Graco 312777E User's Manual
Contents
1. 212 d 203 ane TT 2141 a 214e N 214j 207 205 206 204 215 221 211 213 223 206 T113070b 52 312777E 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 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 214 214a 214b n a 255 86 n a 214c 214d 214e 214f 214g 214h 214j 214k 117526 119257 114095 121314 n a n a n a n a 312777E Description CONTROL BOX with display SWITCH power LATCH includes item 3a 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 e MEMBRANE GRAPHIC display BOARD EasyKey display not part of kit PLATE 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 40 for fuse loca tion COVER e SPACER e BAR2. ALM WOWER ion 15 40 14 8 11 7 2 35 T p 9 1 7 8 568585858858858885886 U4 wN un S R5 TP2 o TP3 7 255767 EasyKey Display Board 20 2 Analog In Signal 2 Analog In Common Reset Alarm Input Common Output Common General Alarm Gun Trigger Flow Control Calibrate 12924 BK885 CR1220 Battery 12 5 mm lithium coin D11 312777E Troubleshooting Table 4 EasyKey Display Board Diagnostics Em Indicator Description Graphic Display Backight 8 RibbonCabeioMembane inputs and Outputs 96 00 ram Fiber Optic Cable Input black J8 Fiber Optic Cable Output blue J1 J4 J5 J6 J7 J8 312777E 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 Contrast Dimmer Switch turn by hand 21 Troubleshooting 22 312777E Fluid Station Control Board Diagnostics
3. gt CS 1 Close main air shutoff valve on air supply line and X 2 unit Depressurize air line 317a 13069 2 Remove filter cover A See FIG 17 8 X 3 Unscrew filter bowl B 4 c 4 Remove and replace element 3172 5 Screw filter bowl B on securely Install cover A C Des gt N SS HO 112691 17 Replacing Air Filter Element 312777E 41 Service Wall Mount Fluid Station Preparation 1 Follow Before Servicing page 36 2 Loosen the 4 screws 307 then remove the Wall Mount Fluid Station cover 322 FIG 20 Servicing Air Flow Switch 1 Follow Preparation above 2 See Fic 18 Disconnect the air flow switch AFS wires from J1 pins 1 4 on the Control Board Dis connect the air lines Remove the air flow switch and hardware from the side of the fluid station 3 Install a new air flow switch Connect the wires to J1 pins 1 4 Reconnect the air lines A Connect AFS 1 wires to terminals 1 and 2 at J1 of Fluid Station Control Board PP Connect AFS 2 wires to terminals 3 and 4 at J1 of Fluid Station Control Board Fluid Station Control Board 13347 Fic 18 Servicing Air Flow Switch 42 Servicing GFB Pressure Switch 1 Follow Preparation page 42 2 See Fic 19 Disconne
4. L c gt gt oO 2 gt o 2 955 9549 Uld V 9A EA 4 PIE Uld 6 eA eA V 9014 oJeds J8 J15 J14 FiG 9 255765 Fluid Station Control Board Input Output Connections 312777E 24 Troubleshooting Table 5 Fluid Station Control Board Diagnostics Connector ED and Pin Nos Signal Description Diagnosis 015 J1 1 amp 2 Air Flow Switch 1 Turns on when gun 1 is triggered 1 5 amp 6 Solvent Flow Switch Turns on when solvent is flowing 1 9 amp 10 Gun Flush Box 2 Pressure Switch on when a is Gun Flush Box 2 J10 Turns on when power is supplied to the board Communication yellow Turns on when board is communicating with EasyKey 7 020 Blinks heartbeat during normal operation J15 1 amp 2 Purge Valve C Water Purge 14 4 4 5 Purge Valve A Air Purge 9 0 18 384 46 J1 7 amp 8 Turns on when gun is Gun Flush Box 1 n a Replaceable Fuse for Flow Meter A Check fuse condition if Flow Meters Dose Valves and Dose Valve A B Sole Purge Valves are not working noids and Purge Valve A and B Solenoids Dm oy 4 0 nuo oH Replaceable Fuse for So
5. 58 312777E Related Manuals Component Manuals in English 313386 Basic Web Interface Advanced Web Interface 406799 15V256 Automatic System Upgrade Kit 406800 15V825 Discrete I O Board Kit 312777E 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 for label locations EasyKey and Fluid Station Label ATEX Certificate is listed here 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 PARTNO SERIES MFG YR GRACO INC P O Box 1441 Minneapolis MN GRACO 55440 U S A FMO8ATEX0074 APPROVED Intrinsically safe equipment for Class I Div 1 Group D T3 Ta 20 C to 50 C C AIR WPR SERIAL MPa bar PSI MAX TEMP 50 C 122 F Fluid Station Label ProMix 2KS SERIES SERIAL MFG YR FLUID PANEL MAX AIR WPR 7 7 100 PART Intrinsically safe equipment MPa bar PSI for Class I Div 1 Group D T3 G GRACO INC US Ta 20 C to 50 C APPROVED Install per 289833 FMO8ATEX0073 P O Box 1441
6. C40 5 5 mmm J3 j 52 Meter A Input Ta WM t J5 E Flow Control Ha of ae 8 i iz i 5 49 8 SOLENOID OUTPUT Solenoid Output Dose Valves A and B J14 Solenoid Output Air Purge Valve and Solvent Flush Valve 21 255765 Fluid Station Control Board 44 J8 Solenoid Output Dump Valve B Gun Flush Boxes A and B J15 Solenoid Output 3rd Flush Valve Dump Valve A 312777E 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 9 and Sche matic Diagrams page 30 To replace a single solenoid 1 Follow Preparation page 42 and shut off power at main circuit breaker 2 Disconnect 2 solenoid wires N from control board 302 See FiG 22 and System Electrical Sche matic page 33 3 Unscrew 2 screws P and remove solenoid 313 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 Fuses Replacing a fuse F1 or F2 with a non Graco fuse voids the IS system safety approva
7. 412 0 z CLR 26 COM mE 14 1829 COM lae 33 Schematic Diagrams Tubing Schematic A6 Tet 2 4 13857 B3 B5 B7 1 GFB2 C GFB1 A T113862a 5 co ATOM 1 21 GFB1 S GFB2 S 1 ATOM 2 13863 113861 113860 1 312777 Schematic Diagrams Table 8 Tubing Chart Color Description Starting Point in mm Tube Ref No A A A A Green Dose A On 5 32 4 336 B3 B5 13 5 32 4 lt C2 NO 5 32 4 5 32 4 Included in optional Dump Valve Kit lt C2 NO LN MO A _ A _ DA LN s Bro s nuni 334 Dose B Off 5 32 4 Natural Solenoid Air Supply Natural Gun Flush Box 1 Pressure GFB1 A GFB1 A Switch Signal Natural Gun Flush Box 2 Pressure GFB2 A GFB2 A 5 32 4 Switch Air Natural Gun Flush Box 1 Trigger GFB1 C GFB1 C 5 82 4 Air Natural Gun Flush Box 2 Trigger GFB2 C GFB2 C 5 82 4 Air gt gt Point A2 A4 A6 A8 DA B1 B3 B5 B7 13 H 3 3 6 5 32 4 N IK Included in optional Gun Flush Box Kit 15V826 Natural Gun Flush Box 1 Sup
8. OPTIONAL J Jan PUMP B OPTIONAL W GFB 1 VALVE OPTIONAL 2 VALVE LIT OPTIONAL D 1 4 TUBE FLUSH AIRTO FLUID INLET COLOR COLOR CHANGE VALVE CONTROL STACKS COLOR 1 COLOR2 COLOR3 COLOR4 COLORS COLOR 6 COLOR 7 COLOR 8 COLOR SOLVENT COLOR 9 COLOR 10 COLOR 11 COLOR 12 CATALYST 1 CATALYST 2 St 17 CATALYST 3 CATALYST 4 CATALYST SOLVENT COLOR 13 COLOR 14 COLOR 15 COLOR 16 COLOR 17 COLOR 18 COLOR 19 14 COLOR 20 COLOR 21 COLOR 22 COLOR 23 COLOR 24 COLOR 25 COLOR 26 COLOR 27 COLOR 28 COLOR 29 COLOR 30 MAC 36 SERIES SOLENOID VALVES 312777E Schematic Diagrams EasyKey Electrical Schematic 31 Sd R d QuvosAv1dsia Syry lt 3 If Haltlivg 0v18 NOWWOD es GasANn Ped qasaun 575018 TWNIWYSL FR RE q3snNn unus aasnwn 91 NMOU8 qasnwn DMY 9L Q3H 81 034 GND DMY 81 4219 DMY 91 3 NUS NI 104110 DMY 81 038 024 GAvC NOWWOD OMY BDV IG Ue CC 3LIHWJOV T8 038 E CC3LIHWDOV 41451 312777 Schematic Diagrams System Electrical Schematic NOTE The electrical schem
9. Gun Flush Box in Coriolis B low pressure high pressure its 1 8 in Coriolis A TONES G3000HR pressure G3000HR A and 2 1 8 in Coriolis high pressure 1 8 in Coriolis A fee Valves and B high pressure ProMix 2KS Intrinsically Safe IS System Install Electronic Proportioner per IS Control Drawing No 289833 EasyKey Interface IS Associated Apparatus for use in non hazardous fu location with IS Connection to Smart 74 APPROVED Fluid Plate IS Label Location Apparatus for use in Label Location Class Division 1 G D T3 on Fluid Station 2 EasyKey 12423 2998 Read Instruction Manual TI12418a MAX AIR WPR Warning Substitution of components Maximum Fluid 7 7 100 may impair intrinsic safety Workin YI SERIES SERIAL g Pressure Configured Part Number is listed here GRACO INC P O Box 1441 MP bar PSI Minneapolis MN MAX TEMP 50 C 122 F GRACO 55440 U S A FiG 1 Identification Label 4 312777E System Configuration and Part Numbers Hazardous Location Approval Models using G3000 G3000HR or intrinsically safe Coriolis meter for both A and B meters are approved for installation in a Hazardous Location Class Div Group D T3 or Zone Group IIA T3 Maximum Working Pressure Maximum working pressure rating is dependent on the fluid compo
10. 120 7 Minneapolis 0359 Exa NATS eraco 55440 U S A Artwork No 293538 13581 Certificate is listed here EasyKey Label POWER REQUIREMENTS AMPS 2 AMPS MAX ProMix 2KS PART NO SERIES YR Artwork No 293467 Intrinsically safe connections for Class Div 1 Group 50 60 Hz US Ta 20 C to 50 C 7 Minneapolis MN APPROVED Install 289833 9 2 G 55440 U S A i Ex ia Um 250 V FMO8ATEX0072 C 32 GRACO INC P O Box 1441 13582 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 one digit from each of the following six categories depending on the configuration of your system Manual Control and Display A and B Meter Color Valves Catalyst Valves Applicator Handling D EasyKey with LCD 0 No Meters No Valves No Valves 1 One Air Flow Display 33000 A and B single color single catalyst Switch Kit G3000HR A and Two Valves 1 Two Valves Two Air Flow B low pressure low pressure Switch Kits 1 8 in Coriolis A Valves 2 Valves a Gun Flush Box and G3000 B low pressure low pressure 3000 A and 1 8 2 Valves 3 4
11. BLK B 8 DIGITAL OUTPUT COMMON POWER 1 2 GUN TRIGGER WHT 2 1 DIGITAL OUTPUT COMMON POWER 12 3 DIGITAL IN COMMON RED 3 2 SPECIAL OUTPUT 1 13 4 REMOTE STOP GRN 4 3 SPECIAL OUTPUT 2 2 0 4 SPECIAL OUTPUT 3 5 ALARM RESET BRN i 5 14 6 ALARM OUTPUT BLU 162 5 SPECIAL OUTPUT 4 15 i 6 DIGITAL OUTPUT COMMON POWER 16 7 DIGITAL OUTPUT COMMON ORG i 7 17 8 POT LIFE YEL XM 8 18 9 FLOW RATE ANALOG IN PUR 9 10 FLOW RATE ANALOG COMMON GRAY i 110 I O HARNESSES 24 YEL GRAY BEACON TERMINAL RS485 INTEGRATION A WHT BLU BLOCKS RS485 INTEGRATION B BLU WHT RS485 INTEGRATION GROUND SHIELD RS485 NETWORK A WHT ORG RS485 NETWORK ORG WHT RS485 NETWORK GROUND SHIELD FILL ACTIVE CABLE J7 FOIN BLK 8 L FOOUT BLU WEB SERVER MODULE 32 312777E 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 FLUID PANEL CONTROL BOX CIT LU al gt 1 UNUSED 2 LUNUSED J10 3 UNUSED 4 UNUSED 5 U
12. No 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 317a 318 319 320 321 322 323 324 325 327 Part No 256529 255765 n a 119257 119162 116773 113783 15R668 C06061 15U533 112781 114263 121374 111987 114669 n a 114124 114228 116343 100985 101345 120685 15U507 100139 552183 15U510 n a 312777E 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 position 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 50 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 intrinsically 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 BRACKET valve mount COVER fluid station Qty RA AB iN Na B Ref No 328 329 330 331 332 334 335 336 337 338 339A 340A 341 342 3439 Part No 121072 15D320 104644
13. 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 312777 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2008
14. 4 Solenoid cable or fluid station Check voltage level to solenoid by pulling solenoid connector and checking control board failure 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 5 Blown fuse 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 J15 3rd Purge Valve Dump Valve A and B and GFB 1 and 2 solenoids 312777E 17 Troubleshooting Fluid Manifold Troubleshooting See 5 To remove the fluid manifold see page 47 See manual 312781 for complete information on the fluid manifold ASL ACV DVA OFF DVB OFF BCV BSL SSL Fl DVB ON LIB MB Sa SCV MA DVA DVA ON ON APV OFF SVA SVB SPV ON SPV SPV OFF RVA SM RVB TI12556b Key Component A Side Component B Side Mixed Material MA Component A Meter MB Component B Meter SM Static Mixer DVA Component A Dose Valve DVB Component B Dose Valve Fl Fluid Integrator 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 a
15. EasyKey power on to test operation Replacing Power Switch 1 Follow Before Servicing page 36 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 14 4 Install new power switch 202 Reconnect wires in 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 14 Power Supply 38 Power Supply Inputs Vac 2141 214m Input Power Terminal Block TI12578b 312777E 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 36 2 Unlock and open EasyKey door with its key 3 Disconnect the cables and connectors from J1 J4 and J5 FIG 16 4 Using the security tool provided Part No 122239 remove 2 screws 214k and the cover 214b See 15 5 Noting their location remove 5 screws 214g 214h from the barrier board 214a Do not remove the screw noted in Fic 16 Remove board 6 Apply thermal compound to the heatsink Z on the back of the new barrier board 214a See FIG 16 7 Install the new barrier board with the 5 screws 214g 21
16. Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Hevision E June 2014
17. Solvent Purge Valve Air Purge Valve Static Mixer Fluid Integrator Air Purge Valve Air Supply Tube 13 Pressure Relief Procedure 14 312777E Troubleshooting Troubleshooting Table 1 System Alarm Codes Communication Error Alarm Potlife Alarm 2 Ratio High Alarm Follow Pressure Relief Procedure page 11 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 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 312777E 15 Troubleshooting Solenoid Troubleshooting NOTE Refer to the Schematic Diagrams page 30 IA NX ooooonjooooooooon OOOOO Valve Overrides IN mY Dose Valve A Solenoid Purge Valve B Solenoid Dose Valve B Solenoid Purge Valve A Solenoid Fic 4 Fluid Station Board and Solenoids 16 1 e Power 1 can Fiber Optic Dump Valve A Dump Valve B Optional Solenoid GFB 1 Locations GFB 2 3rd Purge Valve Solenoid 1126520 3127
18. Troubleshooting See FIG 8 FIG 9 and Table 5 to troubleshoot the fluid station control board Also see the System Electrical Sche matic on pages 32 and 33 J4 019 018 1 Fuse 2 Fuse J6 Fiber Optic Output blue Fiber Optic Input black D15 a z 8 ho E 00 D45 EE _ 2 3 3 5 I3 TLE D16 5 E Q z 01 2 9o S e NS 7 ww E 30 D46 d 5 228 in 9 E dc 1 1 25 017 5 Hl D17 EIET M m E Anni C26 He 28 N R79 N R74 2 a E g52 R78 R28 2 2 cB4G 82 C24 S E on s imul a 8 227 TE ae 2 c7 nnn 5 5 4 C1 044 2 5 PRGRM HOR ROS Ww 8 N as 28883 4 5 o N S 5 SEN FB20 5 bafi u 2 020 E e ke 69 58 X D43 TY OI ato NO OUFJPUUTSSOLENOID OUTPUTAS SOLENOIN Nas 29 SR D28 D30 Fic 8 255765 Fluid Station Control Board I
19. ground 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 or Lll OO Ref No 214 214m 215 2164 218 220 221 223 224 Part 123823 123824 15V280 15G569 15R642 n a 198165 116343 15G869 Description e FILTER line single phase 110 250 V BRACKET line filter HARNESS connection LABEL EasyKey inputs HARNESS wire SOFTWARE application CONNECTOR RJ45 with bulk head fitting SCREW ground M5 x 0 8 CABLE ethernet CAT5 6 ft 1 8 m to make web interface connection to a computer Parts A Replacement 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 Length ft m 15U532 15V205 15V206 15V207 15V208 2 15U533 5 0 0 15 15213 15 25 Standard power and booth control 100 6050 Fiber Optic Cables 15D320 Length 50 1925 53 Parts Wall Mount Fluid Station 314 315 See Detail Below 112425 Control Board Fuses 343 324 331 312 112426 11126526 54 312777 Wall Mount Fluid Station NOTE Parts are shown on page 54 unless noted Ref
20. 0 Plug all connectors into display board 210c FIG 13 Confirm that the cables do not pinch when open ing or closing the door 11 Locate the battery on the board see FIG 7 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 36 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 FIG 14 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 37 Service Replacing Line Filter 1 Follow Before Servicing page 36 2 Unlock and open 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 14 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
21. 121628 223547 n a 15U679 n a n a 16J457 186620 15W775 C19798 104640 123690 Description MUFFLER CABLE fiber optic twin 50 ft 15 25 m see page 50 for location PLUG screw 10 32 x 5 32 in 4 mm SCHREW machine self seal ing 4 40 x 1 4 in 6 mm WIRE ground 25 ft 7 6 m TUBE nylon to connect air manifold 335 to elbow 31 1 at solenoid manifold 308 1 4 in 6 mm OD 2 5 ft 0 76 m MANIFOLD air 3 8 npt m x 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 air to turn valves off 5 32 in 4 mm OD four 2 ft 0 6 m lengths TUBE nylon for purge air sup ply 1 4 in 6 mm OD 25 ft 7 6 m includes caution label 626413 LABEL symbol ground LABEL warning SCREW cap socket hd 1 4 20 x 3 8 in 10 mm GASKET FUSE 125 mA Parts Qty 1 1 A R A R A R 3 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 55 Parts Color Change Accessory Kits Low Pressure Color Change Kits Color Change Catalyst Change Control Module Valve Stack 11 Valve Stack 12 Kit Description 10 see 312787 see 312783 see 312783 High Pressure Color Change Kits Color Chang
22. 4h 214k 15 Replacing Barrier Board 312777E Service 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 TN AN m EM MEME 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 or F4 from its fuse holder FiG 16 3 Snap new fuse into holder 4 Follow Replacing Barrier Board steps 8 12 11126496 2141 2140 214 39 Service J4 Power to Display Board J1 Power In 2149 214g F2 F4 F1 F3 214h J5 Power to Fluid Station 214g Do not remove this screw 214h Z o N 11 o o o o o o N Apply thermal compound M to surface of heatsink Z o o o oon Back of Barrier Board showing Heatsink 2 Fic 16 Barrier Board Connectors and Fuses 40 312777E 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 lt gt
23. 77 Troubleshooting NOTE Refer to the Schematic Diagrams page 30 If the dispense or purge valves are not turning or off correctly it could be caused by one of the following Table 2 Solenoid Troubleshooting 1 Air regulator pressure set too Check air pressure 80 90 psi 550 630 kPa 5 5 6 3 bar is commonly used high or too low 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 Visually inspect air and electrical lines for kinks damage or loose connec connections loose tions Service or replace as needed 3 Solenoid failure Manually operate the valves by removing the Fluid Station cover and press ing and releasing solenoid valve override buttons FIG 4 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
24. ALOG OUT WHT PRESS GRN 12 RED GND BLK CHASSIS BARE 1 5 METERS Schematic Diagrams CLR 8 CLR7 CLR6 CLR 5 CLR 4 CLR 3 CLR 2 CLR 1 SOL CLR CLR 21 CLR 20 CLR 19 CLR 18 CLR 17 CLR 16 CLR 15 CLR 14 CLR 13 MANIFOLD raoc l AL DC 12VDC com ERES 2 2 Ow Un Ov Un gt 4ADC ose REED 7 MANIFOLD 1 HADC ae HEUS aa gt E Ov Un 12 1 SIG RED 2 COM BLK 1 PRESSURE 2 COM RED 3 EX WHT d PRESSURE BLK SHIELD BARE 14 5 2 3 COLOR BOARD 1 COLORS 1 THRU 12 CATALYST 1 THRU 4 7 6 i Iz CLR9 CLR 10 J8 J9 3 1200 et 1 sane a ps 6 COM 5 O oTo 4 COM 3 CAT4 2 COM O 1 p 6 COM 5 0 T m 4 HZ 2 1 12VDC mar D SOLCAT 14523 6 STD 14523 COLOR BOARD 2 COLORS 13 THRU 30 5 zA CLR 22 emk 1 COM Lin 24 e SON THAT Jans T
25. Diagnostics Connector Board 1 Signal Board 2 Signal LED and Pin Nos Description Description Diagnosis Board OK Board OK Blinks heartbeat during normal operation n a Communication Communication Turns on when board is communicating with ProMix yellow yellow 2KS 027 J15 8 amp 6 16 Power Turns on when power is supplied to the board 028 14 384 Color 14 Color 17 D27 through D46 turn on when 2KS sends Color 13 a signal to actuate the related solenoid valve Replaceable n a n a Check fuse condition if there is no power to the Fuse board or if communication is interrupted between the fluid station and the color change module m 027 DN 0 bor 0 312777E 29 Schematic Diagrams Schematic Diagrams System Pneumatic Schematic AIR INPUT 30 PURGE AIR 3 8 AIR FILTER MANUAL DRAIN 5 MICRON WALL MOUNT ONLY AIR INPUT MANIFOL to TO MANIFOLD 1 4 TUBE CONTROL AIR AIR EXHAUST MUFFLER MANIFOLD 12 VDC _ 4 WAY SOLENOID 4 WAY 5 1 4 WAY 4 WAY SOLENOID AIR EXHAUST MUFFLER 12VDC 3 WAY SOLENOID aq 12 VDC 3 WAY SOLENOID 7 lt Ko M LAM ue 3 WAY SOLENOID lt gt vee DOSE A VALVE PURGE A VALVE PURGE C VALVE OPTIONAL lt H h DUMP A
26. 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 additional technical data 312777E 57 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and
27. NUSED 6 L UNUSED SHIELD GRN 1 8 RED BLACK HAZARDOUS AREA 3X CABLE 1 RED BLACK 0 WHITE L RED SIG WHITE 020 WHITE SHIELD GRN GROUND TERMINAL 6 STD 12VDC 3 WAY SOLENOID 12 VDC 4 WAY SOLENOID Emm BER yon 6 FLOW METER SOLVENT 3 100 OPTIONS 3 RD BLK 2 p 1 5 SHIELD BARE 4 WHT 1 TH CAN L BLU 50 STD 3 1 1 GRD BLK 3 2114 5 01200 RED 2 5 H SHIELD BARE 5 4 CANE Wit 3 1 CAN L BLU 1 Le E _ MANIFOLD 6 BLACK CS 4 4 11 80 eL gt C BLACK 1 0 0 1 2 GB 2 6 BLACK xe DUMP A 4 BLACK 0 00 09 6 BLACK 5 RED 4 BLACK 2 0 ra PURGE A 2 2 H BLA 6 C BLACK 5 RED 4 BLACK 0 0 T DOSE B 2 BLACK 20 3 O sG 3 H 26 Le AIRFLOW SWITCH 2 5 96 2 Sm e SOLVENT FLOW SWITCH BLU AM LL 1 GFB 1 PRESSURE SWITCH T ta GFB 2 PRESSURE SWITCH BLK a I a ey a 25 52 312777E V P AN
28. ProMix 2KS Manual System Part No MD0001 to MD7634 includes EasyKey with LCD display 329 N P EA ru Mo ic aug 53 Mss _ 4 47 7 3 ae Tide Jj 13b Ref A Items 310 and 329 are part of the Wall Mount Fluid Station See the parts list beginning on page 55 for descriptions 112504 Detail of Air Flow Switch and GFB Pressure Switch 13b Ref 113350 13a 50 312777 Parts Configured Digit see page 49 or part usage Description 277869 CONTROL DISPLAY EasyKey see page 52 standard see page PANEL fluid 2 lt 89695 MANIFOLD mix see manual 312781 5V350 BOOTH CONTROL includes items 6 and 7 77853 BRACKET mounting booth control 15U533 CABLE CAN intrinsically safe connects booth control to fluid station 50 ft 15 25 m KIT flow meter A none 5V804 KIT 13000 flow meter see manual 308778 5V827 G3000HR flow meter see manual 308778 5V806 KIT Coriolis flow meter see manual 313599 5V804 KIT G3000 flow meter see manual 308778 5V806 KIT Coriolis flow meter see manual 313599 5V827 KIT G3000HR flow meter see manual 308778 5V806 KIT Coriolis flow meter see manual 313599 KIT flow meter B none none 5V804 KIT G3000 flow meter see manual 308778 5V827 KIT G3000HR flow meter see manual 308778 5V804 KIT G3000 flow meter see manual 308778 5V806 KIT Coriolis flo
29. Repair Parts lt gt 7 GRACO ProMix 2KS Plural Component Proportioner EN Manual system for proportional mixing of plural component coatings For professional use only For use in explosive atmospheres except the EasyKey See page 4 for model information including maximum Important Safety Instructions working pressure Equipment approval labels are Read all warnings and instructions in this page 3 Some components shown are not included with manual Save these instructions all systems ras aH 4 P x Ji fie 0 4 PON 112504 C 0359 APPROVED x 12 6 PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 3 Equipment Approvals 3 System Configuration and Part Numbers 4 Configurator 4 Standard Features 5 ACCeSSOTIGS eee 7 Warnings rU 8 Important Two Component Material Information 10 Isocyanate Conditions 10 Material Self ignition 10 Keep Components A and B Separate 10 Moisture Sensitivity of Isocyanates 10 Changing Materials 10 GIOUNGING ov amba Ride ed 11 Check Resistance 11 Pressure Relief Procedure 11 Troubleshooting 15 Alarm e vedo uar DE abies 15
30. Solenoid Troubleshooting 16 Fluid Manifold Troubleshooting 18 EasyKey Barrier Board Diagnostics 19 EasyKey Display Board Diagnostics 20 Fluid Station Control Board Diagnostics 23 Booth Control Troubleshooting 26 Color Change Board Diagnostics 28 2 Schematic Diagrams 30 System Pneumatic Schematic 30 EasyKey Electrical Schematic 31 System Electrical Schematic 32 Tubing Schematic 34 ae Lors oe suat 36 Before Servicing 36 After Servicing 36 Servicing 37 Replacing Air Filter Element 41 Wall Mount Fluid Station 42 Servicing Flow Meters 46 Servicing Fluid Manifold 47 Servicing Color Change Module Color Catalyst Valves and Dump Valves 47 PAWS sersa LEVA Ern ied uen du eee id 49 Configurator Key 49 ProMix 2KS Manual System 50 EasyKey Controls 52 Available Cables 53 Wall Mount Fluid Station 54 Color Change Accessory Kits 56 Technical Data hoe ee he 57 Graco Standard Warranty 58 Graco Information
31. and 1 8 in Coriolis B 1 8 in Coriolis A G3000HR GS3000HR and 1 8 in Coriolis B 1 8 in Coriolis A and B ProMix 2KS Electronic Proportioner US APPROVED Intrinsically safe equipment for Class I Div 1 Group D T3 C Ta 20 C to 50 C 0359 FMO8ATEX0074 120 Ex ia MAX AIR WPR MPa bar PSI MAX TEMP 50 C 122 F No Valves 1 Two Valves 2 Four Valves Seven Valves No Valves single color single catalyst 1 Two Valves low pressure low pressure 2 Four Valves low pressure low pressure 3 Two Valves low pressure high pressure 4 Twelve Valves low pressure 5 Two Valves high pressure 6 Four Valves high 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 SERIES SERIAL GRACO INC P O Box 1441 Minneapolis MN GRACO 55440 U S A MFG YR 1 One Air Flow Switch Kit Two Air Flow Switch Kits One Gun Flush Box Kit Two Gun Flush Box Kits Label Location on EasyKey 112418 6 Digit Configured Part No 49 Parts
32. anifold 4 and mounting plate 325 with three screws 341 2 Install meters See Installation steps 1 3 page 46 3 Connect air and fluid lines 4 Calibrate meters as instructed in ProMix Operation manual 312777E Service 12654 Fic 25 Fluid Manifold Servicing Color Change Module Color Catalyst Valves and Dump Valves 1 1 Follow Before Servicing page 36 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 47 Service 48 312777E Parts Configurator Key Parts 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 Manual Control and Display A and B Meter Color Valves Catalyst Valves Applicator Handling D EasyKey with LCD 0 No Meters Display Label Location on Fluid Station 12423 Maximum Fluid Working Pressure is listed here 312777E G3000 A and B GS3000HR A and B 1 8 in Coriolis A and G3000 B G3000 A
33. atic illustrates all possible wiring expansions in a ProMix 2KS system Some compo nents shown are not included with all systems Non Hazardous Area NON HAZARDOUS AREA ew UT pem VE SSS S m SSS SSS SSS e SS m SS SSS SS SSS m m SSS eS eS SS SSS OS SS SSS SS e SS SSS SSS SS mum 7 OPERATOR INTERFACE LINE L1 FILTER DC OK 1 L1 85 250 VAC N 24VDC TOWER 2 E N ND N i SUPPLY COMMON GND LUG 8 GNDNLI 85 250 L ROCKER SWITCH UNUSED UNUSED EN UNUSED HARNESS POWER HARNESS s 412VDC I S RED BARRIER pe F PA BOARD CABLE 24VDC 50 STD 228 2532 08 25 100 OPTION TOI P DISPLAY BOARD 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 POWER DIST TERMINAL gt gt COND iE it 1 RECIPE CHANGE INPUT DISPLAY 2 INTEGRATION 3 BOARD 1 4 2 PURGE RECIPE CHG ACTIVE OUTPUT 5 3 MIX ACTIVE OUTPUT 6 MIX READY OUTPUT 6 FLOW CAL ACTIVE 9 i 7 FLOW RATE ALARM OUTPUT 10 1 FLOW CONTROL CAL
34. 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 verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If
35. ccessory SCV Solvent Meter Check Valve Fic 5 Fluid Manifold 18 312777E Troubleshooting EasyKey Barrier Board Diagnostics See FIG 6 and Table 3 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 y CN 2 w ILJ EN 21 en D5 e 9 a e 2 F4 m e 2 e 28 D4 01 815 19 ee 19 R7 TOP SILK 150303 J5 Pin 1 e 5j e o o Fic 6 255786 EasyKey Barrier Board Table 3 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 If there is no input power D5 does not light fuses F1 and F2 Graco Part No 114788 may be blown 12 Vdc Power Output to D4 turns on if barrier board is functioning If D4 does not turn on fuses 312777E 19 Troubleshooting EasyKey Display Board Diagnostics See FIG 7 and Table 4 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 a J10 RS485 T 4 ERI QO ac Z Integration Control 12923 49 JO 6 v lt 27
36. ct the pressure switch PS wires from J1 pins 7 10 on the Control Board Disconnect the air line Remove the switch and hardware from the side of the fluid station Install a new pressure switch Connect the wires to J1 pins 7 10 Reconnect the air line 4 To repair the gun flush box see manual 312784 A Connect GFB 1 wires D to terminals 7 and 8 at J1 of Fluid Station Control Board je to terminals 9 and 10 at J1 of Fluid Station Control Board A Connect GFB 2 wires 10 Me 1 Fluid Station Control Board 13347 1114162 Fic 19 Servicing GFB Pressure Switch 312777E Service 9 315 st T N O 301 303 See Detail Below 340 1112425 318 332 317 5 Q 5 5 9 12426 Fic 20 Wall Mount Fluid Station 43 312777E Service Replacing Control Board To avoid damaging circuit board when servicing wear Part No 112190 grounding strap on wrist and ground appropriately Follow Preparation page 42 Disconnect fiber optic wires J4 J6 and all cables 41 43 45 7 48 49 412 13 914 J15 from con trol board 302 Fic 21 F1 343 Hemove 4 screws 303 Remove connector jam nuts on the outside of the enclosure 301 Remove control board 302 FIG 20 Install new control boar
37. d 302 with 4 screws 303 Connect cables to control board 302 FIG 21 Insert fiber optic cable connectors into board con nectors J4 J6 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 b1 mm bend radius Replace the cover 322 Turn EasyKey power on to test operation 2 343 F O Output blue J6 F O Input black js A A am 2 ef oN 5 3 59 J10 a sz 2 Digital Input 2 NI Power Input SEE mu 20 wc 2 a R51 1 of En d S rapa Ej J11 c o 2 2 5 2 EJ Pe T Color Change Module J13 025 8 D one Bl B Bra x NL 5 Not Used E E 5 uai P fares TN 87 cua R79 pum T M P R18 9 20 8 a Re Que E J12 ORE cis Nase ER 2 Solvent Meter Input m we UE 7 P mom I R14 Eako Booth Control oc 5 PRGRM 2 9
38. d to the board J11 26 312777E Troubleshooting D2 Q6 07 o2 ade T a ilf U1 e CHASSIS GND WIRE A H 325522225 e U2 lt ma e a 2 um D6 Bs e D5 D3 R38 D4 J11 on rear of board Bottom View of Booth Control 12789 Fic 10 Booth Control Board 312777E 27 Troubleshooting Color Change Board Diagnostics See FIG 11 and Table 7 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 2 NE JI D34 D43 ae Dee gt J9 Pin 1 ee 7 034 zu D39 5 uec 5 2 3 Bee J16 Pin 1 2 D37 sue Ac FB15 s 46 E EXE G HEE 1 09 T lt S mi k D 8 E NODE CAT COL D9 Fic 11 256172 Color Change Board 28 312777E Troubleshooting Table 7 Color Change Board
39. ded 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 23000 G250 G3000HR G250HR or intrinsically safe Coriolis meter are approved for installation in a Hazardous Location Class Div I Group D or Zone Group 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 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
40. e 7 Press and hold the solvent solenoid override until solvent flow from the sampling valve stops 8 Open the A side shutoff valve SVA FIG Close the A side sampling valve RVA 12 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 11 2 Shut off all color and catalyst supplies to the valve stacks 3 Press and hold the dump valve A solenoid override FIG 4 4 See Fic 2 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 override FIG 4 6 See Fic 2 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 4 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 4 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 rid
41. e Catalyst Change Control Module Valve Stack 11 Valve Stack 12 Description 10 see 312787 see 312783 see 312783 56 312777E 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 High pressure color change 3000 psi 21 MPa 210 bar Coriolis meter 2300 psi 15 86 MPa 158 6 bar Maximum working air pressure 100 psi 0 7 MPa 7 bar eee eh eA Bess ae 75 100 psi 0 5 0 7 MPa 5 2 7 bar 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 30 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 20 5000 cps Fluid filtration user supplied 100 mesh minimum Fluid flow rate range G3000 G250 75 3800 cc min 0 02 1 00 gal min G3000HR G250HR
42. es and dump valve overrides until solvent flow from the dump valves stops 312777E Pressure Relief Procedure Oz C 5 9 E 9 Solenoid 5 9 2 5 8 Identification gt 2 2 6 Label E E olo opo isAyeye Solenoid Identification Label Solvent Solenoid Overrides Fic 2 Color Change Solenoids DVA Fl DVB MB MA 5 RVB AT 1125560 SVA SM SVB SPV Fic 3 Wall Mount Fluid Station 312777E Key MA DVA RVA SVA MB DVB RVB SVB 12826 Component Meter Component A Dose Valve Component A Sampling Valve Component A Shutoff Valve Component B Meter Component B Dose Valve Component B Sampling Valve Component B Shutoff Valve Solvent Meter accessory
43. ies Accessories 15U955 Injection Kit for Dynamic Dosing 312777E 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 symbols refer to procedure specific risks When these symbols appear in the body of this manual refer back to these Warnings Product specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion Use equipment only in well ventilated area Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground all equipment in the work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area ELECTRIC SHOCK HAZARD This equipment must be groun
44. 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 event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing
45. l Fuse Part No Description F1 F2 123690 Fuse 125 mA intrinsically safe 1 Follow Preparation page 42 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 312777E Service 302 343 TI12652b P 313 Fic 22 Replacing Solenoids and Fuse Table 9 Wall Panel Solenoids Solenoid Fe a peva 2 Devas 8 Fi Air Purge Valve 4 Solvent Purge Vave FT Optional Third Flush Valve F2 7 6 FR 7 8 FR 9 GunFlushBox2 FR 45 Service Servicing Flow Meters 2 Secure meter M and plate MP to fluid station with screws MS N NOTE You must assemble the meter sensor to the meter body before connecting the cable to the sensor for the meter to function properly Coriolis Meter 3 Connect meter cable CC See FIG 23 1 Follow Before Servicing page 36 4 Connect fluid line P 2 remove and service the Coriolis meter see man 5 Calibrate meter as instructed in ProMix Operation manual ual 313599 G3000 G3000HR Meter Removal 1 Follow Before Servicing page 36 2 Unscrew cable connector CC from meter M FIG 23 3 Unscrew four 1 4 20 screws MS holding the meter mounting plate MP FIG 23 4 Unscrew fluid line from
46. lvent Check fuse condition if Solvent Meter Dump Valves Meter Dump Valve and B Sole 3rd Purge Valve and Gun Flush Boxes not work noids 3rd Purge Valve Solenoid and Gun Flush Box 1 and 2 Sole noids 312777E 25 Troubleshooting Booth Control Troubleshooting See Fic 10 and Table 6 to troubleshoot the booth control board Also see the System Electrical Schematic on pages 32 and 33 The booth control does not contain any servciceable parts and must be replaced as a complete unit To replace the booth control disconnect the cable from J7 on the fluid station control board See FIG 8 on page 23 Install the new booth control and connect the cable to J7 Table 6 Booth Control Board Diagnostics LED blinks when an alarm occurs and turns off after alarm is reset LED turns on when in Mix mode LED turns on when in Standby mode LED turns on when in Purge mode Job Complete Indicator green LED blinks once after key is pressed signalling that job is complete and A and B totalizers are reset Recipe Indicator green LED turns on when a recipe is in use and shuts off when a new recipe is being selected or if an alarm occurs LED blinks when a new recipe is loading and turns solid after loading is complete 08 Board OK green Blinks heartbeat during normal operation D9 Communication yellow Turns on when board is communicating with EasyKey D10 Power green Turns on when power is supplie
47. meter inlet P 5 Unscrew meter M from dose valve connector FIG 23 6 Service meter as instructed in the meter manual 308778 Installation 112653 1 Screw meter M securely onto the dose valve con nector H using a wrench FIG 23 G3000 G3000HR Flow Meters NOTE To avoid leakage secure the meter M to the dose valve connector H before connecting it to the fluid station 3X CABLE 241799 801 LL PWR RED COM BLACK o FLOW METER A SHIELD GRN eq 3 L PWR RED SaD Length 6 L COM BLACK FLOW METER B SIG WHITE 241 99 51 1 52 1 SHIELD GRN PWR RED 241800 16 in 406 241801 13 in 330 mm 2 o FLOW METER SOLVENT m SHIELD GRN A UN IR a gt mA S GROUND TERMINAL Connectors on Fluid Station Control Board Fic 24 Meter Cable Schematic 46 312777E Servicing Fluid Manifold We Removal 1 Follow Servicing Flow Meters Removal steps 1 5 page 46 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 m
48. ndicators 312777E J10 Power Input J11 Color Change Module Set Switch S1 as shown below J7 Booth Control 115223a Set switch 51 to OFF up if system has Booth Control AND Color Change S 15224 Set switch 51 to down if system has Booth Control OR Color Change or neither 23 Troubleshooting RB529 9 Am FB23 mu R25 R26 MH 1 FB17 TOP SILK mr 037 C21 EC S Bree sey ER 17 R86 E NN NH NH N C357 R65 DN R83 R59 E u 4 a 21 je C5 R2 RN2 H R81 5 5 C2 dur 255 013 014 al a RI 4 TE sl N 242 R49 R48 oc O O a D R62 R61 ple 83 E E H 4 gt 0 2 R72 SS c7 E RN E SM R66 A W TTTTTTTTT Jl TTTTT J1 DIGITAL INPUT 413 METER INPUT c 9 9 Gg x T 0 Oa Q 2 gt gt LL LL H en 0
49. nent options selected The pressure rating is based on the rating of the lowest rated fluid manifold component Refer to the component pressure ratings below Example Model MD2531 has a maximum working pressure of 3000 psi 21 MPa 210 bar Check the identification label on the EasyKey or fluid station for the system maximum working pressure See FIG 1 ProMix Fluid Manifold Components Maximum Working Pressure Base System no meters option 0 no color catalyst change option 0 4000 psi 27 58 MPa 275 8 bar Meter Option 1 2 G3000 G3000HR 4000 psi 27 58 MPa 275 8 bar Meter Option 3 4 5 6 and 7 one or two Coriolis Meters 2300 psi 15 86 MPa 158 6 bar Color Change Option 1 2 3 and 4 and Catalyst Change Option 1 and 2 low pressure valves 300 psi 2 07 MPa 20 6 bar Color Change Option 5 and 6 and Catalyst Change Option 3 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 S3000 Solvent Meter accessory 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 Wall Mount Fluid Station 50 cc Integrator and Static Mixer B Side Dump Valve if catalyst valve s is selected Booth Control Basic Web Interface 312777E 5 System Configuration and Part Numbers 6 312777E Accessor
50. ply GFB1 P GFB1 P 5 82 4 Air Natural Gun Flush Box 2 Supply GFB2 P GFB2 P 5 32 4 Air Natural Gun Flush Box 1 Safety GFB1 S GFB1 S 5 32 4 Interlock Natural Gun Flush Box 2 Safety GFB2 S GFB2 S 5 82 4 Interlock Natural Gun 1 Atomizing Air 1 1 1 4 6 Natural Gun 2 Atomizing Air ATOM 2 2 1 4 6 Use as a separate line 1 4 6 connected directly to the main shop air line Do not connect to the unit s main air supply or to the air manifold 335 312777E 35 User supplied Con nects air flow switch to gun air shutoff valve 338 Natural Purge Air Supply Service Service Before Servicing 3 Shut off ProMix 2KS power 0 position FIG 12 4 If servicing EasyKey Display also shut off power at main circuit breaker To avoid electric shock turn off EasyKey power before servicing Servicing EasyKey exposes you to high voltage Shut off power at main circuit breaker before open ing enclosure 0 OFF All electrical wiring must be done by a qualified electrician and comply with all local codes and reg ulations Do not substitute or modify system components as this may impair intrinsic safety Read Warnings page 8 112657 Fic 12 Power NOTICE Teaia demana eredt boarten sevena wear After Servicing appropriately After servicing the system be sure to follow the Start Up checklist and procedure in the ProMix 2KS 1 Flush s
51. rial 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 10 Moisture Sensitivity of Isocyanates Isocyanates ISO are catalysts used in two component coatings ISO will react with moisture such as humidity to form small hard abrasive crystals which become suspended in the fluid Eventually a film will form on the surface and the ISO will begin to gel increasing in vis cosity If used this partially cured ISO will reduce perfor mance and the life of all wetted parts NOTE The amount of film formation and rate of crystal lization varies depending on the blend of ISO the humidity and the temperature To prevent exposing ISO to moisture e Always use a sealed container with a desiccant dryer in the vent or a nitrogen atmosphere Never store ISO in an open container e Use moisture proof hoses specifically designed for ISO such as those supplied with your system e Never use reclaimed solvents which may contain moisture Always keep solvent containers closed when not in use e Never use solvent on one side if it has been con tamina
52. ted 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 e Most materials use ISO on the A side but some use ISO on the B side 312777E Grounding Your system must be grounded See the Grounding instructions in your ProMix 2KS Installation manual Check Resistance ensure proper grounding resistance between Pro Mix components and true earth ground must be less than 1 ohm Read Warnings page 8 Have a 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 312777E Grounding 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 A and B fluid supply pumps pressure pots Close all fluid shutoff valves at
53. 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 4 NOTE If a Dose Time alarm E 7 E 8 occurs clear the alarm 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 FIG 3 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 4 Verify that solvent pressure is reduced to 0 NOTE If a Purge Volume alarm E 11 occurs clear the alarm 11 Pressure Relief Procedure 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 11 2 Close the A side shutoff valve SVA Fic Open the A side sampling valve RVA 3 Direct the A side sampling tube into a waste con tainer 4 See Fic 2 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 valv
54. 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 Important Two Component Material Information Important Two Component Material Information 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 Mate
55. w meter see manual 313599 5V827 KIT G3000HR flow meter see manual 308778 5V806 KIT Coriolis flow meter see manual 313599 5V806 KIT Coriolis flow meter see manual 313599 see page MODULE control color catalyst change see page 56 standard part standard part standard part standard part 2 A i O see page O see page VALVE STACK color change see page 56 see page O O N N N see page VALVE STACK catalyst change see page 56 see page O1 Ni OD OD OD a a 4 4 4 4 APPLICATOR HANDLING AFS KIT air flow switch 51632 KIT air flow switch 5V826 KIT gun flush box see manual 312784 5V826 KIT gun flush box see manual 312784 used with color 15U532 CABLE CAN intrinsically safe connects color change control 0 or 1 change only module to fluid station 3 ft 1 m 51632 x CO 4 O O 312777E 5 Parts EasyKey Controls 277869 EasyKey with Display Detail of Display Interface Kit 210 206 214 2141 201 208 N 210c not part of kit 210e 12554 11124170
56. your hand body glove or rag Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment 8 312777E 312777E 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 e 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 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 e Read MSDS s to know the specific hazards of the fluids you are
57. ystem and follow Pressure Relief Proce Operation manual dure page 11 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 36 312777E Servicing EasyKey Updating Software To update software upload new software from your PC using the basic web interface See manual 313386 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 36 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 7 on page 20 4 Remove 4 screws 210e and the display board assembly 210b 210c Fic 13 210 210 12554 Fic 13 Display Interface 312777E Service 5 Disconnect graphic display power cable J1 from the display board 210c 6 Separate graphic display 210b from display board 210c connector J2 on back of board 7 To 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 13 8 Reconnect the graphic display power cable J1 to the display board 210c 9 Mount display board assembly with screws 2106 1
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