Operation ® ProMix 2KS 312776E EN Plural Component Proportioner 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 Read all warnings and instructions in this manual. Save these instructions. See page 4 for model information, including maximum working pressure. Equipment approval labels are on page 3. Some components shown are not included with all systems.
Contents Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Equipment Approvals . . . . . . . . . . . . . . . . . . . . . . . 3 System Configuration and Part Numbers . . . . . . . 4 Configurator Key . . . . . . . . . . . . . . . . . . . . . . . . . 4 Standard Features . . . . . . . . . . . . . . . . . . . . . . . 5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Manuals Related Manuals Equipment Approvals Component Manuals in English Equipment approvals appear on the following labels which are attached to the Fluid Station and EasyKey™. See FIG. 1 on page 4 for label locations.
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.
System Configuration and Part Numbers Hazardous Location Approval Models using a G3000, G3000HR, or intrinsically safe Coriolis meter for both A and B meters are approved for installation in a Hazardous Location - Class I, Div I, Group D, T3 or Zone I Group IIA T3. 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.
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.
Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation 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.
Warnings WARNING 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. • Tighten all fluid connections before operating the equipment. • Do not point gun at anyone or at any part of the body. • Do not put your hand over the spray tip. • Do not stop or deflect leaks with your hand, body, glove, or rag.
Important Two-Component Material Information Important Two-Component Material Information Isocyanate Conditions Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates. Read material manufacturer’s warnings and material MSDS to know specific hazards and precautions related to isocyanates. Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area.
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.
Glossary of Terms Job Total - a resettable value that shows the amount of material dispensed through the system for one job. A job is complete when a color change or complete system flush occurs. K-factor - a value that refers to the amount of material that passes through a meter. The assigned value refers to an amount of material per pulse. Ki - refers to the degree fluid flow over shoots its set point. Kp - refers to the speed in which the fluid flow reaches its set point.
Overview Overview Usage The Graco ProMix 2KS is an electronic two-component paint proportioner. It can blend most two-component solvent and waterborne epoxy, polyurethane, and acid-catalyzed paints. It is not for use with “quick-setting” paints (those with a potlife of less than 15 minutes). • Can proportion at ratios from 0.1:1 to 50:1 in 0.1 increments with the wall mount fluid station.
Overview Table 1: Component Descriptions Component Flow Meters (MA, MB, MS) Description Three optional flow meters are available from Graco: • G3000 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 viscosities of 20–3000 centipoise. The K-factor is approximately 0.119 cc/pulse. • G3000HR is a high resolution version of the G3000 meter. It is typically used in flow ranges of 38–1900 cc/min. (0.01–0.
Overview EK CCM PS BC BCV FO ACV MS ST MA MB FM GFB TI12504a FIG. 2.
Overview DVA FI DVB MB MS MA RVB AT APV RVA SVA SM SVB SPV TI12556b FIG. 3.
Booth Control Booth Control Used by the operator for daily painting functions including: changing recipes, signalling 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. Table 2: Booth Control Key and Indicator Functions (see FIG. 4) Table 2: Booth Control Key and Indicator Functions (see FIG. 4) Key/Indicator Definition and Function Up Key Scrolls recipe numbers up.
EasyKey Display and Keyboard EasyKey Display and Keyboard Keypad LCD Display TI11630A Navigation Keys Alarm Reset Key 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.
EasyKey Display and Keyboard Fiber Optic Strain Relief Port Audible Alarm AC Power Switch Main Power Access Port Ground Screw I/S Power Graco Web Interface Discrete I/O Cable Connector Ports TI12638a TI12657a 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: I/S Power Power circuit to Fluid Station. Potlife Exceeded Audible Alarm Alerts the user when a Potlife Exceeded alarm occurs.
Run Mode Screens Run Mode Screens NOTE: See FIG. 9 for a map of the Run screens. Detailed screen descriptions follow. Splash Screen At power up, the Graco logo and software revision will display for approximately 5 seconds, followed by the Status Screen (see page 21). FIG. 7. Splash Screen The Splash screen will also momentarily display “Establishing Communication.
Run Mode Screens Press the Setup key to enter Setup mode. TI12783a FIG. 9.
Run Mode Screens Status Screen 4 Potlife Timer: shows remaining potlife time in min- utes. Two times are shown if there are two guns. • • • Use the Up or Down Run screens. Press the Setup keys to scroll through the 5 Status Bar: shows current alarm or operation mode key to enter the Setup screens (standby, mix, purge, recipe change, or the current alarm). from the Status screen. 6 Current Flow Rate: in cc/min. The other keys have no function in this Status screen.
Run Mode Screens Totals Screen Reset Solvent Screen FIG. 11. Totals Screen FIG. 13. Reset Solvent Total Screen This screen shows the job totals, grand totals, and job number. Use the tabs to reset job totals (Job Complete), reset solvent totals (Rst Solvent), or go to Level Control Screen, page 23. The screen will ask if you want to reset solvent total. Select Yes or No.
Run Mode Screens Level Control Screen FIG. 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-level threshold, the EasyKey screen will display the Tank Level Low alarm and prompt the user to do one of the following: 1. Refill tank volume to clear the alarm. 2.
Setup Mode Setup Mode Press the Setup key to enter 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. This screen appears only if a password is activated. To access Advanced Setup Screens, page 33 and Recipe Setup Screens, page 36. To access System Configuration Screens, page 27. Press the Setup key to exit Setup mode and return to the Status screen. This screen appears momentarily if a password is activated.
Setup Mode Password Screen Set Up Home Screen If a password has been activated (see Configure Screen 1, page 28), the Password screen will appear. You must enter the password to access the Set Up Home Screen. Entering the wrong password returns the display to the Status Screen. NOTE: If you forget the password, you can reset the password (to 0), using the ProMix 2KS Web Interface (see manual 313386). FIG. 20. Set Up Home Screen This screen displays when you enter Setup mode.
Setup Mode Table 4: Component Software Versions Component Display (may vary from examples shown) Description EK (EasyKey) 2.00.012 EasyKey software version. FP (Fluid Plate) 2.00.012 Fluid Plate software version. BC (Booth Control) -.- Booth Control not installed, not detected, or not operational. 1.XX Booth Control software version 1.00 or 1.01. 2.XX Booth Control software version 2.XX. -.- Color Change Module 1/2 not installed, not detected, or not operational. 1.
Setup Mode System Configuration Screens NOTE: See FIG. 21 for a map of the System Configuration Screens. Detailed screen descriptions follow. NOTE: Each screen displays the current screen number and the total number of screens in the group. TI12785a FIG. 21.
Setup Mode Configure Screen 1 Configure Screen 2 FIG. 22. Configure Screen 1 FIG. 23. Configure Screen 2 Language Month Defines the language of the screen text. Select English (default), Spanish, French, German, Italian, Dutch, Japanese (Kanji), Korean, and Chinese (Simplified). Enter current month. Password Day Enter current day. The password is only used to enter Setup mode. The default is 0, which means no password is required to enter Setup.
Setup Mode Configure Screen 3 Configure Screen 4 FIG. 24. Configure Screen 3 FIG. 25. Configure Screen 4 Run Mode Dose Size Indicates that this is a Manual system. 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). 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.
Setup Mode Configure Screen 5 FIG. 26. Configure Screen 4, dynamic dosing selected FIG. 28. Configure Screen 5 Special Outputs Select special outputs (0-4). Each output has two different start times and durations. Solvent Monitor Select solvent monitor (Off, Flow Switch, or Meter). Web Browser IP FIG. 27. Configure Screen 4, dynamic dosing setup mode enabled 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.
Setup Mode Option Screens NOTE: See FIG. 21 on page 27 for a map of the Option Screens. Detailed screen descriptions follow. Verification Screen NOTE: Each screen displays the current screen number and the total number of screens in the group. Option Screen 1 FIG. 30. Verification Screen Verification FIG. 29. Option Screen 1 This screen appears if Flush and Fill Input or K-factor Input are changed from “Recipe” to “Global” in Option Screen 1.
Setup Mode Option Screen 2 FIG. 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 Recipe Setup Screen 6 on page 39 will not appear.
Setup Mode Advanced 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. TI12786a FIG. 32.
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 in the System Configuration Screens and Option Screens. Advanced Setup Screen 1 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 (0 to 99 seconds).
Setup Mode Advanced Setup Screen 3 Advanced Setup Screen 4 FIG. 35. Advanced Setup Screen 3 FIG. 36. Advanced Setup Screen 4 This screen appears only if Flush and Fill Input is set to “Global” in Option Screen 1, page 31. This screen appears only if K-factor Input is set to “Global” 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. K-factor A Meter First Purge Time Enter the k-factor (cc/pulse) for flow meter A.
Setup Mode Recipe Setup Screens NOTE: See FIG. 38 for a map of the Recipe screens. Detailed screen descriptions follow. Recipe 0 Screens Recipe screens 3, 4, 5, 6, and 7 appear depending on selections made in Option screens 1 and 2 TI12787a FIG.
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 in the System Configuration Screens and Option Screens. Recipe Setup Screen 2 Recipe Setup Screen 1 FIG. 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.
Setup Mode Recipe Setup Screen 3 Recipe Setup Screen 4 FIG. 41. Recipe Setup Screen 3 FIG. 42. Recipe Setup Screen 4 This screen appears only if Flush and Fill Input is set to “Recipe” in Option Screen 1, page 31. This screen appears only if Flush and Fill Input is set to “Recipe” in Option Screen 1, page 31. First Purge Source If Number of Guns is set to “2” in Configure Screen 4, page 29, a Gun 2 column will appear in this screen.
Setup Mode Recipe Setup Screen 5 FIG. 43. Recipe Setup Screen 5 This screen appears only if K-factor Input is set to “Recipe” 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.
Setup Mode Recipe 0 Screens NOTE: See FIG. 38 on page 36 for a map of the Recipe 0 screens. Detailed screen descriptions follow. Recipe 0 is typically used: • in multiple color systems to purge out material lines without loading a new color • at the end of a shift to prevent hardening of catalyzed material. NOTE: Each screen displays the current screen number and the total number of screens in the group.
Setup Mode Recipe 0 Screen 3 Recipe 0 Screen 4 FIG. 48. Recipe 0 Screen 3 FIG. 49. Recipe 0 Screen 4 This screen only appears if Solvent Monitor is set to “Meter” in Configure Screen 5, page 30 and Flush Volume Check is set to “On” in Option Screen 1, page 31 or 3rd Flush Valve is set to “On” in Configure Screen 3 on page 29. This screen appears only if Flush and Fill Input is set to “Recipe” in Option Screen 1, page 31 and Special Outputs is set to 1, 2, 3, or 4 in Configure Screen 5, page 30.
Setup Mode Calibration Screen FIG. 50. Calibration Screen Use this screen to calibrate a meter. Set to “Meter A,” “Meter B,” or “Solvent Meter” (available if Solvent Monitor in Configure Screen 5, page 30, is set to “Meter”). • Start - start calibration • Abort - stop calibration • Purge - purge sampling valves after calibration See Meter Calibration, page 61, for when and how to calibrate a meter.
System Operation System Operation Operation Modes Mix System mixes and dispenses material. Standby Stops the system. Purge Purges the system, using air and solvent. Sequential Dosing Components A and B dispense sequentially in the necessary volumes to attain the mix ratio. General Operating Cycle, Sequential Dosing 1. The spray gun operator enters and loads the desired recipe. The color change LED blinks while recipe is loading, then turns solid when complete. 2. The operator presses the Mix operation.
System Operation 7. If the gun is not triggered for two minutes, the system switches to Idle mode, which closes off the mix manifold dose valves. 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. 8. When the gun is triggered again, the ProMix 2KS continues the process where it left off. 6.
System Operation General Operating Cycle, Dynamic Dosing Overview Dynamic Dosing System Parameters Dynamic Dosing provides on-demand proportioning, eliminating the need for an integrator and therefore minimizing undesired material contact. This feature is especially useful with shear-sensitive and waterborne materials. The following parameters affect dynamic dosing performance: A restrictor injects component B into a continuous stream of component A.
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 appropriate restrictor size based on the desired flow and mix ratio. NOTE: Do not use the material mixed when in DD setup mode, as it may not be on ratio due to the disabled alarms. Turn On Dynamic Dosing 1. On the EasyKey press the Setup 3.
System Operation Balancing A/B Pressure If component B pressure is too high, it will push the component 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.
System Operation Table 6: Dynamic Dosing Troubleshooting Guide (for complete system troubleshooting, see Table 11 beginning on page 76) Warning/Alarm Message Solution 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 • • Increase A pressure or decrease B pressure. Use a smaller restrictor. Off Ratio Low • • Increase A pressure or decrease B pressure. Use a smaller restrictor.
System Operation Air Flow Switch (AFS) Function Operating Without Air Flow Switch Air or Air-assisted Guns It is not recommended to run without an air flow switch. If a switch fails, replace it as soon as possible. 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.
System Operation Start Up 1. Go through the Pre-Operation Checklist in Table 8. Table 8: Pre-Operation Checklist ✓ Checklist System grounded Verify all grounding connections were made. See the Installation manual. All connections tight and correct ➜ Graco logo, software revision, and “Establishing Communication” will display, followed by Status screen. See page 19. ➜ At power up the system defaults to Recipe 61, which is not a valid recipe number.
System Operation 6. Adjust component A and B fluid supplies as needed for your application. Use lowest pressure possible. 7. Do not exceed the maximum rated working pressure shown on the system identification label or the lowest rated component in the system. 8. Open the fluid supply valves to the system. 9. Adjust the air pressure. Most applications require about 80 psi (552 kPa, 5.5 bar) air pressure to operate properly. Do not use less than 75 psi (517 kPa, 5.2 bar). 10.
System Operation Shutdown Pressure Relief Procedure Overnight Shutdown NOTE: The following procedures relieve all fluid and air pressure in the ProMix 2KS system. Use the procedure appropriate for your system configuration. 1. Leave the power on. 2. Run 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. 3. Shut off ProMix 2KS power (0 position). FIG. 64. 4.
System Operation Systems with Color Change and without Dump Valves Systems with Color/Catalyst Change and Dump Valves NOTE: This procedure relieves pressure through the sampling valve. NOTE: This procedure relieves pressure through the dump valves. 1. Complete all steps under Single Color Systems, page 52. 1. Complete all steps under Single Color Systems, page 52. 2. Close the A side shutoff valve (SVA), FIG. 67. Open the A side sampling valve (RVA). 2.
System Operation F2 F1 J1 Power Fiber Optic CAN J13 CAN J12 1 J14 1 J15 GFB 2 GFB 1 Dump B J9 Dump A 1 Purge B Dose A Dose B Purge A Valve Overrides 3rd Purge J3 1 J8 Dump Valve A Dump Valve B GFB 1 Optional Solenoid Locations GFB 2 3rd Purge Valve Solenoid Dose Valve A Solenoid Dose Valve B Solenoid Purge Valve A Solenoid Purge Valve B Solenoid TI12652b FIG. 65.
System Operation Color Solenoid Identification Label Catalyst Color Solenoid Identification Label TI12826a Solvent Solenoid Overrides FIG.
System Operation Purging Read Warnings, page 7. Follow the Grounding instructions in your system Installation manual. To avoid splashing fluid in the eyes, wear eye protection. There are 4 purging procedures in this manual: • • • • If using an electrostatic gun shut off the electrostatics before flushing the gun. 2. Set the solvent supply pressure regulator at a pressure high enough to completely purge the system in a reasonable amount of time but low enough to avoid splashing or an injection injury.
System Operation Purging Using Recipe 0 Purging Fluid Supply System Recipe 0 is typically used: • in multiple color systems to purge out material lines without loading a new color • at the end of a shift to prevent hardening of catalyzed material. Follow this procedure before: • the first time material is loaded into equipment* • servicing • shutting down equipment for an extended period of time • putting equipment into storage To setup Recipe 0, go to Advanced Setup.
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 solenoid valves. See FIG. 65. 5. Purge as follows: • 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.
System Operation Purging Sampling Valves and Tubes Follow this procedure after meter calibration. 1. Press the Standby 8. Close sampling valves. NOTE: Select Abort on Calibration screen to cancel current calibration and close dose or purge valves. key on the Booth Control. 9. Fully open both fluid shutoff valves. 2. See FIG. 67. Close both fluid shutoff valves and sampling valves. 10. On a single color system, reconnect component A fluid supply line to flow meter A. 3.
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. 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 remaining (0-99%) of the 50% of the potlife volume.
Meter Calibration Meter Calibration 4. Place the beakers (minimum size - 250 cc) in holders. Put the sampling tubes into the beakers. To avoid splashing fluid in the eyes, wear eye protection. 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 pressurized. If you cannot turn the valve stems manually, relieve the system pressure, then disassemble and clean the valve to remove the resistance.
Meter Calibration 8. Dispense component A, B, or Solvent into beaker. a. To avoid splashing, slowly open sampling valves. b. c. For more accurate calibration, adjust the valve to dispense at a flow rate similar to your production spray flow rate. Dispense a minimum of 250 cc; make sure enough material is dispensed to accurately read the volume with your beaker. The A and B volumes do not have to be equal or at any particular ratio. 12.
Color Change 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 4. Use the scroll keys, color. Press Enter sequence. mode at the Booth Control. or , to select the new to begin the color change 5. If a gun flush box is not used, trigger the gun into a grounded metal pail until the color change sequence is complete. 6.
Color Change Color Purge/Dump Step P0-P1 • This sequence flushes out the color with solvent, from the color valve to the Dump A valve. • The color change solvent valve and the Dump A valve open during the Purge Time. • The color change solvent valve closes when the Purge Time expires. Color Fill Step P1-P2 • This sequence fills the line with the new color all the way to the Dump A valve. • The new color valve and the Dump A valve open during the Fill Time.
Color Change Table 9: Color Change Chart Reference Number of Gun Flush Boxes Refer to Fig. Starting Recipe Ending Recipe Color Change Catalyst Change Dump Valves 3rd Purge Valve X X Yes Yes Yes Yes 0 FIG. 71 X X Yes Yes Yes No 0 FIG. 70 X X Yes No No No 0 FIG. 73 X X Yes No Yes No 0, 1, or 2 FIG. 72 X X No Yes Yes No 0, 1, or 2 FIG. 74 X X No No No No 0, 1, or 2 FIG. 84 X X Yes Yes Yes No 1 FIG. 76 X X Yes No No No 1 FIG.
Color Change ProMix 2KS Recipe Change Chart 1: A1 to A2, B1 to B2 with Dump Valves Valve Time-Sequence Dump A Dump B A B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B A B A B P0 P1 P2 P3 P4 Color Purge Time P0->P1 Color Fill Time P1->P2 Catalyst Purge Time P2->P3 Catalyst Fill Time P3->P4 CC Purge/Fill Timers are independent of Mixed Material Purge Timers. This line defines when the Mixed Fill Time begins.
Color Change ProMix 2KS Recipe Change Chart 3: A1 to A2, same B with Dump Valves Valve Time-Sequence Dump A Dump B A Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B A B A P0 P1 P2 P3 P4 Color Purge Time P0->P1 Color Fill Time P1->P2 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.
Color Change ProMix 2KS Recipe Change Chart 5: B1 to B2, same A with Dump Valves Valve Time-Sequence Dump A Dump B B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B A B B P0 P1 P2 P3 P4 Catalyst Purge Time P0->P1 Catalyst Fill Time P1->P2 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.
Color Change ProMix 2KS Recipe Change Chart 7: A1 to A2, B1 to B2 with Dump Valves, 1 GFB Valve Time-Sequence A Dump A Dump B B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B A A B B P0 P1 P2 P3 P4 Color Purge Time P0->P1 Color Fill Time P1->P2 Catalyst Purge Time P2->P3 Catalyst Fill Time P3->P4 CC Purge/Fill Timers are independent of Mixed Material Purge Timers. This line defines when the Mixed Fill Time begins.
Color Change ProMix 2KS Recipe Change Chart 9: A1-A2, same B without Dump Valves, 1 GFB Valve Time-Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B A A B Air Chop Time Solvent Chop Time 3rd Flush Chop Time First Purge (one of these) Air Purge Solvent Purge 3rd Flush Valve Final Purge (one of these) Dispense A Dispense B A A A B B Gun Flush Box Output #1 Gun Flush Box Output #2 0 1 2 3 4 5 6 Color Purge Time 0->1 Color Fill Time 1->2 Fi
Color Change ProMix 2KS Recipe Change Chart 11: Recipe 0 OR 61 to Recipe X with Dump Valves Valve Time-Sequence Dump A Dump B A B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B A A B B Air Purge Solvent Purge 3rd Flush Purge Dispense A Dispense B A A B B Gun Trigger(s) by Operator 0 1 2 3 Color Fill Time 0->1 Catalyst Fill Time 1->2 Mixed Fill Time 2->3 Notes: Purge from old recipe Fill from new recipe Load tables from new recipe FIG.
Color Change ProMix 2KS Recipe Change Chart 13: Recipe 0 OR 61 to Recipe X without Dump Valves Valve Time-Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B A A Air Purge Solvent Purge 3rd Flush Purge Dispense A Dispense B A A A B B Gun Trigger(s) by Operator 0 1 2 Color Fill Time 0->1 Mixed Fill Time 1->2 Notes: Purge from old recipe Fill from new recipe Load tables from new recipe FIG.
Color Change ProMix 2KS Recipe Change Chart 15: Same A, Same B Valve Time-Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B A B Air Chop Time Solvent Chop Time 3rd Flush Chop Time First Purge (one of these) Air Purge Solvent Purge 3rd Flush Purge Final Purge (one of these) Dispense A Dispense B A A B B Gun Trigger(s) by Operator 0 1 2 3 4 First Purge Time 0->1 Chop Time (air/solvent or air/3rd flush) 1->2 Final Purge Time 2->3 Mixed Fill Ti
Color Change ProMix 2KS Recipe Change Chart 17: Recipe 0 OR 61 to Recipe X with Dump Valves and 3rd Flush Valve Valve Time-Sequence Dump A Dump B A B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B A A B B Air Purge Solvent Purge 3rd Flush Purge Mixed Fill Time does not begin until the Exiting Fill Time and Color/Catalyst Fill Time is complete.
Alarms and Warnings Alarms and Warnings NOTE: Do not use the fluid in the line that was dispensed off ratio as it may not cure properly. To Reset Alarm and Restart System Alarms NOTE: When an alarm occurs be sure to determine the E-Code before resetting it. See Table 10. If you forget which E-Code occurred, use the Alarms Screens (page 22) to view the last 10 alarms, with date and time stamps. System alarms alert you of a problem and help prevent off-ratio spraying.
Alarm Troubleshooting Alarm Troubleshooting Table 11. Alarm Troubleshooting E-1: COMM ERROR Cause No power to the EasyKey. Solution Connect power to EasyKey. No power to Fluid Station. The intrinsically safe power Verify that the cable is correctly connected. See Installacable between the EasyKey and Fluid Station is not con- tion manual. nected. No power to Fluid Station. The fluid control board fuse is Verify condition of fuse and replace if necessary. See blown. Repair-Parts manual.
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. Cause There is too little restriction in the system. Solution • Check that the system is fully loaded with material. • Check that the supply pump’s cycle rate is set properly.
Alarm Troubleshooting Table 11. Alarm Troubleshooting E-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. Cause There is too much restriction in the system. Solution • Check that the system is fully loaded with material. • Check that the supply pump’s cycle rate is set properly.
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. Cause Solution Valve seal or needle/seat are leaking. Check FIG. 11 Totals Screen on page 22.
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. Cause System is in Mix mode and gun is only partially triggered, allowing air but no fluid to pass through gun. Solution Fully trigger the gun.
Alarm Troubleshooting Table 11. Alarm Troubleshooting E-9: MIX IN SETUP ALARM Cause Attempt to operate system while in Setup mode. Solution System must be in Standby to change current recipe, and cannot be operated. E-10: REMOTE STOP ALARM Cause Solution Automation has requested that the system abort all oper- Abort operations. Troubleshoot automation system. ations. E-11: PURGE VOLUME ALARM Cause Solution ProMix 2KS solvent flow switch is not activated while purging.
Alarm Troubleshooting Table 11. Alarm Troubleshooting E-12: CAN COMM ERROR ALARM Cause Communication between the Color Change Module and the Fluid Station is interrupted. Communication between the Color Change Module and the Fluid Station is interrupted. The fluid control board fuse is blown. Solution • Verify that all cables are connected securely and that the Color Change and Booth Control power LEDs turn on. If the power LED does not turn on, the problem is probably caused by a bad connection.
Alarm Troubleshooting Table 11. Alarm Troubleshooting E-13: HIGH FLOW ALARM or E-14: LOW FLOW ALARM (may also be set as Warnings) Cause Fluid system is producing too much or too little flow. Solution Troubleshoot fluid system for restrictions, leaks, exhausted fluid supply, incorrect settings, etc. Increase or decrease flow rate, as required. E-15: SYSTEM IDLE WARNING Cause Solution Mix input is high, but the gun has not been triggered for 2 If not painting, clear alarm and resume operation. minutes.
Alarm Troubleshooting Table 11. Alarm Troubleshooting E-19: I/O ALARM Cause Solution 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.
Alarm Troubleshooting Table 11. Alarm Troubleshooting E-20: PURGE INITIATE ALARM Cause Solution System detects atomizing air to the gun when purge is selected. Shut off gun air. For systems with a gun flush box, gun is not in the box when purge is selected. Place gun in gun flush box. Verify that gun flush box is operating properly. For systems with auto dump on, gun is not in the box when auto dump is initiated. Place gun in gun flush box. Verify that gun flush box is operating properly.
Alarm Troubleshooting Table 11. Alarm Troubleshooting E-25: AUTO DUMP COMPLETE ALARM Cause Solution A potlife alarm is active for more than 2 minutes, the gun Be sure to spray all mixed material before potlife expires. flush box is enabled and gun is in the gun flush box, and an auto dump flush sequence is complete. E-26: COLOR/CATALYST PURGE ALARM Cause Solution System detects no meter pulses, or a disruption in meter Check that meter cable is connected.
Schematic Diagrams Schematic Diagrams System Pneumatic Schematic COLOR CHANGE CONTROL A B SE BE CLO 2 TU 5/3 N E OP DOSE A VALVE 12 VDC 4-WAY SOLENOID A B SE BE CLO 2 TU 5/3 N E OP DOSE B VALVE 12 VDC 05 AIR INPUT 4-WAY SOLENOID CONTROL AIR 3/8 AIR FILTER MANUAL DRAIN 5 MICRON WALL MOUNT ONLY A B 4-WAY SOLENOID A B 12 VDC A B AIR EXHAUST MUFFLER PURGE AIR SE BE CLO 2 TU 5/3 N E OP PURGE A VALVE SE BE CLO 2 TU 5/3 EN OP PURGE B VALVE SE BE CLO 2 TU 5/3 N E OP PURGE C VALVE (OPTIONAL)
Schematic Diagrams System Electrical Schematic NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS system. Some components shown are not included with all systems.
Schematic Diagrams System Electrical Schematic NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS system. Some components shown are not included with all systems.
DISPLAY BOARD P1 BARRIER BOARD J9 1 2 3 4 RJ45 DISPLAY BOARD RJ45 J5 J1 J4 24 VDC+ IN RED 18 AWG BLACK 18 AWG RED/BLACK/WHITE 22 AWG J5-1 J5-2 J5-3 SHIELD/GRND COMMON (BLACK) +12 VDC I/S (WHITE) UNUSED UNUSED J1-2 J1-1 UNUSED UNUSED J1-4 J1-3 UNUSED RED 18 AWG BLACK 18 AWG J1-5 J4-1 J4-2 J4-3 GREEN/BLACK/WHITE 22 AWG IS POWER 12 VDC + + + + - RED 18 AWG BLACK 18 AWG DC OK + - - 24 VDC+ HIGH VOLTAGE IN POWER SUPPLY 24 VDC+ OUTPUT GND LUG COMMON RJ45
312776E 1:1 2:1 3:1 4:1 5:1 6:1 7:1 8:1 25cc Dose 50cc Dose Ratio 9:1 10:1 11:1 12:1 13:1 14:1 15:1 16:1 17:1 18:1 19:1 20:1 21:1 22:1 23:1 24:1 25:1 26:1 27:1 28:1 29:1 30:1 10cc Dose Fluid: Hydraulic Oil Viscosity: 65.7 centipoise Ratio Tolerance: 5% Valve Setting: 1.25 Turns Open (standard setting) A and B Feed Pressure: 300 psig Test Conditions 0 500 1000 1500 2000 2500 3000 3500 3800 NOTE: Maximum system flow is 3800 cc/min.
1:1 2:1 3:1 4:1 5:1 6:1 7:1 8:1 10cc Dose 25cc Dose 25cc Dose 50cc Dose Ratio 9:1 10:1 11:1 12:1 13:1 14:1 15:1 16:1 17:1 18:1 19:1 20:1 21:1 22:1 23:1 24:1 25:1 26:1 27:1 28:1 29:1 30:1 50cc Dose Fluid: Hydraulic Oil Viscosity: 65.7 centipoise Ratio Tolerance: 5% Valve Setting: 1.25 Turns Open (standard setting) A and B Feed Pressure: 300 psig Test Conditions 0 500 1000 1500 2000 2500 3000 3500 3800 NOTE: Maximum system flow is 3800 cc/min.
Technical Data Technical Data Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . 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) Maximum working air pressure. . . . . . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7 bar) Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 - 100 psi (0.5 - 0.7 MPa, 5.
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.
