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Graco 312776E User's Manual

1. A lu BOARD 1 3 100 OPTIONS eset 3L 415 8 ua 4 CaN H WHT 4 1 J CAN L BLU qas peg H 1 d OM ec ip ADC 50 STD zi Cs 2 UL larn CLR6 12VDC EIE RR ind m n 5 uum BOND ars a a s O aja o m CAN H WHT 4 12VDC COM T 1 TN Ern 2H D te CAT 4 CLR3 2 O fom te B Vine m sO OTe er IE ron ae 4 DUMP 2 5 RED com O ee A jeen m 2 BLACK 2 6 STD 1 LJ RED jore o8 m 6 BLACK Bx B E COLOR 4 e BOARD 2 _ MANFOLD orit Co 13 30 10 iih Taso pce 6 BLACK MANIFOLD 1 4L 8RAK purcea d gmi ca 3 3 80 sr 1 aes BLACK CLR 19 INOC 2 ve 1 USED 82 COM He pe aris nac L 6 COM INOTUSED EE ME EE NX ax Iu 4 BLACK Tu BOSER 2 1 99
2. OM TTT 3 RED M 6 ELM Tu aa 2 BLACK 1 12VDC 1 RED EUREN CLR 15 at a E DE Tz jana 12vDc 1 SIG 2 AIRFLOW SWITCH 1 A oy 4 axe a l CLR29 2 UM 2 CON a lano J 225 222 AIR FLOW SWITCH 2 Ut dt M ax FOOUT H 6M SOLVENT FLOW SWITCH foe BLU E QM GFB 1 PRESSURE SWITCH FOIN J p GFB 2 PRESSURE S SWITCH i B 312776E 89 Schematic Diagrams EasyKey Electrical Schematic Qv3pna svfd R 932018 TWNIWYSL YIMOd DMY 91 NMOU8 DMY 91 DMY 91 Wavv AlddfiS 83 04 NI JOVLIOA 104110 81 939 DMY 81 10919 SI q3snNn q3snNn GasnNn aasnwn 81 81 2 18 81 934 DMY 81 4219 DMY CC 3LIHWPIDV 18 038 d quvogAvidsia Stry 0308 3313399 Qt DMY 3IIHWODV 18 N3385 t Quvosg Av 1dSId 312776E 90 Meter Performance Data G3000 on A and B Meter Performance Data G3000 on A and B 00 pue puepuels uedo Sz ALA 92U8J9J O esiodn
3. 16 EasyKey Display and Keyboard 17 Display xis ex vede 17 Keypad Sau oe arab d 17 AC Power Switch 18 POWER 52 14 ote ete 18 Potlife Exceeded Audible Alarm 18 Graco Web Interface Port 18 Ethernet Connection 18 Run Mode Screens 19 Splash Screen 19 Status Screen xe ea ae 21 Totals S6reeht iecur dice hare o oe 22 Reset Total Screen 22 Reset Solvent Screen 22 Alarms 5 22 Level Control Screen 23 Setup Mode 24 Password Screen 25 Set Up Home Screen 25 System Configuration Screens 27 Option Screens 31 Advanced Setup Screens 33 Recipe Setup Screens 36 Recipe 0 Screens 40 Calibration 5 42 2 System Operation 43 Operation Modes 43 Sequential Dosing 43 Dynamic Dosing 43 Recipe Color Change 43 Solvent PUSH 43 General Operating Cycle Sequential Dosing 43 General
4. Ye Ne _ 0o N N N esr o Yes orNo YesorNo 1 m Yes L5 X mW Ya w o X NM NM NOTES 79 and Fia 80 show both color and catalyst change If the color or catalyst is not changing disregard that portion of the chart Yes e Yes O 0 2 Z mn NIN u X Ki gt lt 81 and FIG 82 show color change If the color is not changing disregard that portion of the chart FiG 83 page 72 shows a recipe change with Special Outputs FiG 85 page 73 shows an External Color Change 312776E 65 Color Change ProMix 2KS Recipe Change Chart 1 A1 to A2 B1 to B2 with Dump Valves Time Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Catalyst Fill Time P3 gt P4 Air Chop Time Solvent Chop Time First Purge one of these 3rd Flush Chop Time Air Purge NI Solvent Purge 3rd Flush Valve Dispense B Gun Trigger s by Operator Z CC Purge Fill Timers are independent of Mixed Material Purge Timers This line defines when the Mixed Fill Time begins The longer of the two timers defines when the Mixed Fill Time begins Final Purge one of thes
5. 10 Status Screen Key to Fic 10 D Active Recipe shows the active recipe NOTE At power up the system defaults to Recipe 61 which is not a valid recipe number 2 Target Ratio for the active recipe The ratio can be from 0 0 1 50 0 1 in 0 1 increments 3 Actual Ratio in hundredths calculated after each dose of A and B 312776E Run Mode Screens Potlife Timer shows remaining potlife time in min utes Two times are shown if there are two guns Status Bar shows current alarm or operation mode standby mix purge recipe change or the current alarm Current Flow Rate in cc min Animation when the gun is triggered the gun appears to spray and the component A or B hose lights up showing which component dose valve is open Current Date and Time Screen Number and Scroll Arrows displays the current screen number and the total number of screens in a group The Up and Down arrows on the right edge of the screen indicate the scroll feature The total number of screens in some groups may vary depending on system configuration selections Lock Symbol indicates that Setup screens are password protected See page 25 21 Run Mode Screens Totals Screen Job Total cc solvent Job 0 ae Solvent Level Control 11 Totals Screen rand Total 0 Liters 0 Liters 0 Liters Liters Usaqe This screen shows the j
6. Final Purge Source Air Chop Time solvent Chop Time Advanced Calibration Fic 34 Advanced Setup Screen 2 This screen appears only if Flush and Fill Input is set to Global in Option Screen 1 page 31 First Purge Source Select Air Solvent or Ord Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 29 Chop Type Select Air Solvent or Air 3rd Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 29 This refers to the process of mix ing air and solvent or air and 3rd flush fluid together during the flush cycle to help clean the lines and reduce solvent usage Final Purge Source Select Air Solvent or 3rd Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 29 Air Chop Time Enter the air chop time 0 0 to 99 9 seconds Solvent Chop Time 3rd Flush Valve Chop Time Enter the solvent or 3rd flush valve chop time 0 0 to 99 9 seconds 312776E Setup Mode Advanced Setup Screen 3 Advanced Setup Screen 4 Gun 1 Gun First Purge Time 10 sec K Factar cc pulse Total Chop Time 20 Meter Final Purge Time 10 sec Meter 0 113 Mixed Fil Time 19 Solvent Meter 0 1198 Advanced Calibration Advanced Calibration Fic 35 Advanced Setup Screen Fic 36 Advanced Setup Screen 4 This screen appears only if Flush and Fill Input i
7. NOTE See FiG 38 for a map of the Recipe screens Detailed screen descriptions follow hecipe Tolerance Color Valve Catalyst Valve Calibration Gun 1 Potlfe Volume 350 Color Catalyst Purge sec Color Catalyst Fill DL Advanced Calibration Recipe 0 Screens Recipe Recipe First Purge Source Minimum Flush Volume Chop Fir Solvent 1 Potlfe Time minutes Final Purge Source 4 Color Catalyst Purge 5 Air Chop Time Sec Color Catalyst Fill sec Solvent Chop Time SEC 4 Calibration Calibration Recipe Gun 1 Gun 2 Color Catalyst Purge sec First Purge Time Sec Total Chop Time Sec Final Purge Time sec Recipe First Purge Source t Chop Tupe 3 Final Purge Source Air Chop Time Sec Solvent Chop Time sec 1 Calibration Calibration Recipe Minimum Flush Volume Exiting Fill Source Exiting Fill Time sec Gun 1 Gun 2 sec sec sec Recipe First Purge Time Total Chap Time Final Purge Time Mixed Fill Time TM Calibration Calibration Recipe K Factor cC pulse Meter 0 119 B Meter 0 119 Solvent Meter 0 119 Recipe special 1 On Purge 0 Lo 1 07 Lenath On Fill Length Calibration Calibration Fic 38 Recipe Screens 36 Se
8. gun flush box place the gun into the box e Purging Using Recipe 0 page 57 e Purging Fluid Supply System page 57 Samping valves Ang TUDES page 932 and close the lid Press the Purge key on the Use the criteria listed in each procedure to determine Booth Control The purge sequence automatically which procedure to use starts If the gun flush box is not used trig Purging Mixed Material ger the gun into a grounded metal FON There are times when you only want to purge the fluid pail until the purge sequence is com xf manifold such as plete lt e end of potlife When done purging the Booth Control automati e breaks in spraying that exceed the potlife cally switches to Standby mode e overnight shutdown before servicing the fluid manifold assembly hose or If the system is not completely clean repeat step 3 gun NOTE If necessary adjust purge sequence so only Solvent purges the component B catalyst right side of one cycle is required the mix manifold and the inner tube of the integrator Air purges the component A resin left side and the outer Trigger the gun to relieve pressure Engage trigger 5 If spray tip was removed reinstall it 6 Adjust the solvent supply regulator back to its nor Trigger the gun to relieve pressure mal operating pressure If you are using a high pressure gun engage the trig ger lock Remove spray tip and clean tip separately 56 312776E Purg
9. or swallowed Read 5 5 to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines e Always wear 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 8 312776E 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 manufacturers 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 im
10. 5 MICRON WALL MOUNT ONLY lt E COLOR 13 4 WAY SOLENOID COLOR 14 COLOR 15 5 COLOR 16 AIRINPUT O COLOR 18 VALVE COLOR 19 4 WAY SOLENOID A lt ITI OPTIONAL COLOR 20 i 7m COLOR 21 c AIR EXHAUST MUFFLER COLOR 22 lt COLOR 23 i EI COLOR24 5 COLOR 25 E 3 WAY SOLENOID 7 OPTIONAL COLOR 26 de t essem AIR INPUT COLOR 29 12VDC COLOR 30 3 WAY SOLENOID 7 4 IT OPTIONAL ail lt E MAC 36 SERIES SOLENOID VALVES VALVE ex IT OPTIONAL po os S VANE oh OPTIONAL CE MANIFOL 222 312776 87 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 NON HAZARDOUS AREA rr cr pe L1 DCOK Sms 1 L1 85250VAC 424 VDC H o N L1 TERMINAL COMMON GN BLOCK COMMON 1 GND LUG EE RE GNDNLI 85 250 L ROCKER 2A POWER HARNESS HARNESSES 24 YEL COM GRAY ORG BEACON BRN R
11. 6 Perform a manual purge or recipe change to purge the remaining mixed material This will clear the sys tem out of Solvent Push allowing you to resume Mix mode NOTE Once the system senses that solvent exceeds 5096 of potlife volume attempts to re enter Solvent Push will cause an Overdose A B Alarm E 5 E 6 DVB is closed TI12556b SS SPV is open 312776E Meter Calibration To avoid splashing fluid in the eyes wear eye protec tion The fluid shutoff valves and ratio check valves are retained by mechanical stops that prevent accidental removal of the valve stem while the manifold is pres surized If you cannot turn the valve stems manually relieve the system pressure then disassemble and clean the valve to remove the resistance Calibrate the meter e The first time the system is operated e Whenever new materials are used in the system especially if the materials have viscosities that differ significantly e Atleast once per month as part of regular mainte nance e Whenever a flow meter is serviced or replaced NOTE e K factors on the Calibration Screen are updated automatically after the calibration pro cedure is completed e K factor values on the screen are viewable only If needed you can manually edit the K factors in Advanced Setup Screen 4 page 35 or Rec ipe Setup Screen 5 page 39 e values on this screen in cc independent of the units set in Configure Scr
12. 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 G250 G3000HH G250HH or intrinsically safe Coriolis meter are approved for installation a Hazardous Location Class Div Group D or Zone Group 1 3 Do not install equipment approved only for non hazardous location in 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 gt 312776 7 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 po
13. auto dump is initiated operating properly For systems with a gun flush box Fuse F2 is blown Verify condition of fuse and replace if necessary See Repair Parts manual E 21 MATERIAL FILL ALARM For systems with minimum mixed material fill volume Check for restrictions or leaks in the fluid supply system entered the system detects that fill volume is not achieved during mixed material fill time Check if the fill volume is properly configured e Adjust fill volume e Adjust fill time For systems without color change and with minimum Verify condition of fuse and replace if necessary See mixed material fill volume entered Fuse F1 is blown Repair Parts manual E 22 TANK A LOW ALARM E 23 TANK B LOW ALARM or E 24 TANK S LOW ALARM The tank volume reaches the low level threshold The EasyKey screen will display the alarm and prompt the user to do one of the following e Refill tank volume to clear the alarm e Resume mixing by selecting Spray 25 of remain ing volume If this selection is chosen a second alarm will occur after 25 of the remaining volume is mixed Refill tank volume to clear the alarm 312776E 85 Alarm Troubleshooting Table 11 Alarm Troubleshooting E 25 AUTO DUMP COMPLETE ALARM Cause A potlife alarm is active for more than 2 minutes the gun Be sure to spray all mixed material before potlife expires flush box is enabled and gun is in the gun flush box and an auto dump flush se
14. buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente d
15. fluid flow rate is too high reduce the air pressure close the fluid manifold dose valves fur ther or adjust the fluid pressure regulator NOTE Pressure adjustments of each component will vary with fluid viscosity Start with the same fluid pres sure for component A and B then adjust as needed NOTE Do not use the first 4 5 oz 120 150 cc of mate rial as it may not be thoroughly mixed due to alarms while priming the system 12 Turn on atomizing air to the gun Check the spray pattern as instructed in your spray gun manual NOTE Do not allow a fluid supply tank to run empty It is possible for air flow in the supply line to turn gear meters in the same manner as fluid This can lead to the propor tioning of fluid and air that meets the ratio and tolerance settings of the equipment This can further result in spraying uncatalyzed or poorly catalyzed material 51 System Operation Shutdown Overnight Shutdown 1 Leave the power on 2 Recipe 0 to purge solvent through meters and gun Service Shutdown 1 Follow Pressure Relief Procedure on page 52 2 Close main air shutoff valve on air supply line and on ProMix Shut off ProMix 2KS power 0 position 64 4 If servicing EasyKey also shut off power at main cir cuit breaker 0 OFF 12657 Fic 64 Power Switch 52 Pressure Relief Procedure NOTE The following procedures relieve all fluid and air pressure in t
16. group Right Arrow move to next screen group Alarm Reset resets alarms 17 EasyKey Display and Keyboard AC Power Fiber Optic Strain Audible Alarm Switch Relief Port Ground Screw 1 5 Power Graco Web Discrete I O Cable Interface Connector Ports Access TI12638a T112657a FiG 6 EasyKey Connections and AC Power Switch AC Power Switch Graco Web Interface Port Turns system AC power on or off Used to communicate from a PC to Upgrade software I S Power View software version Download Job and alarm logs Material usage report Setup values can also upload Potlife Exceeded Audible Alarm usd de reports Upload a custom language to view on screen Restore factory defaults Restore setup password Power circuit to Fluid Station Alerts the user when a Potlife Exceeded alarm occurs gt Clear by pressing the Alarm Reset 59 E gt See manual 313386 for more information Ethernet Connection You can access data on an office or industrial network through the internet with the proper configuration See manual 313386 for more information 18 312776E Mode Screens NOTE See FIG 9 for a map of the Run screens Detailed screen descriptions follow Splash Screen At power up the Graco logo and software revision will display for approximately 5 seconds follow
17. in Option Screen 1 page 31 or 3rd Flush Valve is set to On in Configure Screen 3 on page 29 Minimum Flush Volume This field only appears if Flush Volume Check is set to On in Option Screen 1 on page 31 Enter the mini mum flush volume 0 to 999 cc Exiting Fill Source This field only appears if 3rd Flush Valve is set to in Configure Screen on page 29 Select Off Air Sol vent or 3rd Valve Exiting Fill Time This field only appears if Exiting Fill Source is set to Air Solvent or 3rd Valve Enter the time in seconds 312776E Setup Mode Recipe 0 Screen 4 Fic 49 Recipe 0 Screen 4 This screen appears only if Flush and Fill Input is set to Recipe in Option Screen 1 page 31 and Special Out puts is set to 1 2 3 or 4 in Configure Screen 5 page 30 The I O board has four programmable outputs 41 Setup Mode Calibration Screen Meter Calibration Measured Actual volume Volume k F actor 0 119 cc pulse Recipe Fic 50 Calibration Screen Use this screen to calibrate a meter Set to Meter A Meter or Solvent Meter available if Solvent Moni tor in Configure Screen 5 page 30 is set to Meter e Start start calibration Abort stop calibration e Purge purge sampling valves after calibration See Meter Calibration page 61 for when and how to calibrate a meter 42 312776E Syst
18. mountings for the fluid flow meters and the fluid manifold assembly Its control board manages all proportioning functions Fluid Manifold FM Pneumatically Operated Dose Valves for component A and B Purge Valves for solvent and air purge Sampling Valves for calibrating the flow meters and performing ratio checks Shutoff Valves for component A and B to close their fluid passages to the mix mani fold to allow for accurate calibration and ratio checks Mix Manifold which includes the fluid integrator and static mixer Fluid Integrator is the chamber where component A and B align at the selected ratio and begin to mix gt Static Mixer has 24 elements to uniformly blend the materials downstream of the fluid integrator 12 312776E Component Flow Meters MA MB MS Color Change Valves ACV and Color Change Module CCM Catalyst Change Valves BCV Dual Fiber Optic Fluid Station Power Supply Cable PS Cable FO Applicator Handling use Air Flow Switch AFS or Gun Flush Box GFB 312776E Overview Table 1 Component Descriptions Description Three optional flow meters are available from Graco 3000 is a general purpose gear meter typically used in flow ranges of 75 3800 cc min 0 02 1 0 gal min pressures up to 4000 psi 28 MPa 276 bar and viscosi ties of 20 3000 centipoise The K factor is approximately 0 119 cc pulse G3000HR is a high resolution version of the 23000 mete
19. recipe Fill from new recipe Fic 75 Color Change Chart 6 68 Air Chop Time Solvent Chop Time 3rd Flush Chop Time IM 8 8 8 1 2 CC Purge Fill Timers are independent of System Purge Timers This line defines when the System Fill Time begins The longer of the two timers defines when the System Fill Time Load tables from new recipe 312776E Color Change ProMix 2KS Recipe Change Chart 7 A1 to A2 B1 to B2 with Dump Valves 1 GFB IDumpA Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B dl RENI IE n IEEE Color Purge Time 0 gt 1 Color Fill Time P1 gt P2 Catalyst Purge Time P2 gt P3 Catalyst Fill Time P3 gt P4 CC Purge Fill Timers are independent of Mixed Material Purge Timers This line defines when the Mixed Fill Time Air Chop Time begins The longer of the two timers Solvent Chop Time defines when the Mixed Fill Time First Purge one of these 3rd Flush Chop Time begins iN Air Purge P ISolventPurge Final Purge of these 3rd Flush Valve Gun Flush Box Output 1 MO M First Purge Time 0 gt 1 Chop Time air solvent or air 3rd flush 1 gt 2 Final Purge Time M2 gt M3 Mixed Fill Time M3 gt M4 Notes Load tables from new recipe Purge from old recipe Fill from new recipe Fic 76 Color Change
20. switch is activated while purge is taking place Minimum flush volume is not achieved Increase solvent supply or decrease minimum volume setting No meter pulses during Color Catalyst Dump Color change solvent supply not set up or functional Check Color Change setup 312776E 81 Alarm Troubleshooting Table 11 Alarm Troubleshooting 12 CAN COMM ERROR ALARM Communication between the Color Change Module and Verify that all cables are connected securely and that the Fluid Station is interrupted the Color Change and Booth Control power LEDs turn on If the power LED does not turn on the prob lem is probably caused by a bad connection The nut on the connector must make at least 5 complete turns to ensure a good connection If the power LED still does not light the cable or board is bad e Check the color change board DIP switch settings See the Installation manual e Check the fluid plate board DIP switch setting An incorrect setting will not cause E 12 alarms but a correct setting will help prevent E 12 caused by elec trical noise See the Installation manual e Check EasyKey software version displayed at power up for all versions and when the lock key is pressed for version 2 02 000 and above If older than 1 06 002 upgrade Be sure to save settings through BWI or AWI before upgrading as they will be erased e The sticker on the color change board shows the software part number and version for ex
21. the system Check that the system is fully loaded with material Check that the supply pump s cycle rate is set prop erly Check that the spray tip nozzle is properly sized for the flow and application and that it is not worn Check that the fluid regulator is set properly If the alarm occurs during start up after purging the flow Restrict gun needle travel to slow down the initial fluid rate was probably too high delivery rate until fluid hoses are loaded with material If the alarm occurred after you were spraying for some Adjust component A and B fluid supply regulator pres time the pressures from the fluid supplies could be sures until they are about equal f the pressures are unbalanced already about equal verify that component A and B dose valves are operating properly Slow actuation of the component or B valves This can Manually operate the Dispense and B solenoid valves be caused by as instructed in the ProMix 2KS Repair Parts manual to check operation e Air pressure to the valve actuators is too low e Increase air pressure Air pressure must be 75 120 psi 0 52 0 84 MPa 5 2 8 4 bar 120 psi is recom mended Something is restricting the solenoid or tubing There may be dirt or moisture the air supply Filter interrupting valve actuation air appropriately dose valve is turned in too far e Refer to Table 7 Mix Manifold Valve Settings page 50 for adjustment guid
22. to air purge valve solvent purge valve or 3rd purge valve First Purge Time duration of the first purge cycle User settable from 0 999 seconds Flow Control Resolution a settable value that allows the flow control system to maximize its performance The value is based on maximum desired flow rates Flow Rate Analog Signal the type of communication signal that can be used on the ProControl module Flow Rate Tolerance the settable percent of accept able variance that the system will allow before a flow rate warning occurs Flow Set Point a predefined flow rate target Flush Volume Check system monitors flush volume E 11 Alarm occurs if minimum volume is not achieved Minimum flush volume is user settable 0 999 cc Grand Total a non resettable value that shows the total amount of material dispensed through the system Gun Trigger Input Signal used to manage ratio assur ance dose times and flow control processes Intrinsically Safe IS refers to the ability to locate cer tain components in a hazardous location Idle if the gun is not triggered for 2 minutes the system enters Idle mode Trigger the gun to resume operation 312776E Job Total resettable value that shows the amount of material dispensed through the system for one job A job is complete when a color change or complete system flush occurs K factor a value that refers to the amount of material that passes through a meter The as
23. 12 EasyKey software version FP Fluid Plate 2 00 012 Fluid Plate software version BC Booth Control Booth Control not installed not detected not oper ational Booth Control software version 1 00 or 1 01 Booth Control software version 2 XX C1 C2 Color Change Color Change Module 1 2 not installed not detected Modules 1 and 2 or not operational Color Change Module software version 1 00 or 1 01 Color Change Module software version 2 XX AK Autokey 2K Manual No AutoKey installed or detected System operates in 2K Manual Mode only 2K Auto 2K AutoKey detected System can operate in 2K Man ual Semi automatic or Automatic Mode 3K Auto 3K AutoKey detected System can operate in 3K Man ual Semi automatic or Automatic Mode XP XPORT V6 6 0 2 Example of XPORT network module software version Other versions are acceptable MC Micro Controller 1042 0198 Example of fluid plate micro controller version Other versions are acceptable Internet Address 192 168 178 5 Example of the address EasyKey is set to for basic and advanced web interface reporting MAC address 00204AAD1810 Example of internet MAC address Each EasyKey will have a different value in this format 26 312776E Setup Mode System Configuration Screens NOTE See FIG 21 for a map of the System Configura NOTE Each screen displays the current screen number tion Screens Detailed screen descriptions follow and the total number
24. 12776E Color Change 71 Color Change ProMix 2KS Recipe Change Chart 13 Recipe 0 OR 61 to Recipe X without Dump Valves Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Dispense B Gun Trigger s by Operator Color Fill Time 0 gt 1 Mixed Fill Time 1 22 Notes Load tables from new recipe Purge from old recipe Fill from new recipe FiG 82 Color Change Chart 13 ProMix 2KS Recipe Change Chart 14 A1 to A2 B1 to B2 with All Time Sequence purs a Color Change Solvent NEN Glace m Color Change A p O 1l Cd P1 0 4 Color Purge Time 0 gt 1 CC Purge Fill Timers are independent of Mixed Material Purge Timers This Color Fill Time 1 gt 2 line defines when the Mixed Fill Time defines when the Mixed Fill Time beds Air Chop Time Solvent Chop Time First Purge one of these 3rd Flush Chop Time Air Purge NI Solvent Purge 3rd Flush Valve Dispense A Dispense B Gun Trigger s by Operator First Purge Time 0 gt 1 Chop Time air solvent or air 3rd flush 1 gt 2 Final Purge Time M2 gt M3 Mixed Fill Time M3 gt M4 Notes Load tables from new recipe Purge from old recipe Fill from new recipe 1st On Start 1st On Length Duration 2nd On Start 2nd On Length Special Output 1 FiG 83 Color Change Chart 14 72 312776 Dump Color Change
25. 410 ec Solenoid _ 2 Solenoid Identification ole 5 3 2 Identification abel ell Labe _ 9 6 5 9 pim S of FP eS IO 9e 5 BNET O 7 X LJ 7 112826 Solvent Solenoid Overrides FiG 66 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 Dose Valve HVB Component B Sampling Valve SVB Component B Shutoff Valve AT MS Solvent Meter SPV Solvent Purge Valve APV Air Purge Valve SM Static Mixer TI12556b Fl Fluid Integrator APV AT Air Purge Valve Air RVA SVA SVB Fic 67 Wall Mount Fluid Station 312776E Supply Tube 55 System Operation Purging If using an electrostatic gun shut off the electrostatics before flushing the gun 2 Setthe solvent supply pressure regulator at a pres sure high enough to completely purge the system in a reasonable amount of time but low enough to avoid splashing or an injection injury Generally a setting of 100 psi 0 7 MPa 7 bar is sufficient Head Warnings page 7 Follow the Grounding instructions in your system Installation manual To avoid splashing fluid in the eyes wear eye protec tion There are 4 purging procedures this manual e Purging Mixed Material below 3 If using
26. A Component A Sampling Valve SVA Component A Shutoff Valve MB Component B Meter DVB Component B Dose Valve RVB Component B Sampling Valve Fic 51 Wall Mount Fluid Station Sequential Dosing 44 SM SVB SPV APV Fl AT MB MS RVB aw TI12556b SVB SPV Component B Shutoff Valve Solvent Meter accessory Solvent Purge Valve Air Purge Valve Static Mixer Fluid Integrator Air Purge Valve Air Supply Tube 312776E System Operation General Operating Cycle Dynamic Dosing Overview Dynamic Dosing provides on demand proportioning eliminating the need for an integrator and therefore min imizing undesired material contact This feature is espe cially useful with shear sensitive and waterborne materials A restrictor injects component B into a continuous stream of component A The software controls the dura tion and frequency of each injection See Fic 52 for a schematic diagram of the process Component A continuous flow Component B pulsed Component pulsed injection Dynamic Dosing System Parameters The following parameters affect dynamic dosing perfor mance e Component A Flow Ensure that the supply pump is sized to provide sufficient and uninterrupted flow Note that component A provides majority of system flow at higher mix ratios e Component B Flow Ensure that the supply pump is sized to provide sufficient and uninterrupted flow e Component A
27. Chart 7 ProMix 2KS Recipe Change Chart 8 A1 A2 same B without Dump Valves 2 GFBs Time Sequence 0 Catalyst Change Solvent ug Color Change Catalyst Change B Air Chop Time Solvent Chop Time First Purge one of these 3rd Flush Chop Time 3rd Flush Valve Dispense A Gun Flush Box Output 1 e M 0 1 2 3 4 5 6 Color Purge Time 0 21 Notes Load tables from new recipe Purge from old recipe Fill from new recipe Final Purge one of these FIG 77 Color Change Chart 8 312776E 69 Color Change ProMix 2KS Recipe Change Chart 9 A1 A2 same B without Dump Valves 1 GFB Time Sequence Oooo TimeSequece Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Air Chop Time B Solvent Chop Time 3rd Flush Chop Time pe Final Purge one of these 3rd Flush Valve Dispense A A A Gun Flush Box Output 1 0 1 2 3 4 5 6 Color Purge Time 0 21 Mixed Fill Time 5 26 Notes Load tables from new recipe Purge from old recipe Fill from new recipe FIG 78 Color Change Chart 9 ProMix 2KS Recipe Change Chart 10 Recipe X 0 OR 61 to Recipe 0 with Dump Valves Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B PO Color Purge Time 0 gt 1 Catalyst Purge Time P1 gt P2 First Purge one of these olvent Purge 1 rd F
28. Display Units Select the desired display units e cc liter default e cc gallon Buzzer All Alarms As shipped the alarm buzzer will sound only for the Pot life Alarm E 2 Off is default Set to On to have the buzzer sound for all alarms Screen Timeout Select the desired screen timeout in minutes 0 99 5 is the default 28 Configure Screen 2 Month Tear Time late Format 23 Configure Screen 2 Configure Month Enter current month Day Enter current day Year Enter current year four digits Time Enter current time in hours 24 hour clock and minutes Seconds are not adjustable Date Format Select mm dd yy or dd mm yy 312776E Configure Screen 3 ZES Manual LIFE hun Mode Dump Valve Mt 3 LIFE J Dump Yale ard Flush Valve 24 Configure Screen Configure Run Mode Indicates that this is a Manual system Dump Valve A This field only appears if the system includes an optional dump valve A If dump valve A is included set to On Dump Valve B This field only appears if the catalyst change option is detected from the cc board meaning that dump valve B is present On is the only setting 3rd Flush Valve Off is default If the system includes an optional 3rd flush valve set to On 312776E Setup Mode Configure Screen 4 SEC Dose Size Dose lime Ala
29. ED 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 SWITCH 1 UNUSED OPEN 5 UNUSED UNUSED OPEN 4 UNUSED HARNESS 5 1 UNUSED 12VDC1 S RED COM BLACK BARRIER 3 O SHIELD BOARD CABLE 1L 24vpc 50 STD E 2 SS 3 COMMON 100 OPTION Bees o a 5 ak DISPLAY MEMBRANE 1 BOARD 2 3 4 1 MIX INPUT 5 2 PURGE INPUT 6 3 JOB COMPLETE INPUT EIS C 5 POWER DIST 6 DIGITAL INPUT COMMON 10 TERMINAL 1 DIGITAL INPUT COMMON 11 BLOCKS 2 RECIPE BIT 0 INPUT 3 RECIPE BIT 1 INPUT 4 RECIPE BIT 2 INPUT 5 RECIPE BIT 3 INPUT 6 RECIPE BIT 4 INPUT 7 RECIPE BIT 5 INPUT 1 8 RECIPE CHANGE INPUT DISPLAY 2 INTEGRATION 3 BOARD 1 DIGITAL OUTPUT COMMON POWER 4 2 PURGE RECIPE CHG ACTIVE OUTPUT 5 3 MIX ACTIVE OUTPUT 6 4 MIX READY OUTPUT 5 FILL ACTIVE 6 FLOW CAL ACTIVE 5 7 FLOW RATE ALARM OUTPUT 7 FLOW CONTROL CAL BLK 8 DIGITAL OUTPUT COMMON POWER T 2 GUN TRIGGER WHT 2 1 DIGITAL OUTPUT COMMON POWER 12 3 DIGITAL IN COMMON RED 13 2 SPECIAL OUTPUT 41 4 REMOTE STOP GRN 4 3 SPECIAL OUTPUT 2 13 ES 4 SPECIAL OUTPUT 3 5 ALARM RESET 5 15 6 ALARM OUT
30. EasyKey and the current Autokey setting 2K or has changed since the level control data was originally initialized Level Control LC Range Error Occurs if level control data includes a valve range exceeding the capability of the machine Flush the system or perform a color change If possible identify the origin of the reboot or power cycle Reinstall the Autokey or verify that the Autokey is set properly Verify that the source data is from a valid recipe 1 60 Verify that the Autokey is set properly or that the configu ration file is valid Verify that the configuration file is valid Verify that the configuration file specifications and the hardware conform Verify that the recipe specifications and the hardware conform Verify that the Autokey is set properly Set level control data correctly Modbus MB Overflow Occurs if the Modbus connec Verify the Modbus protocol to the EasyKey tion to a PLC experiences data overflow 84 312776E Alarm Troubleshooting Table 11 Alarm Troubleshooting E 20 PURGE INITIATE ALARM Cause System detects atomizing air to the gun when purge is Shut off gun air selected For systems with gun flush box gun is not in the box Place gun in gun flush box Verify that gun flush box is when purge is selected operating properly For systems with auto dump on gun is not in the box Place gun in gun flush box Verify that gun flush box is when
31. Key Purge Mode Starts Standby mode Green LED remains lit while in Standby mode Starts Purge mode Green LED remains lit while in Purge mode Alarm Indicator red Display Recipe Indicator green TI11614A Fic 4 Booth Control see Table 2 312776E EasyKey Display and Keyboard EasyKey Display and Keyboard LCD Display a Navigation Keys FiG 5 EasyKey Display and Keypad Display Shows graphical and text information related to setup and spray operations Back light will turn off after 10 minutes without any key press Press any key to turn back on Keypad Used to input numerical data enter setup screens scroll through screens and select setup values In addition to the numbered keys on the EasyKey key pad which are used to enter values in setup there are keys to navigate within a screen and between screens and to save entered values See Table 3 312776E Keypad Q TI11630A Alarm Reset Key Table 3 EasyKey Keypad Functions see FiG 5 0 ra Setup press to enter or exit Setup mode Enter if cursor is in menu box press Enter key to view menu Press Enter to save a value either keyed in from the numerical keypad or selected from a menu Up Arrow move to previous field or menu item or to previous screen within a group Down Arrow move to next field or menu item or to next screen within a group Left Arrow move to previous screen
32. Limit Enter the high flow rate limit 1 to 3999 cc min Recipe Setup Screen 7 45 Recipe Screen 7 This screen appears only if Flush and Fill Input is set to Recipe in Option Screen 1 page 31 and Special Out puts is set to 1 2 3 or 4 in Configure Screen 5 page 30 The I O board has four programmable outputs 39 Setup Mode Recipe 0 Screens NOTE See FIG 38 page for a map of the Recipe 0 screens Detailed screen descriptions follow Hecipe 0 is typically used e in multiple color systems to purge out material lines without loading a new color e atthe end of a shift to prevent hardening of cata lyzed material NOTE Each screen displays the current screen number and the total number of screens in the group The total number of screens in a group and the fields displayed on each screen may vary depending on selections made in the System Configuration Screens and Option Screens Recipe 0 Screen 1 hecipe Air Solvent 5 First Purge source Type Final Purge Source Air Chop Time 2 0 sec Solvent Chop Time 2 0 sec MEE Calibration Fic 46 Recipe 0 Screen 1 alant First Purge Source Select Air Solvent or 3rd Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 29 Chop Type Select Air Solvent or Air 3rd Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 29 T
33. Operating Cycle Dynamic Dosing 45 Mix Manifold Valve Settings 48 Air Flow Switch AFS Function 49 Start dede ae Vd S dien 50 OON LO 52 Pressure Relief Procedure 52 4 9 nro 56 Solvent Push Feature 60 Meter Calibration 61 Color Change 63 Color Change Procedures 63 Color Change Sequences 63 Alarms and Warnings 75 System Alarms 75 System Warnings 75 Alarm Troubleshooting 76 Schematic Diagrams 87 System Pneumatic Schematic 87 System Electrical Schematic 88 EasyKey Electrical Schematic 90 Meter Performance Data G3000 on A and B 91 Meter Performance Data G3000 on A Coriolis on B 92 Technical Data 93 Graco Standard Warranty 94 Graco Information 94 312776E Related Manuals Component Manuals in English Manual Description 313386 Basic Web Interface Advanced Web Inter face 406799 15V256 Automatic System Upgrade Kit 406800 15V825 Discrete I O Board Kit 312776E Related Manuals Equipment Approvals Equipment appro
34. Operation G 7 GRACO 2KS Plural Component Proportioner En Manual system for proportional mixing of plural component coatings For professional use only Approved for use in explosive atmospheres except the EasyKey Important Safety Instructions See page 4 for model information including maximum working Read all warnings and instructions in this pressure Equipment approval labels are on page 3 Some manual Save these instructions components shown are not included with all systems amp M Ja 1 e 12504 0359 APPROVED x 1126 PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 3 Equipment Approvals 3 System Configuration and Part Numbers 4 Configurator Key 4 Standard Features 5 ACCeSSOLIBS cac HCM 6 ES I 7 Important Two Component Material Information 9 Isocyanate Conditions 9 Material Self ignition 9 Keep Components A and B Separate 9 Moisture Sensitivity of Isocyanates 9 Changing Materials 9 Glossary of Terms 10 x le Bob CH 12 12 Component Identification and Definition 12 Booth Control
35. PUT BLU fF I 6 8 COMMON POWER 16 7 DIGITAL OUTPUT COMMON ORG 7 17 8 POT LIFE YEL 8 18 9 FLOW RATE ANALOG IN PUR 19 10 FLOW RATE ANALOG COMMON GRAY 1 110 gt gt CABLE 7 FOIN BLK 3 L FO OUT BLU WEB SERVER 88 312776E 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 Hazardous Area HAZARDOUS AREA 3X CABLE PWR RED BLACK FLOW METER A I SG WHITE C 1 PWR RED 4 o artes FLOW METER B LS METERS 56 ALTE FLUID PANEL CONTROL BOX O 2L PWR RED 2 TEL EMI BACH FLOW METER SOLVENT 0 00000000 4 SHIELD GRN SS n 5 1 SIG RED GROUND V P ANALOG OUT WHT 2 COM BLK TERMINAL S PRESS GRN 1 UNUSED a 12 V RED i 2 F1 LUNUSED GND BLK Eg CHASSIS BARE 1 PRESSURE GRN 3 UNUSED 2 COM RED 4 UNUSED 5 UNUSED 3 EX WHT 6 1 tunusep B PRESSURE BLK SHIELD BARE 9 ym ELELE 14523 COLOR
36. Pressure Ensure precise pressure regulation It is recommended that the component A pressure be 5 15 lower than the component B pressure e Component B Pressure Ensure precise pressure regulation It is recommended that the component B pressure be 5 15 higher than the component A pressure NOTE When using dynamic dosing it is very important to maintain a constant well regulated fluid supply To obtain proper pressure control and minimize pump pul sation install a fluid regulator on the A and B supply lines upstream of the meters In systems with color change install the regulator downstream of the color catalyst valve stack To Static Proportioned Material Mixer 52 Schematic Diagram of Dynamic Dosing Operation 312776E 45 System Operation Select a Component B Restrictor Size Install the 15U955 Injection Kit in the fluid manifold as explained in the ProMix 2KS Installation manual Use the charts provided in that manual to select an appropri ate restrictor size based on the desired flow and mix ratio Turn On Dynamic Dosing 1 Onthe EasyKey press the Setup key to access the Set Up Home screen Select System Configu ration to access the configuration screens FIG 53 Set Up Home 2KS Recipe amp Advanced Setup System Configuration EK 2 04 0094 l xA Las FP 2 04009 AK zK Manual AF 1042 0198 IP 192 166 176 1 MAL 0 04 8 504 3 Selecti
37. S Intrinsically Safe IS System Install Electronic Proportioner per IS Control Drawing No 289833 EasyKey Interface IS Associated Apparatus for use in non hazardous location with IS Connection to Smart FMO8ATEX0074 APPROVED Fluid Plate IS Label Location Apparatus for use Label Location EM Class Division 1 Group D T3 on Fluid Station CC Hazardous Locations on EasyKey 12423 Read Instruction Manual 112418 AIR WPR Warning Substitution of components Maximum Fluid may impair intrinsic safety PART SERIES SERIAL Working Pressure Configured Part Number is listed here MPa We GRACO INC P O Box 1441 Ps 5 Minneapolis TEMP 50 C 122 F GRACO 55440 U S A Fic 1 Identification Label 4 312776E Hazardous Location Approval System Configuration and Part Numbers Models using 23000 G3000HR or intrinsically safe Coriolis meter for both A and B meters are approved for installation in a Hazardous Location Class Div Group D or Zone Group 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 MD2531 has a maximum working pressure of 3000 psi 21 MPa 210 bar Chec
38. Solvent Catalyst Change Solvent Color Change A Catalyst Change B First Purge one of these Dispense A Dispense B Gun Trigger s by Operator First Purge Time 0 gt 1 Chop Time air solvent or air 3rd flush 1 22 Final Purge Time 2 23 Mixed Fill Time 3 gt 4 Notes Purge from old recipe Fill from new recipe FiG 84 Color Change Chart 15 Dispense A Dispense B Gun Trigger s by Operator First Purge Time 0 gt 1 Chop Time air solvent or air 3rd flush 1 22 Final Purge Time 2 23 Wait for External Color Change Ready signal before advance to step 4 3 24 Mixed Fill Time 4 25 Notes Purge from old recipe Fill from new recipe Recipe Change Purge Active Output Recipe Change Fill Active Output FiG 85 Color Change Chart 16 312776E ProMix 2KS Recipe Change Chart 15 Same A Same B Time Sequence Solvent Chop Time 3rd Flush Chop Time ProMix 2KS Recipe Change Chart 16 External Color Change Option Time Sequence Air Chop Time Solvent Chop Time 3rd Flush Chop Time Load tables from new recipe Load tables from new recipe Color Change 73 Color Change ProMix 2KS Recipe Change Chart 17 Recipe 0 OR 61 to Recipe X with Dump Valves and 3rd Flush Valve Dump B Color Change Solvent Catalyst Change Solvent Color Change A Time Sequence D E Mixed Fill Time does not begin until the Exiting Fill Time and Color Catalyst Fill Time is compl
39. ally safe connections for Class Div 1 Group D 50 60 Hz US 20 C to 50 C 7 Minneapolis MN APPROVED Install per 289833 2 6 55440 U S A i Ex ia ORAGO Um 250 V FMO8ATEX0072 C us We GRACO INC Box 1441 13582 ATEX Certificate is listed here System Configuration and Part Numbers System Configuration and Part Numbers Configurator Key The configured part number for your equipment is printed on the equipment identification labels See FiG 1 for location of the identification labels The part number includes one digit from each of the following six categories depending on the configuration of your system Manual Control and Display and B Meter Color Valves Catalyst Valves 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 owitch Kits 1 8 in Coriolis A Valves 2 Valves er Gun Flush Box and G3000 B low pressure low pressure i G3000 A and 1 8 4 Valves 3 bes Gun Flush Box in Coriolis B low pressure high pressure its 1 8 in Coriolis A 1 Valves G3000HR pressure G3000HR A and iste 1 8 in Coriolis 0 pressure 1 8 in Coriolis A 4 high pressure ProMix 2K
40. ample 151270 1 01 If the version is older than 1 01 replace the board e software versions and DIP switch settings are correct and you still have E 12 alarms then the sys tem has a bad connection bad cable or bad circuit board Use a multimeter on the CAN connectors to test whether there is a good connection between systems If there is you have a bad circuit board If there is not you have a bad connector connection or cable Communication between the Color Change Module and Verify condition of fuse and replace if necessary See the Fluid Station is interrupted The fluid control board Repair Parts manual fuse is blown Communication between the Booth Control and the Fluid Verify that the cable is correctly connected Station is interrupted 82 312776E Alarm Troubleshooting Table 11 Alarm Troubleshooting E 13 HIGH FLOW ALARM 14 LOW FLOW ALARM may also be set as Warnings Cause Fluid system is producing too much or too little flow Troubleshoot fluid system for restrictions leaks exhausted fluid supply incorrect settings etc Increase or decrease flow rate as required E 15 SYSTEM IDLE WARNING Mix input is high but the gun has not been triggered for 2 If not painting clear alarm and resume operation minutes If painting shut down and inspect fluid meter and air flow switch E 16 SETUP CHANGE WARNING NN The system setup parameters have been changed No action r
41. be Light Alarm Indicator Kit 15V337 Advanced Web Interface 15V256 Automatic Mode Upgrade Kit 280555 3000 Solvent Flow Meter Kit 6 312776E 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 7 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
42. beaker a To avoid splashing slowly open sampling valves b Formore accurate calibration adjust the valve to dispense at a flow rate similar to your produc tion spray flow rate c Dispense a minimum of 250 cc make sure enough material is dispensed to accurately read the volume with your beaker The A and B vol umes do not have to be equal or at any particu lar ratio d Close sampling valve tightly 9 The volume that the ProMix measured displays on the EasyKey 10 Compare the amounts on the EasyKey to the amount in the beakers NOTE For maximum accuracy use a gravimetric mass method to determine the actual volumes dis pensed 11 If the screen and actual volumes are different enter the actual dispensed volume in cc for A B or Sol vent Volume field and press the Enter key If the value was substantially different repeat the calibration process NOTE If the screen and actual volume is the same or if for any reason you want to cancel the calibra tion procedure scroll to Abort on the Calibration Screen menu and press the Enter 62 12 13 14 15 After the volume for A or Solvent is entered the ProMix 2KS controller calculates the new flow meter K factor and shows it on the Calibration Screen NOTE K factor values on the screen are viewable only If needed you can manually edit the K factors in Advanced Setup Screen 4 page 35 or Recipe Setup Sc
43. c 41 Recipe Setup Screen 3 This screen appears only if Flush and Fill Input is set to Recipe in Option Screen 1 page 31 First Purge Source Select Air Solvent or 3rd Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 29 Chop Type Select Air Solvent or Air 3rd Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 29 This refers to the process of mix ing air and solvent or air and 3rd flush fluid together during the flush cycle to help clean the lines and reduce solvent usage Final Purge Source Select Air Solvent or 3rd Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 29 Air Chop Time Enter the air chop time 0 0 to 99 9 seconds Solvent Chop Time 3rd Flush Valve Chop Time Enter the solvent or 3rd flush valve chop time 0 0 to 99 9 seconds 38 Recipe Setup Screen 4 Gun 1 Gun 2 10 sec 20 sec 10 sec 10 sec Recipe First Purge Time Total Chop Time Final Purge Time Fill Time MESE Calibration Fic 42 Recipe Setup Screen 4 This screen appears only if Flush and Fill Input is set to Recipe in Option Screen 1 page 31 If Number of Guns is set to 2 in Configure Screen 4 page 29 a Gun 2 column will appear in this screen First Purge Time Enter the first purge time 0 to 999 seconds Total C
44. ced Setup Screens NOTE See FiG 32 for a map of the Advanced Setup Screens Detailed screen descriptions follow Advanced Setup screens 2 3 4 and 5 appear depending on selections made in Option screens 1 and 2 Chop Final Purge Source Air Chop Time solvent Chop Time Sec Gun 1 Gun 2 First Purge Time 10 sec Total Chop Time 20 sec Final Purge Time 10 sec Fil Time 10 Advance cCc pulse 0 119 0 119 solvent Meter 0 119 mi Fic 32 Advanced Setup Screens 312776E First Purge Source Air Solvent Advanced Calibration ed Calibration Gun 1 Potlite Volume Color Catalyst Purge Color Catalyst Fill Advanced Calibration ooo CH oet Up Home 2 Recipe amp Advanced Setup system Configuration 2 04 009 BC 1 54 1 1 FP 2 104 009 AK ZK hManual C2 1042 0196 IP 192 168 178 1 00204AA3804F Meter Calibration Measured Actual Volume Volume Bee 0 119 cc pulse Calibration Recipe Tolerance Color Valve Catalyst Valve Coloration Setup Mode 112786 33 Setup Mode NOTE Each screen displays the current screen number and the total number of screens in the group The total number of screens in a group and the fields displayed on each screen may vary depending on selections made
45. cludes a color change module Enter the catalyst valve number 1 to 4 312776E Setup Mode Recipe Setup Screen 2 Recipe Minimum Flush Volume z cc Potlife Time minutes Color Catalust Purge 5 sec Color Catalyst Fill sec MESE Calibration Fic 40 Recipe Setup Screen 2 Minimum Flush Volume This field only appears if Flush Volume Check is set to On in Option Screen 1 on page 31 Enter the mini mum flush volume 0 to 999 cc Entering O disables this function Potlife Time Enter the potlife time 0 to 999 minutes Entering O dis ables this function Color Catalyst Purge This field only appears if the system includes a color change module and Flush and Fill Input is set to Rec ipe in Option Screen 1 page 31 Enter the purge time to 99 seconds It refers to the amount of time required to flush the lines from the color or catalyst mod ule to the dose valve or dump valve Color Catalyst Fill This field only appears if the system includes a color change module and Flush and Fill Input is set to Rec ipe in Option Screen 1 page 31 Enter the fill time 0 to 99 seconds It refers to the time required to fill the lines from the color or catalyst module to the dose valve or dump valve 37 Setup Mode Recipe Setup Screen 3 Recipe First Purge Source Type Final Purge Source Air Chop Time 2 0 sec Solvent Chop Time 2 0 sec MEE Calibration Fi
46. e First Purge Time 0 gt 1 Chop Time air solvent or air 3rd flush M1 gt M2 Final Purge Time M2 gt M3 Mixed Fill Time M3 gt M4 Notes Purge from old recipe Fill from new recipe Fic 70 Color Change Chart 1 ProMix 2KS Recipe Change Chart 2 A1 to A2 B1 to B2 with Dump Valves and 3rd Flush Valve Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B PO Color Purge Time 0 gt 1 Color Fill Time P1 gt P2 Catalyst Purge Time P2 gt P3 Catalyst Fill Time P3 gt P4 Time Sequence Air Chop Time Solvent Chop Time First Purge one of these 3rd Flush Chop Time olvent Purge 3rd Flush Valve Two Second Solvent Purge Dispense A Dispense B Gun Trigger s by Operator MO M1 M2 M3 Final Purge Time M3 gt M4 Mixed Fill Time 4 gt 5 Notes Purge from old recipe Fill from new recipe Applies to ALL charts when 3rd Flush Valve is ON Fic 71 Color Change Chart 2 66 Load tables from new recipe M CC Purge Fill Timers are independent of Mixed Material Purge Timers This line defines when the Mixed Fill Time begins The longer of the two timers defines when the Mixed Fill Time begins M5 Load tables from new recipe 312776E Color Change ProMix 2KS Recipe Change Chart 3 A1 to A2 same B with Dump Valves Time Sequence Eu Color Change Solvent Color Change CaaystchaggB PO P1 Color Purge T
47. e Booth Control Trigger the gun to relieve pressure If you are using a high pressure gun engage the trig ger lock Remove spray tip and clean tip separately 2 Attach solvent supply lines as follows Single color single catalyst systems discon nect the component A and B fluid supplies at the flow meter inlets and connect regulated sol vent supply lines e Multiple color single catalyst systems dis connect only the component B fluid supply at the flow meter inlet and connect a regulated sol vent supply line e Multiple color multiple catalyst systems connect the solvent supply lines to the desig nated solvent valve on the color and catalyst valve stacks Do not connect a solvent supply to either flow meter 57 System Operation 3 Adjust the solvent fluid supply pressure Use the lowest possible pressure to avoid splashing 4 Remove the Fluid Station cover to access the sole noid valves See FIG 65 5 Purge as follows e Single color single catalyst systems Purge component A side Press the manual override on the Dose Valve A solenoid valve and trigger the gun into a grounded metal pail Purge component B side Press the manual override on the Dose Valve B solenoid valve and trigger the gun into a grounded metal pail until clean solvent flows from the gun Repeat to thoroughly clean the fluid integrator e Multiple color single catalyst systems Select Recipe 0 and press Enter 0 pu
48. e required to fill the lines from the color or catalyst change module to the mix manifold Coriolis Meter a non intrusive flow meter often used in low flow applications or with light viscosity shear sensi tive or acid catalyzed materials This meter uses vibra tion to measure flow Digital Input and Output a description of data which is transmitted as a sequence of discrete symbols most commonly this means binary data represented using electronic or electromagnetic signals Discrete I O refers to data that constitutes a separate entity and has direct communication to another control Dose Size the amount of resin A and catalyst B that is dispensed into an integrator Dose Time Alarm the amount of time that is allowed for a dose to occur before an alarm occurs Dynamic Dosing Component A dispenses constantly Component B dispenses intermittently in the necessary volume to attain the mix ratio 10 Ethernet a method for directly connecting a computer to a network or equipment in the same physical location Fiber Optic Communication the use of light to trans mit communication signals Final Purge Source source of the media used in the final purge cycle User settable to air purge valve sol vent purge valve or 3rd purge valve Final Purge Time duration of the final purge cycle User settable from 0 999 seconds First Purge Source source of the media used in the first purge cycle User settable
49. ed by the Status Screen see page 21 GRACO Control 2 000 013 Fasukey 2 0 013 FIG 7 Splash Screen The Splash screen will also momentarily display Estab lishing Communication If this display remains for more than one minute check that the fluid station circuit board is powered up LED is on and that the fiber optic cable is properly connected see installation manual NOTE If the software version of the fluid plate does not match the version of the EasyKey the EasyKey will update the fluid plate and the fluid plate programming screen will appear until the update is completed Programming Fluid Flate Lade Fic 8 Fluid Plate Programming Screen 312776E Run Mode Screens 19 Run Mode Screens ob Complete Are uou sure uou want to reset job totals enter to accept default Fic 9 Run Screens Map 20 Job Total Grand Total 0 Reset Solvent Are uou sure uou want to reset solvent total Alarms Date Time Alarm Liters 0 Liters Liters 0 Liters Press the Setup key to enter Setup mode Level Control Liters Alarm Level Current Volume Level Control 12783 312776 Status Screen e Use the Up 4 or Down 7 keys to scroll through the screens e Press the Setup key to enter the Setup screens from the Status screen e The other keys have no function in this Status Screen 11 9 2009 Fic
50. een 1 e The controller will use the active recipe K factors for meter calibration The active recipe must be recipe 1 to recipe 60 Recipes 0 and 61 do not have K factor values 1 Before calibrating meter A or B prime the system with material For a color catalyst change system make sure the color catalyst valve is open 2 Shut off all spray or dispense devices connected to the ProMix 3 Close both fluid shutoff valves and sampling valves 312776E Meter Calibration 4 Place the beakers minimum size 250 cc in hold ers Put the sampling tubes into the beakers NOTE If tubes need replacing use 5 82 in or 4 mm OD tubing 5 Onthe EasyKey press the Setup key to access setup screens 6 Select Recipe amp Advanced Setup and press the Enter key to select set Up Home 2ES Recipe amp Advanced Setup sustem Configuration EK 2 04 009 BC 0 00 L1 0 00 FP nd C 0 00 AP Vb 0000 0000 192 166 176 1 MAL 00204AR 3204F 7 Press the Right Arrow mp key to select the Calibra tion Screen Press the Enter to select either Dose Valve A B or Solvent Press the Down Arrow 7 key and select Start from the menu Start only one at a time start Actual Volume Meter Calibration Measured volume DG k F actor 0 119 cc pulse Recipe 110 0 61 Meter Calibration 8 Dispense component A B or Solvent into
51. elines e Fluid pressure is high and air pressure is low e Adjust air and fluid pressure See recommended air pressure above 312776E 77 Alarm Troubleshooting Table 11 Alarm Troubleshooting 4 RATIO LOW ALARM Sequential Dosing System The mix ratio is lower than the set tolerance on the previous dose cycle Dynamic Dosing System The mix ratio is lower than the set tolerance for an A to B component volume comparison There is too much restriction in the system Check that the system is fully loaded with material Check that the supply pump s cycle rate is set prop erly Check that the spray tip nozzle is properly sized for the flow and application and that it is not clogged Check that the fluid regulator is set properly If the alarm occurs during start up after purging the flow Restrict gun needle travel to slow down the initial fluid rate was probably too high delivery rate until fluid hoses are loaded with material If the alarm occurred after you were spraying for some Adjust component and fluid supply regulator pres time the pressures from the fluid supplies could be sures until they are about equal f the pressures are unbalanced already about equal verify that component A and B dose valves are operating properly Slow actuation of the component or B valves This can Manually operate the Dispense and B solenoid valves be caused by as instructed in the ProMix 2KS Repair Par
52. em Operation Operation Modes Mix System mixes and dispenses material Standby Stops the system LIN Purge Purges the system using air and solvent Sequential Dosing Components A and B dispense sequentially in the nec essary volumes to attain the mix ratio Dynamic Dosing In typical operation ratios 1 1 and above component A dispenses constantly Component B dispenses intermit tently in the necessary volume to attain the mix ratio Recipe Color Change The process when the system automatically flushes out the old color and loads a new color Solvent Push The Solvent Push feature enables the user to save some mixed material by pushing it out to the gun with solvent The feature requires an accessory solvent meter See page 60 for complete information 312776E System Operation General Operating Cycle Sequential Dosing 1 The spray gun operator enters and loads the desired recipe The color change LED blinks while recipe is loading then turns solid when complete The operator presses the P HW key to begin operation The ProMix 2KS controller sends signals to activate the solenoid valves The solenoid valves activate Dose Valves A and B Fluid flow begins when the gun is triggered Components A and B are introduced into the fluid integrator Fl one at a time as follows a Dose Valve A DVA opens and fluid flows into the integrator b Flow Meter A MA moni
53. equired See Event Log available through advanced web interface E 17 POWER ON POWER OFF WARNING _ The power to the system has been cycled No action required See Event Log available through advanced web interface Voltage becoming too low due to weak power supply Replace power supply See Repair Parts manual Power wires are disconnected or making intermittent Check that all wires are securely connected Ensure that contact wires are not stretched too tightly Reset button has been pushed 51 on EasyKey display action required See Event Log available through board S3 on Autokey advanced web interface Software update is initiated on EasyKey No action required See Event Log available through advanced web interface E 18 DEFAULTS LOADED WARNING GN The factory defaults have been installed on the system action required See Event Log available through advanced web interface 312776E 83 Alarm Troubleshooting Table 11 Alarm Troubleshooting 19 ALARM The Mix and Purge digital inputs are on at the same time Ensure that only one input is on at a time At least 1 sec delay is required when switching from Mix to Purge or vice versa NOTE The I O alarm incorporates several sub alarms relating to internal data issues as detailed below These alarms may not apply to all software versions Fluid Plate Reboot FP Reboot Occurs if the system detects a fluid plate control board
54. er Table 2 Booth Control Key and Indicator Functions see FIG 4 Key Indicator Definition and Function Displays recipe number in Run mode If an alarm occurs displays the alarm code E1 to E27 and red Alarm indicator blinks number displays after alarm is reset If Solvent Push is on display alter nately shows dashes and the per centage remaining see page 60 Recipe Indicator Green LED stays lit while a recipe is in use LED shuts off when Up or Down keys are pressed or if an alarm occurs LED blinks while a new recipe is loading and turns solid after load ing is complete LED blinks when purging Select a new recipe by pressing Up or Down 7 keys then pressing Enter il Hed LED blinks when an alarm occurs Press key to reset alarm LED shuts off after alarm is reset Alarm Reset Key and Indicator Job Complete Key and Indicator Signals that job is complete and resets A and B totalizers Green LED blinks once after key is pressed Enters selected recipe and starts color change sequence 16 Table 2 Booth Control Key and Indicator Functions see FIG 4 Key Indicator Definition and Function Up Key Scrolls recipe numbers up Down Key Scrolls recipe numbers down Starts Mix mode Green LED remains lit while in Mix mode or in Idle mode Press and hold for 5 seconds to turn on the Solvent Push feature Mix Mode Key Standby Mode
55. ete Exiting Fill Dispense A Dispense B Gun Trigger s by Operator Exiting Fill Time 0 22 Color Fill Time 0 gt 1 Catalyst Fill Time 1 22 Mixed Fill Time 2 53 Notes Mixed Material Purge Timers from old recipe CC Purge Fill Timers and Mixed Fill Time from new recipe Exiting Fill Source and Length are Programmable Load tables from new recipe Fic 86 Color Change Chart 17 ProMix 2KS Recipe Change Chart 18 Recipe 0 OR 61 to Recipe X without Dump Valves and 3rd Flush Valve Time Sequence PF Dump B Color Change Solvent Catalyst Change Solvent Color Change A Exiting Fill Dispense B Gun Trigger s by Operator Exiting Fill Time 0 gt 1 Color Fill Time 1 gt 2 Mixed Fill Time 2 gt 3 Notes Mixed Material Purge Timers from old recipe CC Purge Fill Timers and Mixed Fill Time from new recipe Exiting Fill Source and Length are Programmable Load tables from new recipe 87 Color Change Chart 18 74 312776E Alarms and Warnings Alarms and Warnings NOTE Do not use the fluid in the line that was dis To Reset Alarm and Restart pensed off ratio as it may not cure properly NOTE When an alarm occurs be sure to determine the E Code before resetting it See Table 10 If you forget System Alarms which E Code occurred use the Alarms Screens page 22 to view the last 10 alarms with date and time System alarms alert you of a problem and help prevent stamps off ratio sprayin
56. evel threshold the EasyKey screen will display the Tank Level Low alarm and prompt the user to do one of the following 1 Refill tank volume to clear the alarm 2 Resume mixing by selecting Spray 25 of Remain der If this selection is chosen a second alarm will occur after 25 of the remaining volume is mixed Refill tank volume to clear the alarm Warning Tank Level Low Alarm Color 1 Liters Alarm Level 10 Liters Current Volume 1 Refil Tank Volume 2 eprau 20 of Remainder Selection ii 16 Tank Level Low Screen Tank A Shown 312776E Run Mode Screens 23 Setup Mode Setup Mode NOTE See FiG 17 for a map of the Setup screens Detailed screen descriptions follow Press the Setup key to enter Setup mode Press the Setup key to enter Setup mode Enter Password This screen appears only if a password is activated To access Advanced Setup Screens page vanced Setup Sustem Configuration 33 and Recipe Setup Screens page 36 2 04009 BC 1 4 1 1 Ce ee To access System Configuration Screens 48 507 MC 1042 0198 IP 192 168 178 1 MAC 00204883804 page 27 Press the Setup key to exit Setup mode and return to the Status Screen Setup Locked This screen appears momentarily if a password is activated 11 9 2009 112784 Fic 17 Setup Screens 24 312776E Setup Mode Password Screen Set Up Home Screen I
57. ey Dose A solvent purge valve B side and color change solvent valves if used will open Meter Calibration BEN Actual Volume k F actor 0 119 cc pulse Recipe Fic 68 Calibration Screen Measured Volume 7 avoid splashing slowly open the sampling valves and dispense solvent until the valves and tubes are clean NOTE When performing a calibration purge the solvent valve s close automatically after 2 minutes or when Abort is selected on the screen 312776E System Operation 8 Close sampling valves NOTE Select Abort on Calibration screen to cancel current calibration and close dose or purge valves 9 Fully open both fluid shutoff valves 10 On a single color system reconnect component fluid supply line to flow meter A NOTE After calibration it is necessary to clean out con taminated mix material Do a manual purge and resume the recipe just tested or do Recipe O then go on to the next recipe 59 System Operation Solvent Push Feature The Solvent Push feature enables the user to save some mixed material by pushing it out to the gun with solvent The quantity saved is 50 of the potlife volume entered in Advanced Setup Screen 1 on page 34 If there are 2 guns the smaller potlife volume is used Solvent Push requires an accessory solvent meter MS Order Graco Part No 280555 3000 Solvent Meter Kit See manual 308778 1 See 69 In
58. f a password has been activated see Configure Screen 1 page 28 the Password screen will appear set Up Home Pros SER You must enter the password to access the Set Up Home Screen Entering the wrong password returns the Recipe Advanced setup display to the Status Screen system Configuration NOTE If you forget the password you can reset the Cr onanno p44wvv password to 0 using the ProMix 2KS Web Interface 2 04 0039 LAA Gl LA 2 04 009 AK 2K Manual P V5 5 0 7 1042 0198 IP 192 168 178 1 MAC 0204883804 Fic 20 Set Up Home Screen Enter Password This screen displays when you enter Setup mode From it you can go to Recipe and Advanced Setup Screens pages 33 39 or System Configuration Screens pages 27 30 Press the Enter key to go to the selected screen set The screen also displays software versions and internet addresses of various components The values shown in 20 are only examples and may vary on your screen NOTE If a password is activated Setup Locked dis See Table 4 for further information plays momentarily after exiting Setup mode and return Fic 18 Password Screen ing to the Status Screen A lock 4 symbol appears on the Status Screen Setup Locked FiG 19 Setup Locked Screen 312776E 25 Setup Mode Table 4 Component Software Versions Display may vary from examples Component shown Description EK EasyKey 2 00 0
59. fuse and replace if necessary See blown Repair Parts manual The fiber optic cable between the EasyKey and Fluid Verify that the cable is correctly connected See Installa Station is not connected tion manual The fiber optic cable is cut or bent Verify that the cable has not been cut or bent at a radius smaller than 1 6 in 40 mm Dirty fiber optic cable ends Disconnect fiber optic cable ends and clean with a lint free cloth A communication cable or connector failed Replace cable E 2 POTLIFE ALARM The potlife time has been exceeded for the mixed mate rial Press the Alarm Reset key to stop the audible alarm Purge the system with solvent fresh mixed mate NOTICE rial or a new color To prevent mixed material from curing in the equip ment do not shut off power Follow one of the solu tions at right e Solvent Purge See Purging Mixed Material on page 56 The system purges until the preset purge time is complete New Mixed Material Purge Go to Mix mode and spray the required volume to restart the timer Color Change Perform a color change page 63 76 312776E Alarm Troubleshooting Table 11 Alarm Troubleshooting E 3 RATIO HIGH ALARM Sequential Dosing System The mix ratio is higher than the set tolerance on the previous dose cycle Dynamic Dosing System The mix ratio is higher than the set tolerance for an A to B component volume comparison There is too little restriction in
60. g If an alarm occurs operation stops and the following occurs To reset alarms see Table 11 Many alarms can be e A red LED illuminates steadily or blinks on the Booth Control Booth Control displays an alarm E Code E 1 to E 27 See FIG 88 Table 10 System Alarm Warning Codes 1 for E 2 only see page 28 to set for Code Description e Status bar on the EasyKey Display shows the alarm E Code with a description see Table 10 pt ete EG Overdose BIA Dose Too Short Alarm Page 79 ES Dose Alam Pages0 ES Min Setup Alarm E 12 CAN Network Communication Error Page 82 Alarm Recipe Indicator green TI11614A Fic 88 Booth Control System Warnings Table 10 lists the System Warning Codes Warnings do not stop operation or sound an alarm They are saved in the date time stamped log which can be viewed on a PC using the ProMix 2KS Web Interface see manual cleared by simply pressing the Alarm Reset 5 312776 75 Alarm Troubleshooting Alarm Troubleshooting Table 11 Alarm Troubleshooting E 1 COMM ERROR No power to the EasyKey Connect power to EasyKey No power to Fluid Station The intrinsically safe power Verify that the cable is correctly connected See Installa cable between the EasyKey and Fluid Station is not con tion manual nected No power to Fluid Station The fluid control board fuse is Verify condition of
61. ge operation aborts The Booth Control enters Standby r mode at the previous color 7 When you are ready to spray remove the gun from the gun flush box if used and close its door NOTE The gun flush box door must be closed for the atomizing air valve to open 8 Press the key to start spraying Single Color Systems 1 Follow procedure for Purging Fluid Supply Sys tem page 57 2 Load the new color See Start Up page 50 3 Press the Mix P key to start spraying 312776E Color Change Color Change Sequences 70 through FIG 87 illustrate various color change sequences See Table 9 to determine which figure to ref erence based on the recipe change and system config uration The time sequences are detailed in the following paragraphs NOTE For software version 2 04 xxx and older the sys tem uses the color catalyst purge and fill times from the new recipe NOTE See Setup Mode on page 24 to select purge sources and set desired purge chop and fill times NOTES e The system uses old recipe data for the purge cycle However it opens the new color catalyst valve based on the new recipe data e The system uses the new recipe data for the fill cycle e For the one gun flush box option the spray gun must be inserted in the GFB during the entire color change cycle purge and fill The GFB trigger output will be on during the recipe change cycle e For the two gun flush b
62. ge Time 0 gt 1 Catalyst Fill Time P1 gt P2 First Purge one of these Air Purge Solvent Purge 3rd Flush Valve Dispense A Dispense B Gun Trigger s by Operator First Purge Time 0 gt 1 Chop Time air solvent or air 3rd flush M1 gt M2 Final Purge Time M2 gt M3 Mixed Fill Time M3 gt M4 Notes Purge from old recipe Fill from new recipe Fic 74 Color Change Chart 5 Sag M eee Color Change Solvent HERE Catalyst Change Solvent Color Change ProMix 2KS Recipe Change Chart 5 B1 to B2 same A with Dump Valves Time Sequence Air Chop Time Solvent Chop Time 3rd Flush Chop Time ProMix 2KS Recipe Change Chart 6 A1 to A2 B1 to B2 with Dump Valves 2 GFBs 4 CC Purge Fill Timers are independent of Mixed Material Purge Timers This line defines when the Mixed Fill Time begins The longer of the two timers defines when the Mixed Fill Time begins Load tables from new recipe Catalyst Change B m Color Purge Time P0 gt P1 Color Fill Time P1 gt P2 Catalyst Purge Time P2 gt P3 Catalyst Fill Time P3 gt P4 First Purge one of these INN Air Purge P Solvent Purge i 3rd Flush Valve Dispense B Gun Flush Box Output 1 Gun Flush Box Output 2 First Purge Time 0 gt 1 Chop Time air solvent or air 3rd flush 1 gt 2 Final Purge Time M2 gt M3 Mixed Fill Time M3 gt M4 Notes Purge from old
63. hane and acid catalyzed paints It is not for use with quick setting paints those with a potlife of less than 15 minutes e Can proportion at ratios from 0 1 1 to 50 1 in 0 1 e Color change options are available for low pressure increments with the wall mount fluid station 300 psi 2 1 MPa 21 bar air spray and high pres e Has user selectable ratio assurance and can main sure 3000 psi 21 MPa 210 bar systems with up tain up to 1 accuracy depending on materials to 30 color change valves and up to 4 catalyst and operating conditions change valves e Models are available to operate air spray air assisted systems with a capacity of up to 3800 NOTE Optional accessories are available for in field cc min installation to achieve 30 colors Component Identification and Definition See Table 1 FiG 2 and FiG 3 for the system components Table 1 Component Descriptions EasyKey EK Used to set up display operate and monitor the system The EasyKey accepts 85 250 VAC 50 60 Hz line power and converts that power to acceptable low voltage and optical signals used by other system components Booth Control BC Used by the operator for daily painting functions including choosing recipes initiating job complete reading clearing alarms and placing the system in Standby Mix or Purge mode It is typically mounted inside the booth or near the painter Fluid Station ST Includes air control solenoids flow switches and
64. he 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 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 65 NOTE If a Dose Time alarm E 7 E 8 occurs clear the alarm 3 Doa complete system purge following the instruc tions under Purging Using Recipe 0 page 57 4 Shut off the fluid supply to the solvent purge valve SPV and the air supply to the air purge valve APV FiG 67 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 65 Verify that solvent pressure is reduced to O NOTE If a Purge Volume alarm E 11 occurs clear the alarm 312776E Systems with Color Change and without Dump Valves NOTE This procedure relieves pressure through the sampling valve 1 Complete all steps under Single Color Systems page 52 Close the A side shutoff valve SVA 67 Open the A side sampling valve RVA Direct the A side sampling tube into a waste con tainer See FIG 66 Open the color change module Using the
65. his refers to the process of mix ing air and solvent or air and 3rd flush fluid together during the flush cycle to help clean the lines and reduce solvent usage Final Purge Source Select Air Solvent or 3rd Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 29 40 Air Chop Time Enter the air chop time 0 0 to 99 9 seconds Solvent Chop Time 3rd Flush Valve Chop Time Enter the solvent or 3rd flush valve chop time 0 0 to 99 9 seconds Recipe 0 Screen 2 Recipe Ii Latalust Purge First Purge Time Total Chop Time Final Purge Time Gun 1 Gun 2 SEC MESE Calibration Fic 47 Recipe 0 Screen 2 If Number of Guns is set to 2 in Configure Screen 4 page 29 a Gun 2 column will appear in this screen Color Catalyst Purge Time This field only appears if the system includes a color change module Enter the purge time 0 to 999 sec onds First Purge Time Enter the first purge time 0 to 999 seconds Total Chop Time Enter the total chop time 0 to 999 seconds Final Purge Time Enter the final purge time 0 to 999 seconds 312776E Recipe 0 Screen 3 IF lsec hecipe Minimum Flush Exiting Fill Source Exiting Fill Time MEE Calibration Fic 48 Recipe 0 Screen 3 This screen only appears if Solvent Monitor is set to Meter in Configure Screen 5 page 30 and Flush Vol ume Check is set to On
66. hop Time Enter the total chop time 0 to 999 seconds Final Purge Time Enter the final purge time 0 to 999 seconds Mixed Material Fill Time Enter the mixed material fill time 0 to 999 seconds It refers to the amount of time that is required to load mixed material from the dose valves to the applica tor gun 312776E Recipe Setup Screen 5 Recipe kK Factar H Meter B Meter cc pulse 0 119 0 119 Solvent Meter 0 119 MEE Calibration FIG 43 Recipe Setup Screen 5 This screen appears only if K factor Input is set to Rec ipe in Option Screen 1 page 31 K factor A Meter Enter the k factor cc pulse for flow meter A This is the amount of material that passes through the flow meter per pulse electrical pulse signal K factor B Meter Enter the k factor cc pulse for flow meter B K factor Solvent Meter This field only appears if Solvent Monitor in Configure Screen 5 page 30 is set to Meter Enter the k factor cc pulse for the solvent flow meter 312776E Setup Mode Recipe Setup Screen 6 Recipe 0 cc min min Flow Rate Monitor Low Flow Limit High Flow Limit MESE Calibration Fic 44 Recipe Setup Screen 6 This screen appears only if Flow Rate Monitor is set to On in Option Screen 2 on page 32 Flow Rate Monitor Select the desired flow rate monitoring Off Warning or Alarm Low Flow Limit Enter the low flow rate limit 1 to 3999 cc min High Flow
67. ime 0 gt 1 Color Fill Time P1 gt P2 CC Purge Fill Timers are independent of Mixed Material Purge Timers This line defines when the Mixed Fill Time Air Chop Time begins The longer of the two timers Solvent Chop Time defines when the Mixed Fill Time First Purge one of these 3rd Flush Chop Time begins Air Purge NI Solvent Purge 3rd Flush Valve Dispense A Dispense B Gun Trigger s by Operator First Purge Time 0 gt 1 Chop Time air solvent or air 3rd flush 1 gt 2 Final Purge Time M2 gt M3 Mixed Fill Time M3 gt M4 Notes Load tables from new recipe Purge from old recipe Fill from new recipe FIG 72 Color Change Chart ProMix 2KS Recipe Change Chart 4 A1 A2 same B without Dump Valves Time Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Solvent Chop Time First Purge one of these 3rd Flush Chop Time 3rd Flush Valve Dispense A Gun Trigger s by Operator Color Purge Time 0 21 Color Fill Time 1 2 First Purge Time 2 23 Chop Time air solvent or air 3rd flush 3 24 Final Purge Time 4 55 Mixed Fill Time 5 26 Notes Load tables from new recipe Purge from old recipe Fill from new recipe FIG 73 Color Change Chart 4 312776E 67 Color Change Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Catalyst Pur
68. in the System Configuration Screens and Option Screens Advanced Setup Screen 1 3S0 sec Sec 1 Potlife Volume Color Catalyst Purge Color Catalyst Fill Advanced Calibration Fic 33 Advanced Setup Screen 1 Gun 1 Gun2 Potlife Volume Enter the potlife volume 1 to 1999 cc for each gun This is the amount of material required to move through the mix manifold hose and applicator gun before the potlife timer is reset Use the following information to determine approximate pot life volume PLV in cc Hose ID inches Volume cc foot Integrator manifold and mixer volume 75 cc Spray Gun Volume 20 cc Hose Volume x Feet of Hose 75 20 PLV Color Catalyst Purge This field only appears if the system includes a color change module and Flush and Fill Input is set to Global in Option Screen 1 page 31 Enter the purge time 0 to 99 seconds It refers to the amount of time required to flush the lines from the color or catalyst mod ule to the dose valve or dump valve 34 Color Catalyst Fill This field only appears if the system includes a color change module and Flush and Fill Input is set to Global in Option Screen 1 page 31 Enter the fill time to 99 seconds It refers to the time required to fill the lines from the color or catalyst module to the dose valve or dump valve Advanced Setup Screen 2 Air Solvent 2 L sec sec First Purge Source Chop Type
69. ing Using Recipe 0 Recipe 0 is typically used e in multiple color systems to purge out material lines without loading a new color e end of a shift to prevent hardening of cata lyzed material To setup Recipe 0 go to Advanced Setup Select the Recipe tab and change the Recipe to 0 The Recipe 0 Setup Screen appears Set the chop times from 0 999 seconds in increments of 1 second 1 Press the Standby r key on the Booth Control Trigger the gun to relieve pressure If you are using a high pressure gun engage the trig ger lock Remove spray tip and clean tip separately 2 If using a gun flush box place the gun into the box and close the lid 3 Select Recipe 0 and press Enter il 4 fagun flush box is not used trigger the gun into a grounded metal pail until the purge sequence is com T AV plete i A 5 The color change LED blinks while Recipe 0 runs and turns solid after purge sequence is complete 6 Ifthe system is not completely clean you can repeat Recipe 0 by pressing Enter A 312776E System Operation Purging Fluid Supply System Follow this procedure before e first time material is loaded into equipment e servicing e shutting down equipment for an extended period of time equipment into storage Some steps are not necessary for initial flushing as no material has been loaded into the system yet 1 Press the Standby key on th
70. int 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 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
71. is spraying and will not generate a Dose Time Alarm E 7 or E 8 This means there is no way to detect a failed meter You could spray pure resin or catalyst for 2 minutes with out knowing e Since the ProMix 2KS does not know it is spraying because there is no gun trigger air flow switch input it will go into System Idle E 15 every 2 minutes when in Mix mode System Idle Warning E 15 This warning occurs if the ProMix is set to Mix gt and 2 minutes have elapsed since the system received a flow meter pulse In applications using the AFS triggering the gun clears the warning and you can start spraying again Without the AFS triggering the gun does not clear the alarm To start spraying again you must press Standby r then Mix gt then trigger the gun 49 System Operation Start Up 1 Gothrough the Pre Operation Checklist in Table 8 Table 8 Pre Operation Checklist V Checklist System grounded Verify all grounding connections were made See the Installation manual All connections tight and correct Verify all electrical fluid air and system connec tions are tight and installed according to the Installation manual Check air purge valve tubing Check the air purge valve supply tube daily for any visible solvent accumulation Notify your supervisor if solvent is present Fluid supply containers filled Check component A and B and solvent supply containers Mix manifold va
72. izes valve response time Closes component A and B ports to integrator during ratio check or meter calibration Open ports during Run Mix operation Open to dispense component A and B while calibrating meters Do not open sampling valves unless fluid shutoff valves are closed 312776E Air Flow Switch AFS Function Air or Air assisted Guns The air flow switch AFS detects air flow to the gun and signals the ProMix controller when the gun is triggered The AFS functions with the flow meters to ensure that system components are functioning correctly For example if a flow meter fails or clogs pure resin or catalyst could spray indefinitely if the ProMix does not detect the condition and intervene which is why the AFS is so important If the ProMix detects through the AFS signal that the gun is triggered yet there is no fluid flow through the meter a Dose Time Alarm E 7 or E 8 occurs after 40 seconds and the system shuts down N AFS lt d 6 113350 60 Air Flow Switches 312776E System Operation Operating Without Air Flow Switch Itis not recommended to run without an air flow switch If a switch fails replace it as soon as possible Airless Gun It is not recommended to use an airless gun with the ProMix 2KS Two issues can arise from operating with out an air flow switch e Without a gun trigger air flow switch input the Pro Mix 2KS does not know it
73. k the identification label on the 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 catalyst change option 0 Meter Option 1 and 2 3000 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 1 and 2 low pressure valves Color Change Option 5 and 6 and Catalyst Change Option 3 high pressure valves 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 312776E 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 3000 psi 21 MPa 210 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 Accessories Accessories Accessory Gun Flush Box Gun Insert Selection 15V354 Third Purge Valve Kit 15V536 Solvent Flow Switch Kit 15V213 Power Cable 100 ft 30 5 m 15G710 Fiber Optic Cable 100 ft 30 5 m 15U955 Injection Kit for Dynamic Dosing 15 034 10 cc Integrator Kit 15 033 25 cc Integrator Kit 15 021 50 cc Integrator Kit 24B618 100 cc Integrator Kit 15W034 Stro
74. keep solvent containers closed when not in use e Never use solvent on one side if it has been contam inated 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 Glossary of Terms Glossary of Terms Air Chop the process of mixing air and solvent together during the flush cycle to help clean the lines and reduce solvent usage Air Chop Time duration of each activation of the air purge valve during a chop sequence User settable from 0 0 99 9 seconds Analog relating to or being a device in which data are represented by continuously variable measurable physical quantities such as length width voltage or pressure Chop Time refers to the total length of the chop sequence during a purge User settable from 0 999 sec onds Closed Loop Flow Control refers to the process when the flow rate is adjusted automatically to maintain a constant flow Color Catalyst Dump refers to the time required to flush the lines from the color or catalyst change module to the mix manifold during a color or catalyst change Color Catalyst Fill refers to the tim
75. l Purge Time and closes when the time expires Fill Step M3 M4 This sequence fills the line from the dose valves to the gun and is also referred to as the mixed material fill The system begins mixing components A and B until the Fill Time expires Purge Active Step M0 M3 The system turns on the Purge Recipe Change Purge Active output during steps Fill Active Step M3 M4 The system turns on the Recipe Change Fill Active out put during step M3 M4 312776E Color Change Table 9 Color Change Chart Reference Starting Ending Color Catalyst Dump 3rd Purge Recipe Recipe Change Change Valves Valve Boxes Refer to Fig OX X w w w 9 X X Xs Ye o _ Low Ww w f e _ Lx e p je _ Number of Gun Flush gt lt gt lt gt lt E Z Z O O O Yes No Yes Yes Yes PE o ow Ys Ww w mnes c X o N oro Fic _ Poorer X _ owe x Ye No Ne oroe _ X Ye N Ne Fes _ ora X No _ X Ne Ne fes _ 0 o Ye 0 No 0 Ys _ 0 Ne
76. lush Purge Dispense A Dispense B Gun Trigger s by Operator First Purge Time 0 gt 1 Chop Time air solvent or air 3rd flush M1 gt M2 Final Purge Time M2 gt M3 Notes All timing from Recipe 0 Fic 79 Color Change Chart 10 70 O P1 P2 Color Catalyst Purge Timers are independent of Mixed Material Purge Air Chop Time Timers Solvent Chop Time 3rd Flush Chop Time Final Purge one of these 312776E 2KS Recipe Change Chart 11 Recipe 0 OR 61 to Recipe X with Dump Valves Time Sequence HESSEN Dump B Color Change Solvent Ng Catalyst Change Solvent Color Change A Catalyst Change B B B Dispense A Gun Trigger s by Operator __ 0 1 2 Color Fill Time 0 gt 1 Catalyst Fill Time 1 22 Mixed Fill Time 2 23 Notes Load tables from new recipe Purge from old recipe Fill from new recipe Fic 80 Color Change Chart 11 ProMix 2KS Recipe Change Chart 12 Recipe X 0 OR 61 to Recipe 0 without Dump Valves Time Sequence Dump A x a Color Change Solvent Color Change Air Chop Time Solvent Chop Time 3rd Flush Chop Time 4 olvent Purge gt gt Final Purge one of these 3rd Flush Valve Dispense A Dispense B Gun Trigger s by Operator Color Purge Time 0 21 First Purge Time 1 22 Chop Time air solvent or air 3rd flush 2 53 Final Purge Time 3 24 Notes All timing from Recipe 0 FiG 81 Color Change Chart 12 3
77. lves set Check that mix manifold valves are set correctly Start with the settings recommended in Mix Mani fold Valve Settings page 48 then adjust as Fluid supply valves open and pressure set Component A and B fluid supply pressures should be equal unless one component is more viscous and requires a higher pressure setting Solenoid pressure set 75 100 psi inlet air supply 0 5 0 7 MPa 5 2 7 bar 2 Turn the AC Power Switch ON ON 0 OFF Z ON 12656 50 62 Status Screen Graco logo software revision and Establishing Communication will display followed by Status screen See page 19 gt At power up the system defaults to Recipe 61 which is not a valid recipe number Initiate a color change to Recipe 0 or a valid recipe num ber 1 60 bottom left corner the system status displays which can be Standby Mix Purge or an alarm notification 11 9 2009 10 29 4 zidccymin 4 Make sure that the Booth Control is working The active recipe number should display and the Standby LED Ore should be lit If this is the first time starting up the system purge it as instructed in Purging Fluid Supply System page 57 The equipment was tested with lightweight oil which should be flushed out to avoid contaminat ing your material Make sure that the Booth Control is in Standby r mode 312776E 6 Adjust component A and B fluid supplies as needed for yo
78. ms Purge when all mixed material is flushed from the sys tem Purge Time the amount of time required to flush all mixed material from the system Purge Volume Alarm E 11 Alarm occurs if minimum flush volume is not achieved Ratio Tolerance the settable percent of acceptable variance that the system will allow before a ratio alarm Occurs Sequential Color Change the process when a color change is initiated and the system automatically flushes the old color and loads a new color Sequential Dosing Components A and B dispense sequentially in the necessary volumes to attain the mix ratio Solvent 3rd Purge Valve Chop Time duration of each activation of the solvent or 3rd purge valve during a chop sequence User settable from 0 0 99 9 seconds Solvent Fill the time required to fill the mixed material line with solvent Solvent Push enables the user to save some mixed material by pushing it out to the gun with solvent Requires an accessory solvent meter Standby refers to the status of the system Third Purge Valve refers to the use of three purge valves used to flush some waterborne materials The valves are used to flush with water air and solvent V P refers to the voltage to pressure device in the flow control module 17 Overview Overview Usage The Graco ProMix 2KS is an electronic two component paint proportioner It can blend most two component solvent and waterborne epoxy polyuret
79. nd 7 are added See pages 38 39 K factor Input If set to Global Advanced Setup Screen 4 page 35 is added If set to Recipe Recipe Setup Screen 5 page 389 is added Minimum Material Fill Volume Enter 0 9999 cc 312776E Setup Mode Verification Screen Warning switching ta source Global source recipe for Flush and Fill Input This will overwrite recipe data Are you sure Fic 30 Verification Screen Verification This screen appears if Flush and Fill Input or K factor Input are changed from Recipe to Global in Option Screen 1 31 Setup Mode Option Screen 2 Ruta Dump Flow Rate Monitor Solvent Push Enable Dptions 31 Option Screen 2 Auto Dump If the auto dump feature is being used set to On Once the auto dump is enabled the gun flush box is enabled and the potlife alarm is active for 2 minutes the system will automatically flush out the old material Flow Rate Monitor If set to On Recipe Setup Screen 6 on page 39 is added enabling setting of high and low flow limits If set to Off flow rate monitoring is disabled and Rec ipe Setup Screen 6 on page 39 will not appear Solvent Push Enable To enable the Solvent Push feature select Solvent or Valve available if 3rd Flush Valve in Configure Screen 3 page 29 is set to On To disable the Solvent Push feature set to 32 312776E Advan
80. nd hold the dump valve B solenoid override FIG 65 Press and hold the B side catalyst solvent solenoid override until clean solvent comes from the dump valve then release Shutoff the solvent supply to the color catalyst change stack solvent valves Press and hold the A and B solvent solenoid over rides and dump valve overrides until solvent flow from the dump valves stops 53 System Operation le 1 E Ponci 1 XT CAN Fiber Optic OOOQOO Valve Overrides J Dump Valve A E Dump Valve B lH Optional Solenoid GFB 1 Locations GFB2 Dose Valve A ard Purge Valve Solenoid Solenoid Dose Valve B Purge Valve A Purge Valve B Solenoid Solenoid Solenoid 71126526 Fic 65 Fluid Solenoids 54 312776 System Operation 7 7 1 5 8 EA
81. ng DD in System Configure Screen 4 makes the DD Setup mode available See 55 To enable DD setup mode select On in the DD Setup mode drop down menu This disables Off Ratio alarms E 3 and E 4 allowing uninterrupted setup and tuning NOTE Do not use the material mixed when in DD setup mode as it may not be on ratio due to the disabled alarms NOTE If DD setup mode is not turned Off at the end of setup it will automatically turn off 3 minutes after initia tion of a Mix command Dose Size cc DD setup mode Dose Time Alarm ra Number of Guns Gun Flush FIG 53 Set Up Home Screen 2 Navigate to System Configure Screen 4 Select DD option from the Dose Size drop down menu FIG 54 Dose Size EDI Dose Time Alarm om Mumber of Guns 55 Gun Flush Box 50 100 Configure 54 Configure Screen 4 dynamic dosing selected 46 FiG 55 Configure Screen 4 dynamic dosing setup mode enabled 312776E Balancing Pressure If component B pressure is too high it will push the com ponent A stream aside during B injection The valve will not open long enough causing a High Ratio alarm If component B pressure is too low it will not be injected in sufficient volume The valve will stay open too long causing a Low Ratio alarm Selecting the correct component B restrictor size and balancing the A B pressures will keep the s
82. ob totals grand totals and job number Use the tabs to reset job totals Job Complete reset solvent totals Rst Solvent or go to Level Control Screen page 23 Solvent Totals and the Rst Solvent tab only appear if Meter is selected under Solvent Monitor in Configure Screen 5 on page 30 NOTE Grand totals are not resettable Reset Total Screen Job Complete Are uou sure uou want to reset job totals Enter job number or press enter to accept default FiG 12 Reset Total Screen If job is reset job number will increment by one for default 22 Reset Solvent Screen Reset Solvent Are uou sure want to reset solvent total Fic 13 Reset Solvent Total Screen The screen will ask if you want to reset solvent total Select Yes or No Alarms Screens ime Alarm Fic 14 Alarms Screen Two screens show the last 10 alarms Use the Up or Down 7 keys to scroll between the two screens See Table 10 on page 75 for a list of alarm codes 312776E Level Control Screen Level Control Liters Hlarm Level Current Volume Color 1 Color Latalyst 1 Solvent Level Control 15 Level Control Screen This screen shows the current volume for each fluid Adjust the current volumes on this screen or use the tab to go to Usage Totals Screen page 22 The Alarm Level values may be adjusted using the advanced web interface See FIG 16 If the tank volume reaches the low l
83. ocument sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Original instructions This manual contains English MM 312776 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC P O BOX 1441 MINNEAPOLIS MN 55440 1441 Copyright 2008 Graco Inc is registered to ISO 9001 www graco com Revised June 2012
84. of screens in the group Flush Volume Check Flush and Fill Input K Factor Input Min Material Fil Volume cc Options ProMix 2ES Warning Manual t Switching to Global Source j Global source recipe for On 7 Flush and Input 3rd Flush Valve 5 This wil overwrite recipe data Are you sure Configure Dose Size Dose Time Alarm Sec ei Gane Solvent Push Enable Gun Flush Configure Options oet Up 2 DEN Recipe amp Advanced Setup Sustem Configuration 192 168178 17 Control Network ID 1 5 EK 2 04009 BC 1 5 1 Lx 2 04 0098 2k Manual C2 AP 6 5 0 2 1042 0198 4 Configure 182 168 178 1 MAC DD204AA3B04F 12785 21 System Configuration and Option Screens Map 312776E 27 Setup Mode Configure Screen 1 Language English Enter Password Display Units H Buzzer All Alarms No Screen Timeout 22 Configure Screen 1 Configure Language Defines the language of the screen text Select English default Spanish French German Italian Dutch Jap anese Kanji Korean and Chinese Simplified Password The password is only used to enter Setup mode The default is 0 which means no password is required to enter Setup If a password is desired enter a number from 1 to 9999 NOTE Be sure to write down the password and keep it in a secure location
85. ox option both spray guns must be inserted in the GFBs during the entire color change cycle purge and fill The system will turn each trigger output and off based on the preset time for each gun e For Special Outputs options the system will turn each output on and off based on the preset times Each Special Output has two different start times and durations e For systems without dump valves the First Purge begins after the Color Catalyst Change steps are completed e Dump Valve B is required for a Catalyst Change system e When going from Recipe X to Recipe only the purge cycle data from Recipe 0 is used e When going from Recipe 0 to Recipe X only the fill cycle data from Recipe X is used 63 Color Change Color Purge Dump Step PO P1 e This sequence flushes out the color with solvent from the color valve to the Dump A valve e The color change solvent valve and the Dump valve open during the Purge Time e The color change solvent valve closes when the Purge Time expires Color Fill Step P1 P2 e This sequence fills the line with the new color all the way to the Dump valve e The new color valve and the Dump A valve open during the Fill Time new color valve and the Dump A valve close when the Fill Time expires Catalyst Purge Dump Step P2 P3 e This sequence flushes out the catalyst with solvent from the catalyst valve to the Dump B valve e The catalys
86. permeable 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 312776E 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
87. quence is complete E 26 COLOR CATALYST PURGE ALARM System detects no meter pulses or a disruption in meter Check that meter cable is connected pulses lasting longer than 1 second throughout the Color Catalyst purge time duration Clean or repair meter 27 COLOR CATALYST FILL ALARM System detects no meter pulses or system must detect Check that meter cable is connected at least 10cc of material from each side throughout the Color Catalyst fill time duration Clean or repair meter Gun dump valve or correct color catalyst valve not Open the valve open Exhausted fluid supply Check fluid level and refill if necessary Switch settings 53 56 on color change board do not Verify that color change board switches are set correctly match hardware configuration See installation manual Fuse F1 F2 or both are blown Verify condition of fuses and replace if necessary See Repair Parts manual 86 312776E Schematic Diagrams Schematic Diagrams System Pneumatic Schematic COLOR COLOR CHANGE VALVE CONTROL STACKS AIR EXHAUST MUFFLER MANIFOLD COLOR2 j COLOR 3 COLOR 4 S IMP COLOR 5 COLOR 6 COLOR7 5 i m COLOR 8 COLOR SOLVENT uj COLOR 9 4 WAY SOLENOID COLOR 10 E COLOR 11 e Su lt 7 CATALYST 1 N E CATALYST 2 4 WAY SOLENOID 2 CATALYST 4 3 8 AIR FILTER m 7 CATALYST SOLVENT MANUAL DRAIN
88. r It is typically used in flow ranges of 38 1900 cc min 0 01 0 5 gal min pressures to 4000 psi 28 MPa 276 bar and viscosities of 20 3000 centipoise The K factor is approximately 0 061 cc pulse 3000 is a gear meter used for solvents in flow ranges of 38 1900 cc min 0 01 0 50 gal min pressures up to 3000 psi 21 MPa 210 bar and viscosities of 20 50 centi poise The K factor is approximately 0 021 cc pulse Required to use the Solvent Push feature Coriolis is a specialty meter capable of a wide range of flow rates and viscosities This meter is available with 1 8 in or 3 8 in diameter fluid passages For detailed information on the Coriolis meter see manual 313599 The K factor is user settable at lower flow rates use a lower K factor 1 8 in fluid passages set K factor to 020 or 061 3 8 in fluid passages set K factor to 061 or 0 119 An optional component It is available as a color change valve stack for either low or high pressure with up to 30 color change valves Each stack includes one additional valve for solvent to clean the fluid line between color changes An optional component It is available as a catalyst change valve stack for either low or high pressure with up to 4 catalyst change valves Each stack includes one additional valve for solvent to clean the fluid line between catalyst changes Used to communicate between the EasyKey and Wall Mount Fluid Station Used to provide powe
89. r to the Wall Mount Fluid Station Air Flow Switch The air flow switch detects air flow to the gun and signals the ProMix controller when the gun is being triggered The switch functions with the flow meters to ensure that the system components are functioning correctly See page 49 for further information Gun Flush Box The gun flush box kit provides an automated flushing system for manual spray guns and includes an air flow switch 13 Overview 12504 Fic 2 Manual System shown with 33000 Meters Color Catalyst Change One Gun Flush Box and Accessory Solvent Flow Meter 14 312776E DVA Fl DVB MB MS MA a i E RVB SVA SM SVB SPV Fic 3 Wall Mount Fluid Station Key MA DVA RVA SVA MB DVB RVB SVB MS SPV APV SM Fl AT Component A 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 Solvent Purge Valve Air Purge Valve Static Mixer Fluid Integrator Air Purge Valve Air Supply Tube 312776E Overview T112556b 15 Booth Control Booth Control Used by the operator for daily painting functions includ ing changing recipes signalling job complete read ing clearing alarms and placing the system in Standby Mix or Purge mode It is typically mounted inside the booth or near the paint
90. re A Pressure NOTE If the restrictor is too small it may be necessary to supply more differential pressure than is available in your system Fic 58 Control Range with Too Large Restrictor 47 System Operation Table 6 Dynamic Dosing Troubleshooting Guide for complete system troubleshooting see Table 11 beginning on page 76 B Pressure Too Low see FIG 56 Increase B pressure Clean restrictor or use a larger size Verify B valve is opening properly B Pressure Too High e Increase A pressure or decrease B pressure e Use a smaller restrictor Off Ratio Low e Increase A pressure or decrease B pressure e Use a smaller restrictor Off Ratio High Manifold Valve Settings Increase B pressure Clean restrictor or use a larger size Verify B valve is opening properly To open dose or purge valves turn hex nut E counter clockwise To close turn clockwise See Table 7 and FIG 59 TI11581a 59 Valve Adjustment Table 7 Mix Manifold Valve Settings Valve Dose Hex nut E 1 1 4 turns out FIG 59 from fully closed Purge Hex nut E 1 1 4 turns out FiG 59 from fully closed Shutoff Fully open during Run Mix SVA and operation SVB FIG 67 Sampling Fully closed during Run Mix RVA and operation RVB FIG 67 48 Limits maximum fluid flow rate into integrator and minimizes valve response time Limits maximum fluid flow rate into integrator and minim
91. reboot or power cycle not triggered from the EasyKey The system reverts to Recipe 61 and mixed material may be in the lines Autokey Lost Occurs if the Autokey is lost or changed after having been detected A short term loss of the Autokey will not be registered Some system functions may become unavailable For example an automatic system will not respond to PLC or robot control Illegal Source Occurs if a recipe outside of the range 1 60 is detected as the source data for global recipe data copies This is possible if an invalid configuration file is sent to the EasyKey 2K 3K Error Occurs if the recipe data is incompatible with the current Autokey setting 2K or 3K This is possi ble if the Autokey is changed or an invalid configuration file is sent to the EasyKey Init Error Occurs if the recipe data codes specifying the type of machine they were made on are not what is expected For example a 3KS machine receives con figuration file originally made on a 2KS machine Config Error Occurs if a configuration file sent to the EasyKey specifies a different hardware setup than what exists For example the configuration file specifies 2 color change boards but only 1 is present Range Error Occurs if a valve used in a recipe is not present in the current hardware setup For example a recipe calls for valve 30 but the system has only 12 valves Level Control LC Error Occurs if level control data is received by the
92. reen 5 page 39 Always purge sampling valves after calibrating meters Use one of the following methods Follow the Purging Sampling Valves and Tubes procedure page 59 e Place the sampling valve fluid tubes into a com patible cleaning fluid TSL or solvent or cap them NOTE If fluid hardens in sampling tubes replace them with 5 32 in or 4 mm OD tubing Make sure both sampling valves are closed and both fluid shutoff valves are fully open Before you begin production clear the system of solvent and prime it with material a Goto Mix mode b Trigger the gun into a grounded metal pail until mixed material flows from the gun nozzle C To begin operation see Start Up page 50 312776E Color Change Color Change Procedures Multiple Color Systems 1 Shut off air to the gun 2 Place the gun in the gun flush box if used and close the lid 3 Switch to Standby r mode at the Booth Control 4 Use the scroll keys 4 or 7 to select the new color Press Enter to begin the color change sequence 5 gun flush box is not used trigger A the gun into a grounded metal pail ZK until the color change sequence is complete 6 When the color change indicator light stops flashing on the Booth Control the color change sequence is complete NOTE The color change timer does not start until the gun is triggered and fluid flow is detected If no flow is detected within 2 minutes the color chan
93. rge the component A side The color change LED blinks while Recipe O runs and turns solid after purge sequence is complete Purge component B side Press the manual override on the Dose Valve B solenoid valve and trigger the gun into a grounded metal pail until clean solvent flows from the gun Repeat to thoroughly clean the fluid integrator e Multiple color multiple catalyst systems Select Recipe 0 and press Enter io purge the component A side and the component B side The color change LED blinks while Recipe 0 runs and turns solid after purge sequence is complete Repeat to thoroughly clean the fluid integrator 6 Reinstall the Fluid Station cover 7 Shut off the solvent fluid supply 8 Disconnect the solvent supply lines and reconnect the component A and B fluid supplies 9 See page 50 for Start Up procedure 58 312776E Purging Sampling Valves and Tubes Follow this procedure after meter calibration 1 Press the Standby r key on the Booth Control 2 See 67 Close both fluid shutoff valves and sampling valves 3 Route the sampling tubes into a grounded waste container 4 Onasingle color system attach a solvent supply line to Flow Meter A inlet 5 Onthe EasyKey press the Setup access the Advanced Setup screens Press the Right Arrow mp key to select the Calibra tion screen Press the Down Arrow 7 select Purge from the menu Press the Enter ii k
94. rk ID 1 Fic 28 Configure Screen 5 Configure Special Outputs Select special outputs 0 4 Each output has two differ ent start times and durations Solvent Monitor Select solvent monitor Off Flow Switch or Meter Web Browser IP The default web browser IP address prefix is 192 168 178 __ Assign a unique number for each EasyKey in your system 1 99 and enter it here Control Network ID Used for the Graco Gateway network system See Graco Gateway manual 312785 for further information 312776E Option Screens NOTE See FIG 21 on page 27 for a map of the Option Screens Detailed screen descriptions follow NOTE Each screen displays the current screen number and the total number of screens in the group Option Screen 1 Flush Valume Check Flush and Fill Input K Factor Input Min Material Fill Volume Options FiG 29 Option Screen 1 Flush Volume Check This field only appears if Solvent Monitor is set to Meter in Configure Screen 5 page 30 If set to Minimum Flush Volume will appear in Rec ipe Setup Screen 2 page 37 Flush and Fill Input If set to Global Color Catalyst Purge and Color Cata lyst Fill are added to Advanced Setup Screen 1 page 34 Advanced Setup Screen 2 3 and 5 are added See pages 34 35 If set to Recipe Color Catalyst Purge and Color Cata lyst Fill are added to Recipe Setup Screen 2 page 37 Recipe Setup Screen 3 4 a
95. rm Number of buns Lun Flush Box Configure Fic 25 Configure Screen 4 Dose Size Select the total dose size cc from the pulldown menu 100 50 25 10 or select DD to turn on dynamic dosing see page 45 Example For a total dose size of 50 cc and a ratio of 4 0 1 the component A dose size is 40 cc and component B dose size is 10 cc NOTE Increase the dose size in applications with higher flow rates or wider ratios Decrease the dose size for a better mix under low flow conditions DD Setup Mode See Fig 26 and Fig 27 on page 30 Selecting DD makes the Dynamic Dosing Setup mode field appear Select On to enable DD setup mode or Off to disable See page 46 for further information 29 Setup Mode Dose Size Dose lime Alarm Mumber of Guns Gun Flush Configure Fic 26 Configure Screen 4 dynamic dosing selected Dose size 00 setup moge Dose Time Alarm Number of Guns 0n Fic 27 Configure Screen 4 dynamic dosing setup mode enabled Gun Flush Bax Configure Dose Time Alarm Enter the dose time 1 to 99 seconds This is the amount of time allowed for a dose to occur before a dose time alarm occurs Number of Guns Enter the number of spray guns 1 or 2 Gun Flush Box Enter the number of gun flush boxes Off 1 or 2 30 Configure Screen 5 1972 158178 1 7 5 special Uutputs Solvent Monitor Web Browser IP Control Netwo
96. s set to This screen appears only if K factor Input is set to Global in Option Screen 1 page 31 Global in Option Screen 1 page 31 If Number of Guns is set to 2 in Configure Screen 4 K factor A Meter page 29 a Gun 2 column will appear in this screen Enter the k factor cc pulse for flow meter A This is the First Purge Time amount of material that passes through the flow meter per pulse electrical pulse signal Enter the first purge time 0 to 999 seconds K factor B Meter Total Chop Time Enter the k factor cc pulse for flow meter B Enter the total chop time 0 to 999 seconds K factor Solvent Meter Final Purge Time This field only appears if Solvent Monitor in Configure Screen 5 page 30 is set to Meter Enter the k factor cc pulse for the solvent flow meter Enter the final purge time 0 to 999 seconds Mixed Material Fill Time Enter the mixed material fill time 0 to 999 seconds It Advanced Setup Screen 5 refers to the amount of time that is required to load mixed material from the dose valves to the applica tor gun Special Un Purge Length Advanced Calibration Fic 37 Advanced Setup Screen 5 This screen appears only if Flush and Fill Input is set to Global in Option Screen 1 page 31 and Special Out puts is set to 1 2 3 or 4 in Configure Screen 5 page 30 The I O board has four programmable outputs 312776E 35 Setup Mode Recipe Setup Screens
97. sh minimum 75 3800 cc min 0 02 1 00 gal min 38 1900 cc min 0 01 0 50 gal min 20 3800 cc min 0 005 1 00 gal min 38 1900 cc min 0 01 0 50 gal min 1 4 npt f 1 4 npt f 1 4 npt f 85 250 Vac 50 60 Hz 2 amps maximum draw 15 amp maximum circuit breaker required 8 to 14 AWG power supply wire gauge 41 122 F 5 50 C indoor use pollution degree 2 installation category below 70 dBA below 85 dBA 303 304 SST Tungsten carbide with nickel binder perfluoroelastomer PTFE Dependent on 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 312776E 93 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 warrant
98. signed value refers to an amount of material per pulse Ki refers to the degree fluid flow over shoots its set point Kp refers to the speed in which the fluid flow reaches its set point Manual Mode when the proportioning or flow control system is controlling the inputs without any input from an outside control Minimum Material Fill Volume system monitors mate rial fill volume E 21 Alarm occurs if minimum volume is not achieved Minimum material fill volume is user setta ble 0 9999 cc Mix when cross linking of the resin A and catalyst B occurs Mix Input Signal refers to system mode status where system begins a dose sequence each time the mix sig nal is made High Mixed Material Fill Time the amount of time that is required to load mixed material from the dose valves to the applicator gun Modbus TCP a type of communication protocol used to communicate Digital I O signals over an ethernet Network Station a means to identify a particular indi vidual proportioning or flow control system Overdose Alarm when either the resin A or catalyst B component dispenses too much material and the system cannot compensate for the additional material Potlife Time the amount of time before a material becomes unsprayable Potlife Volume the amount of material that is required to move through the mix manifold hose and applicator before the potlife timer is reset 312776E Glossary of Ter
99. solenoid identification labels as a guide press and hold the override button on each color solenoid until flow from the sampling valve stops Press and hold the solvent solenoid override until clean solvent comes from the sampling valve then release Shutoff the solvent supply to the color change stack solvent valve Press and hold the solvent solenoid override until solvent flow from the sampling valve stops Open the A side shutoff valve SVA 67 Close the A side sampling valve RVA 312776E System Operation 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 52 Shut off all color and catalyst supplies to the valve stacks Press and hold the dump valve A solenoid override FIG 65 See FIG 66 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 Press and hold the dump valve B solenoid override FIG 65 See FIG 66 Using the solenoid identification labels as a guide press and hold the override button on each catalyst solenoid until flow from dump valve B stops Press and hold the dump valve A solenoid override FIG 65 Press and hold the A side color solvent solenoid override until clean solvent comes from the dump valve then release Press a
100. stall the solvent meter MS on the side of the fluid station as explained in the ProMix 2KS Installation Manual 2 enable Solvent Push select Solvent or 3rd Valve as desired See Option Screen 2 page 32 NOTE If you are using a 3rd purge valve instead of the solvent purge valve to run the Solvent Push feature connect the solvent supply line from the solvent meter to the inlet of the 3rd purge valve 3 Press and hold the Mix P key tor 5 seconds to turn on Solvent Push The green Mix LED will light and the Recipe LED will blink The system will close the Dose Valves DVA DVB and open the Solvent Purge Valve SPV DVA is closed Key DVA Component Dose Valve DVB Component B Dose Valve MS Solvent Meter required SPV Solvent Purge Valve APV Air Purge Valve SMC Solvent Meter Cable SS Solvent Supply Line Fic 69 Solvent Push Setup 60 T AA L FJ N lt 4 The system will dispense solvent to push the mixed material out to the gun The Booth Control display alternately shows dashes and the percent remain ing 0 99 of the 50 of the potlife volume NOTE To manually interrupt Solvent Push press the Standby r key The Solvent Purge Valve SPV or 3rd purge valve will close To re enter Solvent Push press the gt key 5 When the total solvent dispensed exceeds 50 of the potlife volume the system will go into Standby
101. t Up 2KS O O O Recipe amp Advanced Setup System Configuration EK 2 04 009 BC 1 C1 1 FP 2 04 008 AK 2k Manual Ce KP 6 5 0 7 1042 0196 IP 192 158 178 1 00204885804 Meter Calibration Measured Volume K Factar 0 119 cc pulse Recipe 01090 Recipe Flow Rate Monitor Low Flow Limit D High Flow Limit cemin Recipe Special On Purge Length On Fill Recipe screens 3 4 5 6 and 7 appear depending on selections made in Option screens 1 and 2 T112787a 312776E NOTE Each screen displays the current screen number and the total number of screens in the group The total number of screens in a group and the fields displayed on each screen may vary depending on selections made in the System Configuration Screens and Option Screens Recipe Setup Screen 1 hecipe Ratio Ratio Tolerance Color Valve Latalyst Vale MEE Calibration Fic 39 Recipe Setup Screen 1 Ratio Enter the mix ratio of component A over component B 0 0 1 to 50 1 Ratio Tolerance Enter the ratio tolerance 1 to 99 This refers to the percent of acceptable variance that the system will allow before a ratio alarm occurs Component A Color Valve if present This field only appears if the system includes a color change module Enter the color valve number 1 to 30 Component B Catalyst Valve if present This field only appears if the system in
102. t change solvent valve and the Dump B valve open during the Purge Time e The catalyst change solvent valve closes when the Purge Time expires Catalyst Fill Step P3 P4 e This sequence fills the line with the new catalyst all the way to the Dump B valve e The new catalyst valve and the Dump B valve open during the Fill Time e The new catalyst valve and the Dump B valve close when the Fill Time expires 64 First Purge Step MO M1 Select the First Purge Source air solvent or 3rd valve and First Purge Time For most applications air is selected The system purges the old material from the dose valves to the gun using only the selected purge media usually air The selected purge valve opens during the First Purge Time and closes when the time expires Chop Cycle Step M1 M2 Select the Chop Type air solvent or air Srd valve and Chop Times The air purge valve opens only during the air chop cycle and the solvent or 3rd valve opens only during the sol vent chop cycle The number of chop cycles is deter mined by dividing the Total Chop Time by the sum of the Air and Solvent Chop Times Final Purge Step M2 M3 Select the Final Purge Source air solvent or 3rd valve and Final Purge Time For most applications solvent is selected The system fills the line with solvent from the dose valves to the gun using only the selected purge media usually solvent The selected purge valve opens during the Fina
103. ter cap to expose sensor Pass a ferrous metal tool in front of the Sensor TI12792a If there is a meter or cable failure you will see a large dif ference between the amount of fluid dispensed and the flow meter volume displayed by the EasyKey Clean or repair meter as necessary Also see meter manual 308778 Follow Meter Calibration procedure page 61 Slow actuation of component A or B valves See E 3 RATIO HIGH ALARM and E 4 RATIO LOW ALARM pages 77 78 The supply pump is not turned on Turn on the supply pump There is an air leak downstream from the air flow switch Check the air lines for leaks and repair The air flow switch is stuck open Clean or replace air flow switch System is in Mix mode with O volume entered for Min Verify condition of fuse and replace if necessary See Material Fill Volume see Option Screen 1 page 31 Hepair Parts manual and Fuse F1 is blown 80 312776E Alarm Troubleshooting Table 11 Alarm Troubleshooting E 9 MIX IN SETUP ALARM Cause Attempt to operate system while in Setup mode System must be in Standby to change current recipe and cannot be operated E 10 REMOTE STOP ALARM Cause Automation has requested that the system abort all oper Abort operations Troubleshoot automation system ations E 11 PURGE VOLUME ALARM ProMix 2KS solvent flow switch is not activated while Verify that the gun is not shut off and that the solvent flow purging
104. there are no leaks from the gun or any other seals or fit tings the flow meters are probably being affected by pressure pulsations Close the fluid shutoff valve between the fluid supply system and the flow meter The flow indication should stop If necessary install pressure regulators or a surge tank on the fluid inlets to the ProMix 2KS to reduce the fluid supply pressure Contact your Graco distrib utor for information Slow actuation of component A or B valves See E 3 RATIO HIGH ALARM and E 4 RATIO LOW ALARM pages 77 78 Running a high mix ratio and a high flow rate It may be necessary to restrict the flow rate through the component B dose valve by adjusting its hex nut E See 312776E page 48 79 Alarm Troubleshooting Table 11 Alarm Troubleshooting E 7 DOSE TIME A ALARM and E 8 DOSE TIME B ALARM E 7 gun trigger input is active AFS or Integration and no A meter pulses are detected during the dose time selected E 8 gun trigger input is active AFS or Integration and no B meter pulses are detected during the dose time selected Fully trigger the gun System is in Mix gt mode and gun is only partially triggered allowing air but no fluid to pass through gun Fluid flow rate is too low Increase flow rate Dose time setting is too short for the current flow rate Increase the dose time setting Flow meter or cable failed or flow meter clogged To check meter sensor operation remove me
105. tors the fluid volume dispensed and sends electrical pulses to the ProMix 2KS controller The controller monitors these pulses and signals c When the target volume dispenses Dose Valve A closes NOTE The dispense volume of component A and B is based on the mix ratio and dose size set by the user and calculated by the ProMix 2KS controller d Dose Valve B DVB opens and fluid flows into the integrator and is aligned proportionately with component A e Flow Meter B MB monitors the fluid volume dispensed and sends electrical pulses to the ProMix 2KS controller f When the target volume is dispensed Dose Valve B closes 43 System Operation 5 The components are pre mixed in the integrator then uniformly blended in the static mixer SM NOTE To control output from the static mixer to the gun install an optional fluid pressure regulator 6 Components A and B are alternately fed into the integrator as long as the gun is triggered 7 Ifthe gun is not triggered for two minutes the sys tem switches to Idle mode which closes off the mix manifold dose valves 8 When the gun is triggered again the ProMix 2KS continues the process where it left off NOTE Operation can be stopped at any time by pressing the Standby r key or shutting off the main power switch Table 5 Sequential Dosing Operation Ratio 2 0 1 DVA MA AT APV Key MA Component A Meter DVA Component A Dose Valve RV
106. ts manual to check operation e Air pressure to the valve actuators is too low e Increase air pressure Air pressure must be 75 120 psi 0 52 0 84 MPa 5 2 8 4 bar 120 psi is recom mended Something is restricting the solenoid or tubing There may be dirt or moisture in the air supply Filter interrupting valve actuation air appropriately e dose valve is turned in too far e Refer to Table 7 Mix Manifold Valve Settings page 50 for adjustment guidelines e Fluid pressure is high and air pressure is low e Adjust air and fluid pressure See recommended air pressure above 8 312776E Alarm Troubleshooting Table 11 Alarm Troubleshooting E 5 OVERDOSE A B DOSE TOO SHORT ALARM and E 6 OVERDOSE B A DOSE TOO SHORT ALARM E 5 the A dose overshoots and when combined with B is too large for the mix chamber capacity E 6 the B dose overshoots and forces an A side dose that when combined with B is too large for the mix chamber capacity Valve seal or needle seat are leaking Check Fia 11 Totals Screen on page 22 If A and B are dosing simul taneously sequential dosing only there is a leak Flow meter fluctuations caused by pressure pulsations Check for pressure pulsations Close all the manifold valves Turn on the circulating pumps and all the booth equipment such as fans and conveyors Check if the ProMix 2KS is reading any fluid flow If the ProMix 2KS shows there is fluid flow and
107. uoo 7 39 AMSOOSIA 9uneJp H pini 1591 L0 1 62 1 16 1 96 1 56 1 66 VGL 1 2 VEN 1 0 1 6 1 8 1 4 1 9 VG bY bb 00S 0001 0091 2206 0002 2504 2201 0095 000 0098 008 UIUJ 29 009 S 5 45 3 LON uiu 22 91eH 91 312776E Meter Performance Data G3000 on A Coriolis on B Meter Performance Data G3000 on A Coriolis on B 6154 00 eunssaJd pue 5 uedo suuin Bunies ALA 92U8J9J O ONLY esiodnuoo 7 89 AJISOOSIA 1591 0 1 62 86 1 92 1 96 bibl 1 66 1 06 1 61 1 81 1 2 WELL 1 0 1 6 1 8 1 4 1 9 1 9 be v is 0 2206 00S 2262 2504 220 000L 00S L oogc 0002 0062 2206 000 0098 0088 UIUJ 29 009 S Ul9 s S 3 LON uiu 22 312776 92 Technical Data Maximum fluid working pressure Maximum working air Air supply Air filter inlet size Air filtration for air logic and purge air Graco supplied Air filtration for atomi
108. ur application Use low est pressure possible 5 7 not exceed the maximum rated work ing pressure shown on the system identification label or the lowest rated component in the system 8 Open the fluid supply valves to the gt system CER ER 9 Adjust the air pressure Most appli cations require about 80 psi 552 kPa 5 5 bar air pressure to operate properly Do not use less than 75 psi 517 kPa 5 2 bar 10 If using a gun flush box place the gun into the box and close the lid Press the Purge key on the Booth Control The purge sequence automatically starts If the gun flush box is not used trig ger the gun into a grounded metal pail until the purge sequence is com plete When done purging the Booth Control automati cally switches to Standby mode 11 Adjust the flow rate The fluid flow rate shown on the EasyKey Status screen is for either component A or B depending on which dose valve is open The fluid supply lines on the screen highlight to show which dose valve is open 11 93 2009 FiG 63 Status Screen Flow Rate Display 312776E System Operation Watch the fluid flow rate displayed on the Status screen while the gun is fully open Verify that the flow rate of components A and B are within 1096 of each other If the fluid flow rate is too low increase air pres sure to component A and B fluid supplies or increase the regulated fluid pressure If the
109. vals 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 Hazardous Locations Read Instruction Manual Warning Substitution of components may impair intrinsic safety PARTNO SERIES MFG YR GRACO INC P O Box 1441 7 Minneapolis GRACO 55440 U S A Electronic 074 APPROVED Intrinsically safe equipment for Class I Div 1 Group D T3 Ta 20 to 50 C C Ex ia MAX 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 PSI PART NO Intrinsically safe equipment MPa bar for Class I Div 1 Group D T3 ye GRACO INC US Ta 20 C to 50 C APPROVED Install 289833 FMO8ATEX0073 P O Box 1441 126 7 Minneapolis MN 0359 Ex ia IIA T3 eraco 55440 U S A Artwork No 293538 13581 ATEX Certificate is listed here EasyKey Label POWER REQUIREMENTS AMPS 2 AMPS MAX ProMix 2KS PART NO SERIES NO MFG YR Artwork No 293467 Intrinsic
110. y does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the 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
111. ystem in the proper pressure range resulting in a consistent mix ratio FiG 57 shows the A to B pressure balance read at the proportioner inlet It is recommended that the compo nent B pressure be 5 15 higher than the component A pressure to keep the system in the control range hold the proper mix ratio and obtain properly mixed material If pressures are not balanced Pressure Too High or B Pressure Too Low it may not be possible to hold the desired mix ratio The system will generate an off ratio alarm and stop operation NOTE In multi flow rate systems it is recommended that you set up the system to run properly at the highest flow rate to ensure adequate fluid supply across the flow rate range In dynamic dosing component A dose valve is con stantly on Component B dose valve will cycle on and off one cycle every 0 5 1 0 seconds indicates proper balance Monitor system performance by watching the EasyKey display for warning messages which provide information on system performance and adjust pressures accord ingly See Table 6 on page 48 11 9 2009 3facc min 4 B Pressure Too Lou FiG 56 B Pressure Too Low displayed EasyKey 312776E System Operation e on Pressure ont x Too Low B Pressure A Pressure B Pressure Fic 57 Control Range with Properly Sized Restrictor Low Too High B Pressu
112. zing air user supplied Mixing ratio On ratio Fluids handled Viscosity range of fluid Fluid filtration Fluid flow rate 33000 0250 Mete i ail Soi dace G3000HR G250HR Coriolis abd PC 53000 Solvent Meter accessory Fluid inlet sizes Flow Dose Valve Color Valve Adapters Fluid outlet size static External Power Supply Requirements Operating temperature Environmental Conditions Rating Noise Level Sound pressure level Sound power level Wetted Technical Data Base system 4000 psi 28 MPa 280 bar Low pressure color change 300 psi 2 1 MPa 21 bar High pressure color change 3000 psi 21 MPa 210 bar Coriolis meter 2300 psi 16 1 MPa 161 bar 100 psi 0 7 MPa 7 bar 75 100 psi 0 5 0 7 MPa 5 2 7 bar 3 8 npt f 5 micron minimum filtration required clean and dry air 30 micron minimum filtration required clean and dry air 0 1 1 50 1 up to 1 user selectable one or two component solvent and waterborne paints polyurethanes epoxies acid catalyzed varnishes moisture sensitive isocyanates 20 5000 cps 100 me

Graco 312776E User's Manual

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