriolis meter are approved for installation in a Hazardous L
48. e 2 Four Valves 2 Four Valves low pressure low pressure 3 Seven Valves low pressure 4 Twelve Valves low pressure 2 5 Intrinsically Safe IS System Install Electronic Proportioner per IS Control Drawing No 289833 EasyKey Interface IS Associated Apparatus for use in non hazardous lt u gt location with IS Connection to Smart FMO8ATEX0074 APPROVED Fluid Plate IS Label Location on M Label Location 5 I iv 1 Group D ass 1 Division 1 Group RoboMix Fluid Station CC Hazardous Locations on EasyKey 0359 7112512 Read Instruction Manual TI12418a MAX AIR WPR Warning Substitution of components may impair intrinsic safety PART SERIES SERIAL MFG YR G GRACO INC MPa bar PSI P O Box 1441 MAX TEMP 50 C 122 F 2 Maximum Fluid Working Pressure Configured Part Number is listed here Fic 2 Identification Label Automatic RoboMix Fluid Station Systems 6 312780F System Configuration and Part Numbers Hazardous Location Approval Models using a G250 or G250HR for both A and B meters are approved for installation in a Hazardous Location Class I Div Group D T3 or Zone Group IIA T3 Maximum Working Pressure Maximum working pressure rating for RoboMix Fluid Station Systems is 190 psi 1 31 MPa 13 1 bar See the identification label on your EasyKey or RoboMix fluid station for the maximum working pres
49. e A 29 255765 Fluid Station Control Board 52 312780F Replacing Solenoids The RoboMix Fluid Station has a minimum of 4 sole noids If you have optional 3rd flush valve or dump valve kits installed you have additional optional solenoids for each additional valve Refer to Table 8 and Sche matic Diagrams page 30 To replace a single solenoid 1 Follow Preparation page 50 Shut off power at the main circuit breaker 2 Remove the control board cover 427 FIG 27 3 Disconnect 2 solenoid wires from control board 426 See FIG 29 and System Electrical Sche matic page 33 Swing the control board up and out of the way FIG 12741 30 Accessing Solenoids and Meters 312780F Service 4 Unscrew 2 screws P and remove solenoid 486 See Fic 31 and Table 8 112655 Fic 31 RoboMix Solenoids Table 8 RoboMix Solenoids Dose Valve A 2 Dose Valve 3 Air Purge Valve 4 Solvent Purge Valve Optional 3rd Purge Valve 06 Dump Valve A Dump Valve B 5 Install new solenoid 486 6 Connect 2 wires N to control board 426 Solenoid wires are polarized red black Refer to Sys tem Electrical Schematic page 33 7 Reinstall covers 427 410 53 Service G250 and G250HR Flow Meters Removal 1 Follow Preparation page 50 2 Unscrew cable from meter connector CC FIG 32 3 Unscrew M6 screws 442 and washers 440 f
50. e Color Change Kits Color Change Catalyst Change Control Module Valve Stack 11 Valve Stack 12 Kit Description 10 see 312787 see 312783 see 312783 312780F 77 Parts 78 312780F Technical Data Technical Data Maximum fluid working pressure Base system 4000 psi 27 58 MPa 275 8 bar Low pressure color change 300 psi 2 07 MPa 20 6 bar Coriolis meter 2300 psi 15 86 MPa 158 6 bar RoboMix system 190 psi 1 31 MPa 13 1 bar Flow control 190 psi 1 31 MPa 13 1 bar Maximum working air pressure 100 psi 0 7 MPa 7 bar Al SUDDIV Be ae be RR SR RE er es 75 100 psi 0 5 0 7 MPa 5 2 7 bar Air filler inlet size 3 8 npt f Air filtration for air logic and purge air 5 micron minimum filtration required clean and dry air Air filtration for atomizing user supplied 30 micron minimum filtration required clean and dry air Mixing ratio 0 1 1 50 1 up to 1 user selectable Fluids handled one or two component solvent and waterborne paints polyurethanes epoxies acid catalyzed varnishes moisture sensitive isocyanates Viscosity range of 20 5000 cps Fluid filtration user supplied
51. e the parts list beginning on page 70 for descriptions 112552 2 rem EC i 5 1 eh gt ss 5 26 26a 12496 312780F 64 Parts Part No RDOOON to RD242Y includes EasyKey with LCD display Configured Digit see page 59 or part usage Description Qt 277869 CONTROL DISPLAY EasyKey used RDOOON to RD242Y see page 66 standard see page PANEL fluid RoboMix lt KIT flow meter A e ERR 70 rinn mme pe CC 308778 for parts 308778 for parts RIT flowmeter mme mne 308778 for parts 308778 for parts 77 77 77 77 FLOW CONTROL none none 49849 REGULATOR flow control 15G61 1 CABLE flow control connects flow control regulator to fluid 0 or 1 station 10 ft 3 05 m 15U533 CABLE CAN intrinsically safe connects color change control 0 or 1 module to fluid station 50 ft 15 25 m 70122 5G768 PLUG push fitting 1 2 in ADAPTER Y fitting 1 4 6 mm OD tube systems without flow control systems with flow control N used with flow control only used with color change only standard part standard part standard part 5 14158 14158 NI O O lt 2 r N Z N A N 41 N standardpart 15 256 26a standard T5V825 standard part TUBE polyethylene 1 4 in 6 mm OD
52. ed Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR 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 ev
53. ent will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s a la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com For patent information see www graco com patents TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Original instructions This manual contains English MM 312780 Graco Headquarters Minneapolis
54. f No 501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516 74 Part No 15U728 n a 151943 151748 151592 151729 101885 114446 150686 Description HOUSING integrator RoboMix O RING ptfe BASE integrator O RING ptfe O RING ptfe SEAL screw 1 4 28 PLUG integrator manifold MIXER integrator 25cc CAP mix HOUSING 25 cc CAP housing VALVE mount RoboMix SCREW cap socket hd 1 4 20 x 1 3 4 44 mm UNION 90 1 4 npt m x 1 4 npsm f O RING ptfe SEAT valve needle high pres sure Qty BR N a OQ Ref No 517 518 519 520 521 522 528 529 Part No 15T600 n a 501867 15T875 15 303 101970 166866 114112 Description ADAPTER valve O RING ptfe VALVE check SCREW cap socket hd 5 16 24 x 5 8 in 16 mm VALVE dispense includes item 518 see 312782 PLUG pipe ELBOW street 1 4 npt m x f FITTING 1 4 npt f x 1 4 in 6 mm OD tube Qty nm Parts included in Manifold Service Kit 15V480 Purchase separately Parts included in 25cc Integrator Service Kit 15V033 Purchase separately Parts labeled n a are not available separately 312780F Parts 256654 RoboMix Manifold x 508 aN 515 522 516 R 529 12513 312780F 75 Parts 249849 Flow Control Regulator
55. gt D45 u E 5 E EISE o e gt O le ac 1 4 2 2 R51 m WE a GW ac D16 gt a mil 1 NU 7 gece mm C ER 2 EE a 2 2 i e Bm 2 p dc 046 25 017 g gt m 2 ae 2 cam MT nmn _ D17 025 WE mm 2 R79 lt ous 9 SN R74 2 2 cj e 5 G 88 A 246 c o 20 Z2 ES R14 L 5 c7 nnn nii S 5 D44 ee 8 8 8 88 w ig g G E 6820 iu c38 A 2 D R66 R61 R62 C37 R65 I 2 8 e A u m2 C 043 J TT 52 20 53 i E H Eo TT TITT nd so OUTPUT SOLENOID OUTPUT JB SOLENO eza 028 030 027 041 033 031 11 255765 Fluid Station Control Board Indicators 312780F Fiber Optic Output blue J6 Fiber Optic Input black 910 Power Input J11 Color Change Module Set Switch S1 as shown below NL J7 Not Used T115223a Set switch S1 to OFF up if system has Booth Control AND D20 Color
56. hazardous location with IS Connection to Smart Fluid Plate IS Apparatus for use in Class Division 1 Group D T3 Hazardous Locations Read Instruction Manual Warning Substitution of components may impair intrinsic safety PART NO SERIES FMO8ATEX0074 Intrinsically safe equipment for Class I Div 1 Group D T3 20 to 50 0359 Ex ia IIA MAX AIR WPR 7 7 100 FLUID WPR SERIAL P O Box 1441 MFG YR G GRACO INC MPa bar PSI MAX TEMP 50 C 122 F Minneapolis MN GRACO 55440 U S A Fluid Station Label ProMix 2KS SERIES SERIAL MFG YR FLUID PANEL PART NO MAX AIR WPR Ade d safe I PD bar oorr Class l M p D T3 GRACO INC 73 1441 289833 G m 0359 Ex ia IIA T3 eraco 55440 U S A Artwork No 293538 T113581a ATEX Certificate is listed here EasyKey Label POWER REQUIREMENTS VOLTS AMPS 2 AMPS MAX GRACO INC for Class PD 50 60 Hz 1441 US 20 to 50 aZ Minneapolis MN APPROVED Install per 289833 9 2 G Ex ia IIA Um 250 V EMOSATEXO072 0359 13582 ProMix 2KS PART NO SERIES NO MFG YR N N x o lt Certificate is listed here System Configuration and Part Numbers System Configuration and Part Numbers Wall Mount Fluid Station Configurator Key
57. l technical data 312780F 79 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty 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 verifi
58. lly inspect air and electrical lines for kinks damage or loose connec connections loose 3 Solenoid failure 4 Solenoid cable or fluid station control board failure 5 Blown fuse 312780F tions Service or replace as needed Manually operate the valves by removing the Fluid Station cover and press ing and releasing solenoid valve override buttons FIG 5 Use the control board diagnostics to check the signals If signals do not occur correctly go to Cause 4 Valves should snap open and shut quickly If the valves actuate slowly it could be caused by Air pressure to the valve actuators is too low See Cause 1 Solenoid is clogged Make sure air supply has 5 micron filter installed Something is restricting the solenoid or tubing Check for air output from air line for corresponding solenoid when valve is actuated Clear restric tion A dose valve is turned in too far See ProMix 2KS Operation manual for settings Fluid pressure is high and air pressure is low Fluid seal in valve has failed See corresponding valve manual for repair information Check voltage level to solenoid by pulling solenoid connector and checking voltage between pins If voltage is 9 15 VDC the solenoid is damaged Replace solenoid or correct electrical line problem If there is no voltage replace the board Check condition of fuses F1 and F2 F1 powers J9 and J14 Dose Valve A and B and Purge Valve A and B solenoids F2 powers J8 and
59. lly safe 20 to 50 C SERIES SERIAL bar MAX FLUID WPR MPa PSI MAX TEMP 50 C 122 F GRACO INC P O Box 1441 5 minneapolis GRACO 55440 U S A Fic 1 Identification Label Automatic Wall Fluid Station Systems 0 No Valves single catalyst 1 Two Valves low pressure 2 Four Valves low pressure Label Location on EasyKey 112418 Configured Part Number 312780F Hazardous Location Approval System Configuration and Part Numbers Models using G3000 G3000HR or intrinsically safe Coriolis meter for both A and B meters are approved for installation in a Hazardous Location Class I 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 AD110Y has a maximum working pressure of 190 psi 1 31 MPa 13 1 bar See the identification label on your EasyKey or fluid station for the system maximum working pressure See FIG 1 ProMix Fluid Components Maximum Working Pressure Base System no meters option 0 no color change option 0 and no flow control option N Meter Option 1 and 2 G3000 or G3000HR Meter Option 3 4 5 6 and 7 one or two Coriolis Meters Color Change Option 1 2 3 and 4 and Catalyst Change Option
60. lves NOTE This procedure relieves pressure through the sampling valve 1 Complete all steps under Single Color Systems page 12 2 Close the A side shutoff valve SVA FIG 4 Open the A side sampling valve RVA 3 Direct the A side sampling tube into a waste con tainer 4 See 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 5 Press and hold the solvent solenoid override until clean solvent comes from the sampling valve then release 6 Shutoff the solvent supply to the color change stack solvent valve 7 Press and hold the solvent solenoid override until solvent flow from the sampling valve stops 8 Open the side shutoff valve SVA FIG 4 Close the A side sampling valve RVA 312780F Pressure Relief Procedure Systems with Color Catalyst Change and Dump Valves NOTE This procedure relieves pressure through the dump valves 1 Complete all steps under Single Color Systems page 12 2 Shut off all color and catalyst supplies to the valve stacks 3 Press and hold the dump valve A solenoid override FIG 5 4 See 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 A stops 5 Press and hold the dump valve B solenoid over
61. n Isocyanate Conditions Spraying or dispensing materials containing isocya nates creates potentially harmful mists vapors and atomized particulates Head material manufacturer s warnings and mate rial MSDS to know specific hazards and precautions related to isocyanates Prevent inhalation of isocyanate mists vapors and atomized particulates by providing sufficient ventila tion in the work area If sufficient ventilation is not available a supplied air respirator is required for everyone in the work area To prevent contact with isocyanates appropriate personal protective equipment including chemically impermeable gloves boots aprons and goggles is also required for everyone in the work area Material Self ignition Some materials may become self igniting if applied too thickly Read material manufacturer s warnings and material MSDS Keep Components A and B Separate Cross contamination can result in cured material in fluid lines which could cause serious injury or dam age equipment To prevent cross contamination of the equipment s wetted parts never interchange component A isocyanate and component B resin parts 312780F Moisture Sensitivity of Isocyanates Isocyanates ISO are catalysts used in two component coatings ISO will react with moisture such as humidity to form small hard abrasive crystals which become suspended in the fluid Eventually a film will form on the surface and
62. n EasyKey door with its key 3 Note position of line filter input and output wires See EasyKey Electrical Schematic page 31 Dis connect wires and remove line filter 2141 from bracket 214m See FiG 16 4 Install new line filter 2141 Reconnect wires in posi tions noted in step 3 5 Close and lock EasyKey door with key 6 Turn on power at main circuit breaker 7 Turn EasyKey power on to test operation Replacing Power Switch 1 Follow Before Servicing page 38 2 Unlock and open EasyKey door with its key 3 Note position of power switch wires See EasyKey Electrical Schematic page 31 Disconnect wires and remove switch 202 FIG 16 4 Install new power switch 202 Reconnect wires positions noted in step 3 5 Close and lock EasyKey door with key 6 Turn on power at main circuit breaker 7 Turn EasyKey power on to test operation Power Supply Outputs Vdc FiG 16 Power Supply 40 214f 202 Power Supply Inputs Vac 2141 214m Input Power Terminal Block TI13349b 312780F Service 312780F 41 Service Replacing Barrier Board To avoid damaging circuit board when servicing wear Part No 112190 grounding strap on wrist and ground appropriately 1 Follow Before Servicing page 38 2 Unlock and open EasyKey door with its key 3 Disconnect the cables and connectors from J1 J4
63. ocation Class Div 1 Group D or Zone Group IIA T3 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 312780F 9 Warnings SKIN INJECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment 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 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 ret
64. oid damaging circuit board when servicing wear p Part No 112190 grounding strap on wrist and ground After Servicing appropriately After servicing the system be sure to follow the Start Up checklist and procedure in the ProMix 2KS 1 Flush system and follow Pressure Relief Proce Operation manual dure page 12 if service time may exceed pot life time and before servicing fluid components 2 Close main air shutoff valve on air supply line and on ProMix 2KS 38 312780F Servicing EasyKey Updating Software To update software upload new software from your PC using the basic web interface See manual 313386 NOTE If using the Graco Gateway in your system dis connect its cable from the EasyKey before updating the ProMix 2KS software Replacing Display Board or Graphic Display NOTICE To avoid damaging circuit board when servicing wear Part No 112190 grounding strap on wrist and ground appropriately 1 Follow Before Servicing page 38 2 Unlock and open EasyKey door with its key 3 Note position of all external connections J4 J5 J6 J7 J8 J9 J10 to display board then unplug the connectors See FIG 8 page 20 4 Remove 4 screws 210e and the display board assembly 210b 210c Fic 15 210b 12554 210 210 Fic 15 Display Interface 312780F Service 5 Disconnect graphic display power cable J1 from the display board 210c
65. oting Table 4 Fluid Station Control Board Diagnostics Connector LED Pin Nos Signal Description Diagnosis Turns on when power is supplied to the board 019 n a Communication yellow Turns on when board is communicating with EasyKey Blinks heartbeat during normal operation mea F1 n a Heplaceable Fuse for Flow Meter A Check fuse condition if Flow Meters Dose Valves and B Dose Valve and B Sole and Purge Valves are not working noids and Purge Valve A and B Solenoids noids 3rd Purge Valve Solenoid ing and Gun Flush Box 1 and 2 Sole noids F2 n a Replaceable Fuse for Solvent Check fuse condition if Solvent Meter Dump Valves Meter Dump Valve A and B Sole 3rd Purge Valve and Gun Flush Boxes are not work 312780F 27 Troubleshooting Color Change Board Diagnostics See FIG 13 and Table 5 to troubleshoot the color change board Also see the System Electrical Schematic on pages 32 and 33 To replace the color change board see manual 312787 J8 Pin 1 D33 D31 D29 J15 Pin 1 D41 D35 D27 J14 Pin 1 D30 D28 D36 D8 U51 gr R82 _ m mm mu NI N d N a mmm rg 1444 90 E 62 sed LHL pi Slr EL TE
66. qualified electrician check resistance between each ProMix component and true earth ground If resis tance is greater than 1 ohm a different ground site may be required Do not operate the system until the problem is corrected 12 Pressure Relief Procedure NOTE The following procedures relieve all fluid and air pressure in the ProMix 2KS 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 and B 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 and B dose valve solenoids to relieve pres sure See FIG 5 NOTE If a Dose Time alarm E 7 E 8 occurs clear the alarm 3 Do a complete system purge following the instruc tions under Purging Using Recipe 0 in your system Operation manual 4 Shut off the fluid supply to the solvent purge valve SPV and the air supply to the air purge valve APV FiG 4 5 With the gun triggered push the manual override on the A and B purge valve solenoids to relieve air and solvent pressure See FiG 5 Verify that solvent pressure is reduced to O NOTE If a Purge Volume alarm E 11 occurs clear the alarm 312780F Systems with Color Change and without Dump Va
67. rast Dimmer Switch turn by hand 21 Troubleshooting Discrete I O Board Diagnostics See FIG 9 and FIG 10 to troubleshoot the Discrete I O board Also see the System Electrical Schematic on pages 32 and 33 Terminal Strip Detail RS485 Integration A RS485 Integration B RS485 Integration Ground RS485 Network A RS485 Network B RS485 Network Ground Flow Control Calibrate Gun Trigger Digital Common INPUTS Remote Stop Alarm Reset General Alarm Digital Common OUTPUTS Potlife Alarm Flow Rate Analog In aoaaa aa a e ea a e eea Flow Rate Analog Common 12958 Display Board Barrier Board Terminal Strips see detail above i Discrete I O Board see FIG 10 E TI12496b FiG 9 EasyKey Control Boards and Terminal Strips 22 312780F Troubleshooting eo N x 6 55 2 2 2 2 O S S S S FE O O O o O a Q O 0 o 0 0 V DIGITAL 29 gt O C Digital Output Common Power r c Flow Rate Ala
68. re 4 Twelve Valves low pressure ProMix 2KS Intrinsically Safe IS System Install EasyKey Interface IS Associated Apparatus for use in non hazardous location with IS Connection to Smart FMO8ATEX0074 APPROVED Fluid Plate IS Intrinsically safe A t f 1 Label Location on PRIATS equipmemtorcassh 00 Class Division 1 Group D T3 Label Location RoboMix Panel CC Ta 20 C to 50 C Hazardous Locations on EasyKey meee Read Instruction Manual 12512 AIR WPR Warning Substitution of components 12418 impair intrinsic safety PARTNO SERIES SERIAL b 6 Digit Configured Part No is listed here YR e GRACO INC P O Box 1441 MP bar PSI 1 5 Minneapolis MN MAX TEMP 50 C 122 F GRACO 55440 U S A 312780F 63 Parts Part No RDOOON to RD242Y includes EasyKey with LCD display 2 23 25 A483 ES Meters 8 and 9 are underneath the RoboMix cover See page 72 for location A Items 474 483 and 484 are part of the RoboMix Fluid Station Se
69. ride FIG 5 6 See Fic 3 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 7 Press and hold the dump valve A solenoid override FIG 5 8 Press and hold the A side color solvent solenoid override until clean solvent comes from the dump valve then release 9 Press and hold the dump valve B solenoid override FIG 5 10 Press and hold the B side catalyst solvent solenoid override until clean solvent comes from the dump valve then release 11 Shutoff the solvent supply to the color catalyst change stack solvent valves 12 Press and hold the A and B solvent solenoid over rides and dump valve overrides until solvent flow from the dump valves stops 13 Pressure Relief Procedure
70. rm Output Flow Calibrate Active E lt lt a g ak NO EU ES lt 5 N C Purge Recipe Change Active Output Fill Active VRE 011 Mix Ready Output ea U13 VEZ Mix Active Output OOO RN1RN2 RNS Digital Output Common Power 5 C4 Recipe Change Input Recipe Bit 5 Input Recipe Bit 4 Input Recipe Bit 3 Input Recipe Bit 2 Input PO J 03 Recipe Bit 1 Input A DIQTAL IN AD oi e o U3 C 2 84 54 8 U5 1206 2 972741451 7 E Recipe Bit O Input U4 017 3 Digital Input Common 4 Mix Input Purge Input Job Complete Input Spare Digital Common External Color Change Ready Fic 10 255766 Discrete I O Board 312780F 23 Troubleshooting 24 312780F Fluid Station Control Board Diagnostics Troubleshooting See FIG 11 and Table 4 to troubleshoot the fluid station control board Also see the System Electrical Schematic on pages 32 and 33 J4 D19 D18 F1 Fuse F2 Fuse Cp e D15 2 74 ie Og 3 9 gt Salo x e
71. rom bottom of meter mounting plate 438 with socket wrench Fic 32 4 Disconnect the fluid line from the meter inlet P 5 Disconnect the meter outlet H fitting from the dose valve 6 Service meter as instructed in the meter manual 308778 Installation 1 Screw meter outlet fitting H securely onto the dose valve inlet using a wrench NOTE To avoid leakage secure the meter outlet fitting H to the dose valve before connecting the meter to the plate 438 2 Secure meter M to plate 438 with screws and washers 442 440 NOTE You must assemble the meter sensor to the meter body before connecting the cable to the sensor for the meter to function properly Connect cable to cable connector CC FIG 32 4 Connect fluid line to meter inlet fitting P PWR RED SIG WHITE J3 PWR RED SIG WHITE PWR RED Ju SIG WHITE O WN TERMINAL 5 Calibrate meter as instructed in ProMix Operation manual 6 Place board into its correct position and reassemble RoboMix Panel COM BLACK r NHIELD GRN C COM BLACK SHIELD GRN COM BLACK x SHIELD GRN GROUND Connectors on Fluid Station Control Board 33 Meter Cable Schematic 54 12646 Fic 32 G250 G250HR Flow Meters 3X CABLE E d
72. ses 312780F Service 2144 F2 1 45 Power to Fluid Station 2144 43 Service Replacing Air Filter Element Removing a pressurized air filter bowl could cause serious injury Depressurize air line before servicing Check the 5 micron air manifold filter daily and replace element 317a Part No 114228 as needed 1 Close main air shutoff valve on air supply line and on unit Depressurize air line 2 Remove filter cover A See FIG 19 3 Unscrew filter bowl B 4 Remove and replace element 317a 5 Screw filter bowl B on securely Install cover A 13069 112691 Fic 19 Replacing Air Filter Element 44 Wall Mount Fluid Station Preparation NA 1 Follow Before Servicing page 38 2 Loosen the 4 screws 307 then remove the Wall Mount Fluid Station cover 322 FIG 20 312780F Service 314 343 O N 9 315 314 N O C 301 See Detail Below 1112425 318 332 317 5 Q 5 S 5 9 12426 Fic 20 Wall Mount Fluid Station 45 312780F Service Replacing Control Board To avoid damaging circuit board when servicing wear Part No 112190 grounding strap on wrist and ground appropriately 1 Follow Preparation page 44 2 Disconnect fiber optic wires J4 J6 and all cables 41 43 45 47 48
73. sure See FIG 2 ProMix RoboMix Systems Maximum Working Pressure RoboMix Panel Options all 190 psi 1 31 MPa 13 1 bar Flow Meter Fluid Flow Rate Range G250 Meter 75 3800 cc min 0 02 1 0 gal min G250HR Meter 38 1900 cc min 0 01 0 50 gal min Standard Features EasyKey with LCD Fiber Optic and Power Cables 50 ft 15 25 m Remote Fluid Station 25 cc Integrator Discrete I O Board A Side Dump Valve if color valve s selected B Side Dump Valve if catalyst valve s selected Flow Control with 15 ft 4 57 m Cable if selected Basic Web Interface 312780F 7 Accessories Accessories 15V964 Gateway Profibus Communication Kit 5 m 15G614 Flow Control Extension Cable 40 ft 12 2 m 8 312780F Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion point symbol alerts you to a general warning and the hazard symbols refer to procedure specific risks When these symbols appear in the body of this manual refer back to these Warnings Product specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion Use equipment only in well ventilated area Eliminate all ignition sources such as pilot lights cig
74. the cable to the sensor for the meter to function properly 3 Connect meter cable CC See 23 Coriolis Meter 4 Connect fluid line P 1 Follow Before Servicing page 38 5 Calibrate meter as instructed in ProMix Operation 2 To remove and service the Coriolis meter see man manual ual 313599 G3000 or G3000HR Meter Removal 1 Follow Before Servicing page 38 2 Unscrew cable connector CC from meter FiG 23 3 Unscrew four 1 4 20 screws MS holding the meter mounting plate MP FiG 23 4 Unscrew fluid line from meter inlet P 5 Unscrew meter M from dose valve connector H FIG 23 6 Service meter as instructed in the meter manual 308778 T112653a Installation Fic 23 G3000 G3000HR Flow Meters 1 Screw meter M securely onto the dose valve con nector H using a wrench NOTE To avoid leakage secure the meter M to the dose valve connector H before connecting it to the fluid station 3X CABLE PWR RED COM BLACK FLOW A SIG WHITE PWR RED Cable Length COM BLACK FLOW SIG WHITE 241799 5 1 52 SHIELD GRN Y PWR RED COM BLACK FLOW METER SOLVENT SIG WHITE SHIELD GRN GROUND TERMINAL r G 241800 16 406 mm 241801 13 in 330 mm
75. ts are marked with a sym bol for example 6021 For best results use all parts in the kit 1 Follow Preparation above 2 Remove the four screws 605 and the nut 601 from the underside of the air plate 607 Separate the air plate and fluid plate 3 Unscrew the pressure sensor 620 from the fluid plate 606 NOTE If you are only replacing the pressure sensor kit 15G867 skip to step 6 4 Remove the plug 615 and o ring 604 from the top of the fluid plate 606 Remove the parts of the dia phragm assembly 613 610 609 612 617 616 Hemove and discard the dowels 623 5 Reassemble the diaphragm assembly using the new parts from the kit Be sure the AIR SIDE of the diaphragm 617 faces down Torque the nut 601 to 8 10 in Ib 0 9 1 1 Nem 312780F Service 6 Install a new o ring 602 on the pressure sensor 620 and screw the sensor into the fluid plate 606 7 Reinstall the fluid plate on the air plate Be careful not to pinch the pressure sensor cable Torque the screws 605 to 30 40 in Ib 3 4 4 5 Nem 8 Reconnect the three cables to J1 J2 and J4 on the circuit board 618 Fic 36 9 Reattach the air plate 607 to the housing 61 1 Torque the screws 605 to 30 40 in Ib 3 4 4 5 Nem 10 Reattach the flow control cable and all air and fluid lines Servicing the Flow Control Board 1 Follow Before Servicing page 38 2 Remove the four screws 605 holding the bracket 6

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