Graco 312776F User Manual

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Operation

ProMix

2KS

312776F

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.

#53

TI12504a

II 2 G0359

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Equipment Approvals . . . . . . . . . . . . . . . . . . . . . . . 3

System Configuration and Part Numbers . . . . . . . 4

Configurator Key . . . . . . . . . . . . . . . . . . . . . . . . . 4

Standard Features . . . . . . . . . . . . . . . . . . . . . . . 5

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Component Identification and Definition . . . . . . 13

Booth Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

EasyKey Display and Keypad . . . . . . . . . . . . . . . 18

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

AC Power Switch . . . . . . . . . . . . . . . . . . . . . . . 19

I/S Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Audible Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Graco Web Interface Port . . . . . . . . . . . . . . . . . 19

Ethernet Connection . . . . . . . . . . . . . . . . . . . . . 19

Run Mode Screens . . . . . . . . . . . . . . . . . . . . . . . . 20

Splash Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Totals Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Reset Total Screen . . . . . . . . . . . . . . . . . . . . . . 23

Reset Solvent Screen . . . . . . . . . . . . . . . . . . . . 23

Alarms Screens . . . . . . . . . . . . . . . . . . . . . . . . . 24

Level Control Screen . . . . . . . . . . . . . . . . . . . . 24

Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Password Screen . . . . . . . . . . . . . . . . . . . . . . . 26

Set Up Home Screen . . . . . . . . . . . . . . . . . . . . 26

System Configuration Screens . . . . . . . . . . . . . 28

Option Screens . . . . . . . . . . . . . . . . . . . . . . . . . 32

Advanced Setup Screens . . . . . . . . . . . . . . . . . 34

Recipe Setup Screens . . . . . . . . . . . . . . . . . . . 38

Recipe 0 Screens . . . . . . . . . . . . . . . . . . . . . . . 43

Calibration Screen . . . . . . . . . . . . . . . . . . . . . . 45

System Operation . . . . . . . . . . . . . . . . . . . . . . . . . 46

Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . 46

Sequential Dosing . . . . . . . . . . . . . . . . . . . . . . . 46

Dynamic Dosing . . . . . . . . . . . . . . . . . . . . . . . . 46

Recipe (Color) Change . . . . . . . . . . . . . . . . . . . 46

Solvent Push . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Mix Fill Push . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

General Operating Cycle, Sequential Dosing . . 46

General Operating Cycle, Dynamic Dosing . . . . 48

Mix Manifold Valve Settings . . . . . . . . . . . . . . . 51

Air Flow Switch (AFS) Function . . . . . . . . . . . . . 52

Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Pressure Relief Procedure . . . . . . . . . . . . . . . . 55

Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Solvent Push Feature . . . . . . . . . . . . . . . . . . . . 63

Mix Fill Push Feature . . . . . . . . . . . . . . . . . . . . . 64

Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Color Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Color Change Procedures . . . . . . . . . . . . . . . . . 67

Color Change Sequences . . . . . . . . . . . . . . . . . 67

Alarms and Warnings . . . . . . . . . . . . . . . . . . . . . . 80

System Alarms . . . . . . . . . . . . . . . . . . . . . . . . . 80

System Warnings . . . . . . . . . . . . . . . . . . . . . . . 80

Alarm Troubleshooting . . . . . . . . . . . . . . . . . . . . . 81

Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . 92

System Pneumatic Schematic . . . . . . . . . . . . . . 92

System Electrical Schematic . . . . . . . . . . . . . . . 93

EasyKey Electrical Schematic . . . . . . . . . . . . . . 95

Meter Performance Data (G3000 on A and B) . . . 96 Meter Performance Data (G3000 on A, Coriolis on B)

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Graco Standard Warranty . . . . . . . . . . . . . . . . . . 100

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 100

2 312776F

Related Manuals

Component Manuals in English

Manual Description

312775 ProMix 2KS Manual System Installation 312777 ProMix 2KS Manual System Repair-Parts 312781 Fluid Mix Manifold 312782 Dispense Valve 312783 Color Change Valve Stacks 312787 Color Change Module Kit 312784 Gun Flush Box Kits 310745 Gun Air Shutoff Kit 312786 Dump Valve and Third Purge Valve Kits 312785 Network Communication Kits 308778 G3000/G3000HR Flow Meter 313599 Coriolis Flow Meter 313290 Floor Stand Kit 313542 Beacon Kit 313386 Basic Web Interface/Advanced Web Inter-

face 406799 15V256 Automatic System Upgrade Kit 406800 15V825 Discrete I/O Board Kit

Equipment Approvals

Equipment approvals appear on the following labels which are attached to the Fluid Station and EasyKey

See F

IG. 1 on page 4 for label locations.

EasyKey and Fluid Station Label

ATEX Certificate is listed here





  













  

  



  



Fluid Station Label

        



 

 





   

™

PART NO. SERIES SERIAL MFG. YR.

CUS

Artwork No. 293538

ProMix 2KS

Intrinsically safe equipment for Class I, Div 1, Group D, T3 Ta = -20°C to 50°C Install per 289833

ATEX Certificate is listed here

EasyKey Label

ProMix 2KS

PART NO.

SERIES NO. MFG. YR.

GRACO INC. P.O. Box 1441 Minneapolis, MN 55440 U.S.A.

CUS

Intrinsically safe connections for Class I, Div 1, Group D Ta = -20°C to 50°C Install per 289833

Um: 250 V

FLUID PANEL

MAX AIR WPR

FM08ATEX0073 II 2 G Ex ia IIA T3

.7 7

MPa bar PSI

100

GRACO INC. P.O. Box 1441 Minneapolis, MN 55440 U.S.A.

TI13581a

POWER REQUIREMENTS

VOLTS

AMPS

85-250 ~

2 AMPS MAX

50/60 Hz

II (2) G [Ex ia] IIA FM08ATEX0072

TI13582a

Artwork No. 293467

ATEX Certificate is listed here

312776F 3

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 System Control and Display A and B Meter Color Valves Catalyst Valves Applicator Handling

M D = EasyKey with LCD

Display

0 = No Meters

1 = G3000 (A and B)

2 = G3000HR (A and

3 = 1/8 in. Coriolis (A)

and G3000 (B)

4 = G3000 (A) and 1/8

in. Coriolis (B)

5 = 1/8 in. Coriolis (A)

and G3000HR (B)

6 = G3000HR (A) and

1/8 in. Coriolis (B)

7 = 1/8 in. Coriolis (A

and B)

0 = No Valves

(single color)

1 = Two Valves

(low pressure)

2 = Four Valves

(low pressure)

3 = Seven Valves

(low pressure)

4 = Twelve Valves

(low pressure)

5 = Two Valves

(high pressure)

6 = Four Valves

(high pressure)

0 = No Valves

(single catalyst)

1 = Two Valves

(low pressure)

2 = Four Valves

(low pressure)

3 = Two Valves

(high pressure)

1 = One Air Flow

Switch Kit

2 = Two Air Flow

Switch Kits

3 = One Gun Flush Box

Kit

4 = Two Gun Flush Box

Kits



 

 





   

Label Location on EasyKey

TI12418aTI12423a

Configured Part Number

Label Location on Fluid Station

Maximum Fluid

Working Pressure

is listed here





  













  

  



  



FIG. 1: Identification Label

4 312776F

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.

Example: Model MD2531 has a maximum working pressure of 3000 psi (21 MPa, 210 bar).

Check the identification label on the EasyKey or fluid station for the system maximum working pressure. See F

IG. 1.

ProMix Fluid Components Maximum Working Pressure

Base System (no meters [option 0], no color/catalyst change [option 0]). . . . . . . 4000 psi (27.58 MPa, 275.8 bar)

Meter Option 1 and 2 (G3000 or G3000HR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000 psi (27.58 MPa, 275.8 bar)

Meter Option 3, 4, 5, 6, and 7 (one or two Coriolis Meters) . . . . . . . . . . . . . . . . . 2300 psi (15.86 MPa, 158.6 bar)

Color Change Option 1, 2, 3 and 4 and

Catalyst Change Option 1 and 2 (low pressure valves) . . . . . . . . . . . . . . . . . . . . . . . 300 psi (2.07 MPa, 20.6 bar)

Color Change Option 5 and 6 and

Catalyst Change Option 3 (high pressure valves) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 psi (21 MPa, 210 bar)

Flow Meter Fluid Flow Rate Range

G3000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-3800 cc/min. (0.02-1.0 gal./min.)

G3000HR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-1900 cc/min. (0.01-0.50 gal./min.)

Coriolis Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3800 cc/min. (0.005-1.00 gal./min.)

S3000 Solvent Meter (accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-1900 cc/min. (0.01-0.50 gal./min.)

Standard Features

Feature

EasyKey with LCD

Fiber Optic and Power Cables, 50 ft (15.25 m)

Wall Mount Fluid Station, 50 cc Integrator and Static Mixer

B Side Dump Valve, if multiple catalyst valves

Booth Control

Basic Web Interface

312776F 5

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

15V034 10 cc Integrator Kit

15V033 25 cc Integrator Kit

15V021 50 cc Integrator Kit

24B618 100 cc Integrator Kit

15W034 Strobe Light Alarm Indicator Kit

15V337 Advanced Web Interface

15V256 Automatic Mode Upgrade Kit

16D329 S3000 Solvent Flow Meter Kit

15V825 Discrete I/O Integration Board Kit

NOTE: This is not a complete list of available accessories and kits. Refer to the Graco website for more information about accessories available for use with this product.

6 312776F

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.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

ELECTRIC SHOCK HAZARD

This equipment must be 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.

• Only models with a G3000, G250, G3000HR, G250HR, or intrinsically safe Coriolis meter are approved for installation in a Hazardous Location - Class I, Div I, Group D, T3 or Zone I Group IIA T3.

• Do not install equipment approved only for a non-hazardous location in a hazardous area. See the ID label for the intrinsic safety rating of your model.

• Do not substitute or modify system components as this may impair intrinsic safety.

312776F 7

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.

•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 manufacturer’s replacement parts only.

• Do not alter or modify equipment.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

• 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:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

•Gloves

• Hearing protection

8 312776F

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. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area.

To prevent contact with isocyanates, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area.

Material Self-ignition

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 viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts.

NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.

To prevent exposing ISO to moisture:

• Always use a sealed container with a desiccant

dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.

• Use moisture-proof hoses specifically designed for ISO, such as those supplied with your system.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Never use solvent on one side if it has been contaminated from the other side.

• Always lubricate threaded parts with ISO pump oil or grease when reassembling.

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 damage equipment. To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (isocyanate) and component B (resin) parts.

312776F 9

Changing Materials

• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after flushing.

• 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

Advanced Web Interface (AWI) - This allows remote

ProMix backup and restore, configuration, logging, and software update options.

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.

B Purge After Chop - Optional 2-second B solvent valve activation after the Chop sequence. This is used to separate the chop material and the Final Purge material to prevent unwanted mixing.

Basic Web Interface (BWI) - This allows remote ProMix backup and restore, logging, and software update options.

Bootloader - The utility program that handles initial system startup re-programming of the main ProMix application.

Chop Time- refers to the total length of the chop sequence during a purge. User settable from 0-999 seconds.

Coriolis Meter - a non-intrusive flow meter often used in low flow applications or with light viscosity, shear sensitive, or acid catalyzed materials. This meter uses vibration to measure flow.

Custom Language - A method to load a translation file into the ProMix to display languages other than those built into the system. Only Unicode characters through codespace 0x00FF are supported.

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. More than 30 pulses from the flow meter of the active dose valve are needed while the Gun Trigger is on to prevent the alarm.

Dynamic Dosing - Component A dispenses constantly. Component B dispenses intermittently in the necessary volume to attain the mix ratio.

Ethernet - a method for directly connecting a computer to a network or equipment in the same physical location.

Closed Loop Flow Control - refers to the process when the flow rate is adjusted automatically to maintain a constant flow.

Color/Catalyst Purge - refers to the time required to flush the lines from the color or catalyst change module to the mix manifold during a color or catalyst change.

Color/Catalyst Fill - refers to the time required to fill the lines from the color or catalyst change module to the mix manifold.

Command Holdoff - The amount of time that flow rate learning is not allowed after the set point is changed to allow the flow rate to stabilize.

10 312776F

ExtSP - External Set Point selection for PLC input of the flow rate set point while operating in Flow Control Override mode.

Fiber Optic Communication - the use of light to transmit communication signals. Blue is the transmitter, and black is the receiver. This must be cross-connected between the EasyKey and the Fluid Panel for communication to work. The Fiber Optic cable has a blue band to indicate the proper connection.

Final Purge Source- source of the media used in the final purge cycle. User settable to air purge valve, solvent purge valve, or 3rd purge valve.

Final Purge Time- duration of the final purge cycle. User settable from 0-999 seconds.

Glossary of Terms

First Purge Source- source of the media used in the first purge cycle. User settable 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 acceptable 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).

Global - indicates that values on the screen apply to all recipes, 1 through 60.

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.

Kd - refers to the amount the fluid flow system attempts to not overshoot the target set point.

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.

Learn Strength - How much and how quickly to apply the difference in the flow rate set point compared to the measured flow rate when updating the flow control data table.

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 material fill volume. E-21 Alarm occurs if minimum volume is not achieved. Minimum material fill volume is user settable (0-9999 cc).

Grand Total - a non-resettable value that shows the total amount of material dispensed through the system.

GT-Off Drive Time - The amount of time to regulate the fluid pressure based on the flow rate set point after the gun trigger is closed.

GT-Off Target Rise - The additional time to regulate the fluid pressure based on the flow rate set point after the gun trigger is closed.

Gun Trigger Holdoff - The amount of time that flow rate learning is not allowed after the gun trigger is opened to allow the flow rate to stabilize.

Gun Trigger Input Signal - used to manage ratio assurance dose times and flow control processes.

Intrinsically Safe (IS) - refers to the ability to locate certain components in a hazardous location.

Idle - if the gun is not triggered for 2 minutes the system enters Idle mode. Trigger the gun to resume operation.

Job Total - a resettable value that shows the amount of material dispensed through the system for one job. A job is complete when a color change or complete system flush occurs.

Mix - when cross-linking of the resin (A) and catalyst (B) occurs.

Mix Fill Push - An option for the Autodump selection to automatically clear the Potlife alarm if the gun is in the Gun Flush Box by running new mixed material through the gun.

Mix Input Signal- refers to system mode status where system begins a dose sequence each time the mix signal 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 individual proportioning or flow control system.

One-Point Learning - Flow Control table calibration method using learned points above a specified flow rate to interpolate the table at low flow rates with short gun trigger times.

312776F 11

Glossary of Terms

Overdose (A, B, C) Alarm - when either the resin (A), or catalyst (B), or reducer (C) component dispenses too much material and the system cannot compensate for the additional material.

Potlife Time - the amount of time before a material becomes unsprayable.

Potlife Volume - the amount of material that is required to move through the mix manifold, hose and applicator before the potlife timer is reset.

Purge - when all mixed material is flushed from the system.

Purge Drive - The voltage drive during the Purge sequence, maximum of 3300 mV. The response curve of the V/P regulator is not linear, so it may be necessary to test the response using Manual Override mode.

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.

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.

Valve Holdoff Maximum - The maximum amount of time that flow rate learning is not allowed after a dose valve cycles. The system may internally use a time less than is based on the stability of the fluid meter pulse stream.

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.

System Idle - This warning occurs if the ProMix is set to

Mix, and 2 minutes have elapsed since the system received a flow meter pulse.

12 312776F

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.

• Has user selectable ratio assurance and can maintain up to +/-1% accuracy, depending on materials and operating conditions.

• Models are available to operate air spray or air-assisted systems with a capacity of up to 3800 cc/min.

• Color change options are available for low pressure (300 psi [2.1 MPa, 21 bar]) air spray and high pressure (3000 psi [21 MPa, 210 bar]) systems with up to 30 color change valves and up to 4 catalyst change valves.

NOTE: Optional accessories are available for in field 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

Component Description

EasyKey (EK)

Booth Control (BC)

Fluid Station (ST)

Fluid Manifold (FM)

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.

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.

Includes air control solenoids, flow switches, and mountings for the fluid flow meters and the fluid manifold assembly. Its control board manages all proportioning functions.

• 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.

 Static Mixer has 24 elements to uniformly blend the materials downstream

of the fluid integrator.

312776F 13

Overview

Table 1: Component Descriptions

Component Description

Flow Meters (MA, MB, MS)

Color Change Valves (ACV) and Color Change Module (CCM)

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. (0.01–0.5 gal/min.), pressures up to 4000 psi (28 MPa, 276 bar). and viscosities of 20–3000 centipoise. The K-factor is approximately 0.061 cc/pulse.

• S3000 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 centipoise. 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.

Catalyst Change Valves (BCV)

Dual Fiber Optic Cable (FO)

Fluid Station Power Supply Cable (PS)

Applicator Handling: use Air Flow Switch (AFS) or Gun Flush Box (GFB)

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 power 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 52 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.

14 312776F

Overview

ACV

CCM

BCV

GFB

FIG. 2. Manual System, shown with G3000 Meters, Color/Catalyst Change, One Gun Flush Box, and Accessory Solvent Flow Meter

TI12504a

312776F 15

Overview

APV

FIG. 3. Wall Mount Fluid Station

RVA

DVA

SVA SVB

DVB

RVB

SPV

TI12556b

Key:

MA Component A Meter DVA Component A Dose Valve RVA Component A Sampling Valve SVA Component A Shutoff Valve MB Component B Meter DVB Component B Dose Valve RVB Component B Sampling Valve SVB Component B Shutoff Valve MS Solvent Meter (accessory) SPV Solvent Purge Valve APV Air Purge Valve SM Static Mixer FI Fluid Integrator AT Air Purge Valve Air Supply Tube

16 312776F

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 F

IG. 4)

Key/Indicator Definition and Function

Display • Displays recipe number in Run

mode.

• If an alarm occurs, displays the alarm code (E1 to E28) and red Alarm indicator blinks.

• Recipe number displays after alarm is reset.

• If Solvent Push is on, display alternately shows dashes and the percentage remaining (see page 63).

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 loading is complete.

• LED blinks when purging.

• Select a new recipe by pressing

Table 2: Booth Control Key and Indicator Functions

(see F

IG. 4)

Key/Indicator Definition and Function

Up Key Scrolls recipe numbers up.

Down Key Scrolls recipe numbers down.

Mix Mode Key • 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.

Standby Mode Key

• Starts Standby mode.

• Green LED remains lit while in Standby mode.

Purge Mode Key

• Starts Purge mode.

• Green LED remains lit while in Purge mode.

Alarm Indicator (red)

Display

or Down keys, then

pressing Enter .

Alarm Reset Key and Indicator

• Red LED blinks when an alarm occurs.

• Press key to reset alarm. LED shuts off after alarm is reset.

Job Complete Key and Indicator

• Signals that job is complete, and resets A and B totalizers.

• Green LED blinks once after key is pressed.

Enter Key Enters selected recipe and starts color

Recipe Indicator (green)

change sequence.

312776F 17

IG. 4. Booth Control (see Table 2)

TI11614A

EasyKey Display and Keypad

LCD Display

IG. 5. EasyKey Display and Keypad

Keypad

TI11630A

Navigation Keys Alarm Reset Key

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.

NOTE: Pressing a key to turn on the display back light will also perform the function of that key. If you are unsure whether that key will impact your current operation, use the setup or navigation keys to turn on the display back light.

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 keypad, 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.

Table 3: EasyKey Keypad Functions (see FIG. 5)

Key Function

Setup: press to enter or exit Setup mode.

Enter: if cursor is in menu box, press Enter

key to view menu. Press Enter to save a value either keyed in from the numerical keypad or selected from a menu.

Up Arrow: move to previous field or menu item, or to previous screen within a group.

Down Arrow: move to next field or menu item, or to next screen within a group.

Left Arrow: move to previous screen group.

Right Arrow: move to next screen group.

Alarm Reset: resets all active alarms. If the display becomes unresponsive, pressing this key 4 times in succession will re-initialize the display.

18 312776F

Relief Port

Audible AlarmFiber Optic Strain

Main Power Access Port

EasyKey Display and Keypad

AC Power

Ground Screw

IG. 6. EasyKey Connections and AC Power Switch

I/S Power Discrete I/O Cable

Graco Web Interface

Connector Ports

AC Power Switch

Turns system AC power on or off.

I/S Power

Power circuit to Fluid Station.

Audible Alarm

Alerts the user when an alarm occurs. Available settings for selecting which alarms will cause an audible alarm are explained in Configure Screen 1, page 29.

Clear the audible alarm by pressing the Alarm Reset

TI12638a TI12657a

Graco Web Interface Port

Used to communicate from a PC to:

 Upgrade software  View software version  Download

• Job and alarm logs

• Material usage report

• Setup values (can also upload)

 Clear job, alarm, and material usage reports  Upload a custom language to view on

screen

 Restore factory defaults  Restore setup password

See manual 313386 for more information.

key.

Ethernet Connection

Even after the Alarm Reset key is pressed, the Potlife Exceeded alarm message will remain displayed until a sufficient amount of mixed material has been dispensed to ensure that the expired material has been ejected.

312776F 19

You can access data on an office or industrial network through the internet with the proper configuration. See manual 313386 for more information.

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 22).

IG. 7. Splash Screen

The Splash screen will also momentarily display “Establishing 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.

IG. 8. Fluid Plate Programming Screen

20 312776F

Run Mode Screens

Press the Setup key to

enter Setup mode.

TI12783a

FIG. 9. Run Screens Map

312776F 21

Run Mode Screens

Status Screen

•Use the Up or Down keys to scroll through the Run screens.

• Press the Setup key to enter the Setup screens

from the Status screen.

• The other keys have no function in this Status screen.

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.

IG. 10. Status Screen

Key to F

IG. 10:

Active Recipe: shows the active recipe.

NOTE: At power up the system defaults to Recipe

61, which is not a valid recipe number.

Target Ratio: for the active recipe. The ratio can be from 0.0:1–50.0:1, in 0.1 increments.

Actual Ratio: in hundredths, calculated after each dose of A and B.

Lock Symbol: indicates that Setup screens are

password protected. See page 26.

22 312776F

Run Mode Screens

Totals Screen

IG. 11. Totals Screen

This screen shows the job totals, fill totals, grand totals, and job number. Use the tabs to reset job totals (Job Complete), reset solvent totals (Rst Solvent), or go to Level Control Screen, page 24.

The job totals generally refer to material dispensed while in Mix mode. This is likely atomized and sprayed material with the gun trigger “On”.

Reset Total Screen

FIG. 12. Reset Total Screen

If job is reset, job number will increment by one for default.

Reset Solvent Screen

The fill totals generally refer to material dispensed while in Mix-fill mode after a color change or a purge operation. This is likely not sprayed or atomized, and is dispensed to a purge container.

Solvent Totals and the Rst Solvent tab only appear if “Meter” is selected under Solvent Monitor in Configure

Screen 5 on page 31.

NOTE: Grand totals are not resettable.

IG. 13. Reset Solvent Total Screen

The screen will ask if you want to reset solvent total. Select Yes or No.

312776F 23

Run Mode Screens

Alarms Screens

IG. 14. Alarms Screen

Two screens show the last 10 alarms. Use the Up or

Down

See Table 10 on page 80 for a list of alarm codes.

keys to scroll between the two screens.

Level Control Screen

occur after 25% of the remaining volume is mixed. Refill tank volume to clear the alarm.

FIG. 16. Tank Level Low Screen (Tank A Shown)

IG. 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 23). The Alarm Level values may be adjusted using the advanced web interface.

See F

IG. 16. If the tank volume reaches the low-level

threshold, the EasyKey screen will display the Tank Level Low alarm and prompt the user to do one of the following:

1. Refill tank volume to clear the alarm.

2. Resume mixing by selecting “Spray 25% of Remainder.” If this selection is chosen, a second alarm will

24 312776F

Setup Mode

Press the Setup key to enter Setup mode.

Press the Setup key to

enter Setup mode.

NOTE: See F

IG. 17 for a map of the Setup screens.

Detailed screen descriptions follow.

This screen appears only if a

password is activated.

To access Advanced Setup Screens, page 34

and Recipe Setup Screens, page 38.

To access System Configuration

Screens, page 28.

Press the Setup key to exit

Setup mode and return to the Status

FIG. 17. Setup Screens Map

screen.

This screen appears momentarily

if a password is activated.

TI12784a

312776F 25

Setup Mode

Password Screen

If a password has been activated (see Configure Screen 1, page 29), 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).

IG. 18. Password Screen

NOTE: If a password is activated, Setup Locked dis-

plays momentarily after exiting Setup mode and return-

ing to the Status Screen. A lock symbol appears

Set Up Home Screen

FIG. 20. Set Up Home Screen

This screen displays when you enter Setup mode. From it you can go to Recipe and Advanced Setup Screens (pages 34-42) or System Configuration Screens

(pages 28-31). Press the Enter key to go to the selected screen set.

The screen also displays software versions and internet addresses of various components. The values shown in F

IG. 20 are only examples and may vary on your screen.

See Table 4 for further information.

on the Status Screen.

IG. 19. Setup Locked Screen

26 312776F

Setup Mode

Table 4: Component Software Versions

Display (may vary from

Component

examples shown) Description

EK (EasyKey) 3.01.001 EasyKey software version.

FP (Fluid Plate) 3.01.001 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.

C1/C2 (Color Change Modules 1 and 2)

-.- Color Change Module 1/2 not installed, not detected, or not operational.

1.XX Color Change Module software version 1.00 or 1.01.

2.XX Color Change Module software version 2.XX.

AK (Autokey) No Key No AutoKey installed or detected. System operates in 2K

Manual Mode only

2K-Auto 2K AutoKey detected. System can operate in 2K Manual,

Semi-automatic, or Automatic Mode.

3K-Auto 3K AutoKey detected. System can operate in 3K Manual,

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.

Axx By Cz A30 B4 Cx Color Change board valve configuration. This shows the num-

ber of valves available for each of the components. This is set by the configuration switches on the color change boards connected to the system.

Code Description

- Component not available with this machine configura-

tion.

x Component not used with this machine configuration.

1 Component available but no change stack.

4-30 Component available with change stack.

Number of valves flushed with a solvent valve.

IP (Internet Address) 192.168.178.3 Example of the address EasyKey is set to for basic and

advanced web interface reporting.

MAC (MAC address) 00204AAD1810 Example of internet MAC address. Each EasyKey will have a

different value in this format.

312776F 27

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

IG. 21. System Configuration and Option Screens Map

28 312776F

Setup Mode

Configure Screen 1

IG. 22. Configure Screen 1

Language

Defines the language of the screen text. Select English (default), Spanish, French, German, Italian, Dutch, Japanese (Kanji), Korean, Chinese (Simplified), and Custom.

NOTE: Refer to document 313386 for instructions on using the Custom Language feature to modify the screens to support undefined languages.

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.

Screen Timeout

Select the desired screen timeout in minutes (0-99). 5 is the default.

Configure Screen 2

FIG. 23. Configure Screen 2

Month

Enter current month.

Day

Enter current day.

Year

Enter current year (four digits).

Time

NOTE: Be sure to write down the password and keep it

in a secure location.

Display Units

Select the desired display units:

• cc/liter (default)

•cc/gallon

Buzzer Alarms

As the default, the alarm buzzer is set to “Potlife Only” and will sound only for the Potlife Alarm (E-2).

Set to “All Alarms” to have the buzzer sound for any alarm.

Set to “All Except Potlife” to have the buzzer sound for any alarm except a Potlife Alarm (E2). This option is not recommended unless another active method of handling the Potlife Alarm is implemented.

312776F 29

Enter current time in hours (24 hour clock), minutes, and seconds. Seconds are not adjustable.

Date Format

Select MM-DD-YYYY, DD-MM-YYYY, or YYYY-MM-DD.

Setup Mode

Configure Screen 3

IG. 24. Configure Screen 3

1K/2K/3K

Set this value to indicate the system performance level designation. Selecting a value other than the installed system level will result in restricted functionality.

Run Mode

NOTE: If an Autokey is installed, additional selections of

Semi-Automatic and Automatic are available.

Indicates that this is a Manual system.

Dump Valve A

This field only appears if the color change option is detected from the cc board. Select “On” if an optional Dump Valve A is installed and desired to be used.

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.

Configure Screen 4

FIG. 25. Configure Screen 4

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.

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 48).

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.

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).

NOTE: For color change and flushing purposes, it is recommended that two GFBs are installed when using a 2-gun system.

DD Setup Mode

See Fig. 26 and Fig. 27 on page 31.

30 312776F

IG. 26. Configure Screen 4, dynamic dosing

selected

Setup Mode

Special Outputs

Use of Special Outputs on Manual systems requires installation of a Discrete I/O Integration Board. Order Graco Part No. 15V825 Discrete I/O Integration Board Kit. See manual 406800.

NOTE: At system power up, the Special Outputs may activate for up to 1/4 second.

Select special outputs (0-4, or 3 + GFB on #4). A selection of “0” will disable use of the Special Outputs. If the “3 + GFB on #4” selection is chosen, the other 3 special outputs (1-3) can be used for user-defined functions and the special output #4 settings will duplicate those settings established for the Gun Flush Box.

Each output has two different start times and durations defined on the Recipe Setup screen (Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32), or on the Advanced Setup screen (Flush and Fill Input is set to “Global” in Option Screen 1, page 32).

IG. 27. Configure Screen 4, dynamic dosing setup

F mode enabled

DD Setup Mode

Selecting “DD” in the Dose Size field makes the Dynamic Dosing setup mode field appear. Select On to enable DD setup mode, or Off to disable. See page 49 for further information.

Configure Screen 5

Solvent Monitor

Select solvent monitor (Off, Flow Switch, or Meter).

A selection of “Meter” will cause the system to track the amount of solvent used. See Totals Screen, page 23 for more information about solvent totals.

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.

IG. 28. Configure Screen 5

312776F 31

Setup Mode

Option Screens

NOTE: See FIG. 21 on page 28 for a map of the Option Screens. Detailed screen descriptions follow.

NOTE: Each screen displays the current screen number

and the total number of screens in the group.

Option Screen 1

IG. 29. Option Screen 1

Flush Volume Check

This field only appears if Solvent Monitor is set to “Meter” in Configure Screen 5, page 31.

Minimum Material Fill Volume

Enter 0-9999 cc.

Verification Screen

FIG. 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.

If set to “On”, Minimum Flush Volume will appear in

Recipe Setup Screen 2, page 39.

Flush and Fill Input

If set to “Global”, Color/Catalyst Purge and Color/Catalyst Fill are added to Advanced Setup Screen 1, page

35. Advanced Setup Screen 2, 3, and 5 are added. See pages 35-37.

If set to “Recipe”, Color/Catalyst Purge and Color/Catalyst Fill are added to Recipe Setup Screen 2, page 39. Recipe Setup Screen 3, 4, and 7 are added. See pages 40-42.

K-factor Input

Global mode is useful when the material properties, flush and fill characteristics, or K-factors are the same for all materials used by the system.

If set to “Global,” Advanced Setup Screen 4, page 36 is added.

If set to “Recipe,” Recipe Setup Screen 5, page 41, is added.

32 312776F

Setup Mode

Option Screen 2

IG. 31. Option Screen 2

Auto Dump

If the auto dump feature is being used, set to “Solvent Push” or “Mix Fill Push”. 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 or push out the old material based on the selected option.

B Purge After Chop

NOTE: This is used to isolate the Chop cycle from the

Final Purge cycle with solvent to prevent reaction issues with some types of materials.

Optional 2-second burst (2 s B) operation of the B Purge valve on the integrator after the Chop cycle.

See Color Change Sequences, page 67 for color change charts and timing information.

“Solvent Push” will flush out expired material using the solvent supply. See Solvent Push Feature on page 63 for more information.

“Mix Fill Push” will push out expired material with new mixed material. When sufficient material has been pushed, the potlife alarm will reset. See Mix Fill Push

Feature on page 64 for more information.

Flow Rate Monitor

If set to “On,” Recipe Setup Screen 6 on page 41 is added, enabling setting of high and low flow limits.

If set to “Off,” flow rate monitoring is disabled and Rec-

ipe Setup Screen 6 on page 41 will not appear.

Solvent Push Enable

NOTE: See Solvent Push Feature on page 63 for more

information.

To enable the Solvent Push feature, select “Solvent” or “3rd Valve” (available if 3rd Flush Valve in Configure Screen 3, page 30, is set to “On”).

To disable the Solvent Push feature, set to “Off.”

312776F 33

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

IG. 32. Advanced Setup Screens Map

34 312776F

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

IG. 33. Advanced Setup Screen 1

Gun 1/Gun2 Potlife Volume

Color/Catalyst Fill

This field only appears if the system includes a color change module and Flush and Fill Input is set to “Global” in Option Screen 1, page 32. Enter the fill time (0 to 99 seconds). It refers to the time required to fill the lines from the color or catalyst module to the dose valve or dump valve.

Advanced Setup Screen 2

FIG. 34. Advanced Setup Screen 2

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)*

3/16 5.43

1/4 9.648 3/8 21.71

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 32. 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 module to the dose valve or dump valve.

This screen appears only if Flush and Fill Input is set to “Global” in Option Screen 1, page 32.

First Purge Source

Select “Air,” “Solvent,” or “3rd Flush Valve” (available only if 3rd Flush Valve is set to “On” in Configure

Screen 3 on page 30).

Chop Type

Select “Air/Solvent” or “Air/3rd Flush Valve” (available only if 3rd Flush Valve is set to “On” in Configure Screen 3 on page 30). This refers to the process of mixing air and solvent (or air and 3rd flush fluid) together during the flush cycle, to help clean the lines and reduce solvent usage.

Final Purge Source

Select “Air,” “Solvent,” or “3rd Flush Valve” (available only if 3rd Flush Valve is set to “On” in Configure

Screen 3 on page 30).

Air Chop Time

Enter the air chop time (0.0 to 99.9 seconds).

Solvent Chop Time/3rd Flush Valve Chop Time

Enter the solvent or 3rd flush valve chop time (0.0 to

99.9 seconds).

312776F 35

Setup Mode

Advanced Setup Screen 3

IG. 35. Advanced Setup Screen 3

This screen appears only if Flush and Fill Input is set to “Global” in Option Screen 1, page 32.

If Number of Guns is set to “2” in Configure Screen 4, page 30, a Gun 2 column will appear in this screen.

First Purge Time

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).

Mixed Material Fill Time

Advanced Setup Screen 4

FIG. 36. Advanced Setup Screen 4

This screen appears only if K-factor Input is set to “Global” in Option Screen 1, page 32.

K-factor A Meter

Enter the k-factor (cc/pulse) for flow meter A. This is the amount of material that passes through the flow meter per pulse (electrical pulse signal).

K-factor B Meter

Enter the k-factor (cc/pulse) for flow meter B.

K-factor Solvent Meter

This field only appears if Solvent Monitor in Configure Screen 5, page 31, is set to “Meter.” Enter the k-factor

(cc/pulse) for the solvent flow meter.

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 applicator/gun.

36 312776F

Advanced Setup Screen 5

IG. 37. Advanced Setup Screen 5

This screen appears only if Flush and Fill Input is set to “Global” in Option Screen 1, page 32 and Special Out- puts is set to 1, 2, 3, or 4 in Configure Screen 5, page

31. The I/O board has four programmable outputs.

Setup Mode

On-Purge

Delay time at the start of the purge cycle before the Special Output turns on.

Length

Duration for the Special Output to be active during the purge cycle.

On-Fill

Delay time at the start of the fill cycle before the Special Output turns on.

Length

Duration for the Special Output to be active during the fill cycle.

312776F 37

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

IG. 38: Recipe Screens Map

38 312776F

Setup Mode

Option Screens.

Recipe Setup Screen 1

IG. 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 includes a color change module. Enter the catalyst valve number (1 to

4).

Recipe Setup Screen 2

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 32. Enter the minimum flush volume (0 to 9999 cc). Entering 0 disables this function.

Potlife Time

Enter the potlife time (0 to 999 minutes). Entering 0 disables 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 “Recipe” in Option Screen 1, page 32. Enter the purge time (0 to 99 seconds). It refers to the amount of time required to flush the lines from the color or catalyst module to the dose valve or dump valve.

Color/Catalyst Fill

This field only appears if the system includes a color change module and Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32. Enter the fill time (0 to 99 seconds). It refers to the time required to fill the lines from the color or catalyst module to the dose valve or dump valve.

312776F 39

Setup Mode

Recipe Setup Screen 3

IG. 41. Recipe Setup Screen 3

This screen appears only if Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32.

First Purge Source

Select “Air,” “Solvent,” or “3rd Flush Valve” (available only if 3rd Flush Valve is set to “On” in Configure

Screen 3 on page 30).

Chop Type

Final Purge Source

Select “Air,” “Solvent,” or “3rd Flush Valve” (available only if 3rd Flush Valve is set to “On” in Configure

Screen 3 on page 30.)

Recipe Setup Screen 4

FIG. 42. Recipe Setup Screen 4

This screen appears only if Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32.

If Number of Guns is set to “2” in Configure Screen 4, page 30, a Gun 2 column will appear in this screen.

First Purge Time

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).

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 applicator/gun.

Air Chop Time

Enter the air chop time (0.0 to 99.9 seconds).

Solvent Chop Time/3rd Flush Valve Chop Time

Enter the solvent or 3rd flush valve chop time (0.0 to

99.9 seconds).

40 312776F

Setup Mode

Recipe Setup Screen 5

IG. 43. Recipe Setup Screen 5

This screen appears only if K-factor Input is set to “Recipe” in Option Screen 1, page 32.

K-factor A Meter

Enter the k-factor (cc/pulse) for flow meter A. This is the amount of material that passes through the flow meter per pulse (electrical pulse signal).

Recipe Setup Screen 6

FIG. 44. Recipe Setup Screen 6

This screen appears only if Flow Rate Monitor is set to “On” in Option Screen 2 on page 33.

Flow Rate Monitor

Select the desired flow rate monitoring (Off, Warning, or Alarm).

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 31, is set to “Meter.” Enter the k-factor

(cc/pulse) for the solvent flow meter.

Low Flow Limit

Enter the low flow rate limit (1 to 3999 cc/min).

High Flow Limit

Enter the high flow rate limit (1 to 3999 cc/min).

312776F 41

Setup Mode

Recipe Setup Screen 7

IG. 45. Recipe Screen 7

This screen appears only if Flush and Fill Input is set to “Recipe” in Option Screen 1, page 32 and Special Outputs is set to 1, 2, 3, 4, or “3 + GFB on #4” in Configure Screen 5, page 31. The I/O board has four programmable outputs.

NOTE: If the Special Outputs is set to “3 + GFB on #4”, the Recipe 0 Screen 4 does not display the column of information for Special 4. That Output assumes the values assigned to GFB #1.

On-Purge

Delay time at the start of the purge cycle before the Special Output turns on.

Length

Duration for the Special Output to be active during the purge cycle.

On-Fill

Delay time at the start of the fill cycle before the Special Output turns on.

Length

Duration for the Special Output to be active during the fill cycle.

42 312776F

Setup Mode

Recipe 0 Screens

NOTE: See FIG. 38 on page 38 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.

Option Screens.

Recipe 0 Screen 1

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

FIG. 47. Recipe 0 Screen 2

IG. 46. Recipe 0 Screen 1

First Purge Source

Select “Air,” “Solvent,” or “3rd Flush Valve” (available only if 3rd Flush Valve is set to “On” in Configure

Screen 3 on page 30).

Chop Type

If Number of Guns is set to “2” in Configure Screen 4, page 30, a Gun 2 column will appear in this screen.

Color/Catalyst Purge Time

This field only appears if the system includes a color change module. It refers to the amount of time required to flush the lines from the color or catalyst module to the dose valve or dump valve. Enter the purge time (0 to 999 seconds).

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).

Final Purge Source

Select “Air,” “Solvent,” or “3rd Flush Valve” (available only if 3rd Flush Valve is set to “On” in Configure Screen 3 on page 30.)

312776F 43

Setup Mode

Recipe 0 Screen 3

IG. 48. Recipe 0 Screen 3

This screen only appears if Solvent Monitor is set to “Meter” in Configure Screen 5, page 31 and Flush Volume Check is set to “On” in Option Screen 1, page 32 or 3rd Flush Valve is set to “On” in Configure Screen 3 on page 30.

Minimum Flush Volume

This field only appears if Flush Volume Check is set to “On” in Option Screen 1 on page 32. Enter the minimum flush volume (0 to 9999 cc).

Recipe 0 Screen 4

FIG. 49. Recipe 0 Screen 4

NOTE: If the Special Outputs is set to “3 + GFB on #4”, the Recipe 0 Screen 4 does not display the column of information for Special 4. That Output assumes the values assigned to GFB #1.

Exiting Fill Source

This field only appears if 3rd Flush Valve is set to “On” in Configure Screen 3 on page 30. Select “Off,” “Air,” “Solvent,” or “3rd Valve.”

On-Purge

Delay time at the start of the purge cycle before the Special Output turns on.

Length

Duration for the Special Output to be active during the purge cycle.

On-Fill

Delay time at the start of the fill cycle before the Special Output turns on.

Length

Duration for the Special Output to be active during the fill cycle.

44 312776F

Calibration Screen

IG. 50. Calibration Screen

Use this screen to calibrate a meter. Set to “A Meter,” “B Meter,” or “Solvent Meter” (available if Solvent Monitor in Configure Screen 5, page 31, is set to “Meter”).

Setup Mode

• Start - start calibration

• Abort - stop calibration

• Purge - purge sampling valves after calibration

See Meter Calibration, page 65, for when and how to calibrate a meter.

312776F 45

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.

Dynamic Dosing

In typical operation (ratios 1:1 and above), component A dispenses constantly. Component B dispenses intermittently in the necessary volume 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 key to begin operation.

3. 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.

4. Components A and B are introduced into the fluid integrator (FI) one at a time as follows.

a. Dose Valve A (DVA) opens, and fluid flows into

the integrator.

b. Flow Meter A (MA) monitors 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

Recipe (Color) Change

The process when the system automatically flushes out the old color and loads a new color.

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.

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 63 for complete information.

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.

Mix Fill Push

The Mix Fill Push feature enables the user to prevent potlife expiration of material by mixing and flowing new material through the Gun Flush Box. See page 64 for complete information.

46 312776F

System Operation

5. The components are pre-mixed in the integrator, then uniformly blended in the static mixer (SM).

7. If the gun is not triggered for two minutes, the system switches to Idle mode, which closes off the mix manifold dose valves.

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. Components A and B are alternately fed into the integrator as long as the gun is triggered.

NOTE: Operation can be stopped at any time by

pressing the Standby key or shutting off the

main power switch.

Table 5: Sequential Dosing Operation

Ratio = 2.0:1 Dose 1 Dose 2 Dose 3

A = 2

B = 1

DVA

DVB

APV

RVA

Key:

MA Component A Meter DVA Component A Dose Valve RVA Component A Sampling Valve SVA Component A Shutoff Valve MB Component B Meter DVB Component B Dose Valve RVB Component B Sampling Valve

SVA SVB

SVB Component B Shutoff Valve MS Solvent Meter (accessory) SPV Solvent Purge Valve APV Air Purge Valve SM Static Mixer FI Fluid Integrator AT Air Purge Valve Air Supply Tube

RVB

TI12556b

SPV

FIG. 51. Wall Mount Fluid Station, Sequential Dosing

312776F 47

System Operation

General Operating Cycle, Dynamic Dosing

Overview

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.

A restrictor injects component B into a continuous stream of component A. The software controls the duration and frequency of each injection. See F schematic diagram of the process.

IG. 52 for a

Dynamic Dosing System Parameters

The following parameters affect dynamic dosing performance:

• 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.

• Component B Flow: Ensure that the supply pump is sized to provide sufficient and uninterrupted flow.

• Component A Pressure: Ensure precise pressure regulation. It is recommended that the component A pressure be 5-15% lower than the component B pressure.

• 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 pulsation, 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

Component A (continuous flow) Proportioned Material

Component B (pulsed injection)

IG. 52. Schematic Diagram of Dynamic Dosing Operation

48 312776F

Mixer

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.

Turn On Dynamic Dosing

1. On the EasyKey press the Setup key to access

the Set Up Home screen. Select “System Configuration” to access the configuration screens. F

IG. 53.

3. Selecting “DD” in System Configure Screen 4 makes the DD Setup mode available. See F

IG. 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 initiation of a Mix command.

IG. 53. Set Up Home Screen

2. Navigate to System Configure Screen 4. Select “DD” option from the “Dose Size” drop down menu. F

IG. 54.

IG. 54. Configure Screen 4, dynamic dosing

F selected

FIG. 55. Configure Screen 4, dynamic dosing setup mode enabled

312776F 49

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.

Selecting the correct component B restrictor size and balancing the A/B pressures will keep the system in the proper pressure range, resulting in a consistent mix ratio.

IG. 57 shows the A to B pressure balance, read at the

proportioner inlet. It is recommended that the component 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 (“B 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.

B Pressure Too Low

B Pressure

Too High

A Pressure B Pressure

FIG. 57. A/B Control Range with Properly Sized Restrictor

(

)

B Pressure Too Low

B Pressure

Too High

A Pressure B Pressure

In dynamic dosing, component A dose valve is constantly 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 accordingly. See Table 6 on page 51.

FIG. 56. B Pressure Too Low, displayed on EasyKey

NOTE: If the restrictor is too small, it may be

necessary to supply more differential pressure than is available in your system.

IG. 58. A/B Control Range with Too Large a

Restrictor

50 312776F

Table 6: Dynamic Dosing Troubleshooting Guide

(for complete system troubleshooting, see Table 11 beginning on page 81)

Warning/Alarm Message Solution

System Operation

B Pressure Too Low (see F

IG. 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.

Off Ratio High • Increase B pressure.

• Clean restrictor or use a larger size.

• Verify B valve is opening properly.

Mix Manifold Valve Settings

To open dose or purge valves, turn hex nut (E) counterclockwise. To close, turn clockwise. See Table 7 and

IG. 59.

TI11581a

FIG. 59. Valve Adjustment

Table 7: Mix Manifold Valve Settings

Valve Setting Function

Dose (F

IG. 59)

Purge (F

IG. 59)

Shutoff (SVA and SVB, F

IG. 67)

Sampling (RVA and RVB, F

IG.

Hex nut (E) 1-1/4 turns out from fully closed

Fully open during Run/Mix operation

Fully closed during Run/Mix operation

Limits maximum fluid flow rate into integrator and minimizes 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.

67)

312776F 51

System Operation

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.

Operating Without Air Flow Switch

It is not recommended to run without an air flow switch. If a switch fails, replace it as soon as possible.

Airless Gun

It is not recommended to use an airless gun with the ProMix 2KS. Two issues can arise from operating without an air flow switch:

• Without a gun trigger/air flow switch input the ProMix 2KS does not know it is spraying and will not generate a Dose Time Alarm (E-7 or E-8). This means there is no way to detect a failed meter. You could spray pure resin or catalyst for 2 minutes with- out knowing.

• 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)

IG. 60: Air Flow Switches

TI13350a

AFS

This warning occurs if the ProMix is set to Mix , 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

, then Mix , then trigger the gun.

52 312776F

Start Up

System Operation

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

Verify all electrical, fluid, air, and system connections 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 valves set

Check that mix manifold valves are set correctly. Start with the settings recommended in Mix Mani- fold Valve Settings, page 51, then adjust as needed.

Fluid supply valves open and pressure set

 Graco logo, software revision, and “Establishing

Communication” will display, followed by Status screen. See page 20.

 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 number (1-60).

 In bottom left corner, the system status dis-

plays, which can be Standby, Mix, Purge, or an alarm notification

FIG. 62. Status Screen

3. Make sure that the Booth Control is working. The active recipe number should display and the

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 (I = ON, 0 = OFF).

I = ON

TI12656

IG. 61. Power Switch

Standby LED

should be lit.

4. If this is the first time starting up the system, purge it as instructed in Purging Fluid Supply System, page 60. The equipment was tested with lightweight oil, which should be flushed out to avoid contaminating your material.

5. Make sure that the Booth Control is in Standby

mode.

312776F 53

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. 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, trigger the gun into a grounded metal pail until the purge sequence is complete.

When done purging, the Booth Control automatically switches to Standby mode.

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 10% of each other.

If the fluid flow rate is too low: increase air pressure to component A and B fluid supplies or increase the regulated fluid pressure.

If the fluid flow rate is too high: reduce the air pressure, close the fluid manifold dose valves further, or adjust the fluid pressure regulator.

NOTE: Pressure adjustments of each component will vary with fluid viscosity. Start with the same fluid pressure for component A and B, then adjust as needed.

NOTE: Do not use the first 4-5 oz. (120-150 cc) of material 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 proportioning 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.

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.

IG. 63. Status Screen Flow Rate Display

54 312776F

System Operation

Shutdown

Overnight Shutdown

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 55.

2. Close main air shutoff valve on air supply line and on ProMix.

3. Shut off ProMix 2KS power (0 position). F

4. If servicing EasyKey, also shut off power at main circuit breaker.

IG. 64.

0 = OFF

Pressure Relief Procedure

NOTE: The following procedures relieve all fluid and air

pressure in the ProMix 2KS system. Use the procedure appropriate for your system configuration.

Relieve pressure when you stop spraying, before changing spray tips, and before cleaning, checking, or servicing equipment.

Single Color Systems

1. While in Mix mode (gun triggered), shut off the A and B fluid supply pumps/pressure pots. Close all fluid shutoff valves at the pump outlets.

2. With the gun triggered, push the manual override on the A and B dose valve solenoids to relieve pressure. See F

NOTE: If a Dose Time alarm (E-7, E-8) occurs, clear the alarm.

IG. 65.

IG. 64. Power Switch

TI12657a

3. Do a complete system purge, following the instructions under Purging Using Recipe 0, page 60.

4. Shut off the fluid supply to the solvent purge valve (SPV) and the air supply to the air purge valve (APV), F

5. With the gun triggered, push the manual override on the A and B purge valve solenoids to relieve air and solvent pressure. See F pressure is reduced to 0.

NOTE: If a Purge Volume alarm (E-11) occurs, clear the alarm.

IG. 67.

IG. 65. Verify that solvent

312776F 55

System Operation

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 55.

2. Close the A side shutoff valve (SVA), F the A side sampling valve (RVA).

3. Direct the A side sampling tube into a waste container.

4. See F

IG. 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 the sampling valve stops.

5. Press and hold the solvent solenoid override until clean solvent comes from the sampling valve, then release.

6. Shutoff the solvent supply to the color change stack solvent valve.

7. Press and hold the solvent solenoid override until solvent flow from the sampling valve stops.

8. Open the A side shutoff valve (SVA), F the A side sampling valve (RVA).

IG. 67. Open

IG. 67. Close

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 55.

2. Shut off all color and catalyst supplies to the valve stacks.

3. Press and hold the dump valve A solenoid override, F

IG. 65.

4. See F

5. Press and hold the dump valve B solenoid override,

6. See F

7. Press and hold the dump valve A solenoid override,

8. Press and hold the A side (color) solvent solenoid

IG. 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.

IG. 65.

IG. 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.

IG. 65.

override until clean solvent comes from the dump valve, then release.

9. Press and hold the dump valve B solenoid override, F

IG. 65.

10. Press and hold the B side (catalyst) solvent solenoid override until clean solvent comes from the dump valve, then release.

11. Shutoff the solvent supply to the color/catalyst change stack solvent valves.

12. Press and hold the A and B solvent solenoid overrides and dump valve overrides until solvent flow from the dump valves stops.

56 312776F

System Operation

Valve

Dose A Dose B

J13

J12

Purge B

Purge A

J14 J15 J8

Dump A

3rd Purge

GFB 2

GFB 1

Power

Fiber Optic

CAN

Dump B

Dump Valve A

Dump Valve B

Optional Solenoid

Dose Valve A

Solenoid

Dose Valve B

Solenoid

Purge Valve A Solenoid

GFB 1

GFB 2

3rd Purge Valve Solenoid

Purge Valve B Solenoid

Locations

TI12652b

FIG. 65. Fluid Solenoids

312776F 57

System Operation

Solenoid

Identification

Label

Color Catalyst

Solenoid Identification Label

Color

TI12826a

FIG. 66: Color Change Solenoids

DVA

APV

RVA

SVA SVB

Solvent Solenoid Overrides

DVB

SPV

RVB

TI12556b

Key:

MA Component A Meter DVA Component A

Dose Valve

RVA Component A

Sampling Valve

SVA Component A

Shutoff Valve MB Component B Meter DVB Component B

Dose Valve RVB Component B

Sampling Valve SVB Component B

Shutoff Valve MS Solvent Meter SPV Solvent Purge Valve APV Air Purge Valve SM Static Mixer FI Fluid Integrator AT Air Purge Valve Air

Supply Tube

FIG. 67. Wall Mount Fluid Station

58 312776F

Purging

Read Warnings, page 7. Follow the Grounding instructions in your system Installation manual.

System Operation

If using an electrostatic gun shut off the electrostatics before flushing the gun.

To avoid splashing fluid in the eyes, wear eye protection.

There are 4 purging procedures in this manual:

• Purging Mixed Material (below)

• Purging Using Recipe 0 (page 60)

• Purging Fluid Supply System (page 60)

• Purging Sampling Valves and Tubes (page 62)

Use the criteria listed in each procedure to determine which procedure to use.

Purging Mixed Material

There are times when you only want to purge the fluid manifold, such as:

• end of potlife

• breaks in spraying that exceed the potlife

• overnight shutdown

• before servicing the fluid manifold assembly, hose or gun.

Solvent purges the component B (catalyst, right) side of the mix manifold and the inner tube of the integrator. Air purges the component A (resin, left) side and the outer tube of the integrator.

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. Generally, a setting of 100 psi (0.7 MPa, 7 bar) is sufficient.

3. 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, trigger the gun into a grounded metal pail until the purge sequence is complete.

When done purging, the Booth Control automatically switches to Standby mode.

4. If the system is not completely clean, repeat step 3.

NOTE: If necessary, adjust purge sequence so only one cycle is required.

1. Press the Standby

Trigger the gun to relieve pressure.

If you are using a high pressure gun, engage the trigger lock. Remove spray tip and clean tip separately.

312776F 59

key on the Booth Control.

Trigger the gun to relieve pressure. Engage trigger lock.

5. If spray tip was removed, reinstall it.

6. Adjust the solvent supply regulator back to its normal operating pressure.

System Operation

Purging Using Recipe 0

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.

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

Trigger the gun to relieve pressure.

If you are using a high pressure gun, engage the trigger lock. Remove spray tip and clean tip separately.

key on the Booth Control.

Purging Fluid Supply System

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

* Some steps are not necessary for initial flushing,

as no material has been loaded into the system yet.

1. Press the Standby

Trigger the gun to relieve pressure.

If you are using a high pressure gun, engage the trigger lock. Remove spray tip and clean tip separately.

key on the Booth Control.

If using an electrostatic gun shut off the electrostatics before flushing the gun.

2. If using a gun flush box, place the gun into the box and close the lid.

3. Select Recipe 0 and press Enter .

4. If a gun flush box is not used, trigger the gun into a grounded metal pail until the purge sequence is complete.

5. The color change LED blinks while Recipe 0 runs and turns solid after purge sequence is complete.

6. If the system is not completely clean, you can

repeat Recipe 0 by pressing Enter

If using an electrostatic gun, shut off the electrostatics before flushing the gun.

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 solvent supply lines.

• Multiple color/single catalyst systems: dis-

connect only the component B fluid supply at the flow meter inlet and connect a regulated solvent supply line.

• Multiple color/multiple catalyst systems:

connect the solvent supply lines to the designated solvent valve on the color and catalyst valve stacks. Do not connect a solvent supply to either flow meter.

60 312776F

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 F

IG. 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. 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.

• Multiple color/single catalyst systems:

Select Recipe 0 and press Enter to purge the component A side. The color change LED blinks while Recipe 0 runs and turns solid after purge sequence is complete.

System Operation

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.

• Multiple color/multiple catalyst systems:

Select Recipe 0 and press Enter to 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 53 for Start Up procedure.

312776F 61

System Operation

Purging Sampling Valves and Tubes

Follow this procedure after meter calibration.

1. Press the Standby

2. See F

IG. 67. Close both fluid shutoff valves and

sampling valves.

3. Route the sampling tubes into a grounded waste container.

4. On a single color system, attach a solvent supply line to Flow Meter A inlet.

5. On the EasyKey, press the Setup key and

access the Advanced Setup screens.

6. Press the Right Arrow key to select the Calibra-

tion screen. Press the Down Arrow

select Purge from the menu. Press the Enter key

key on the Booth Control.

key and

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 A

fluid supply line to flow meter A.

NOTE: After calibration it is necessary to clean out contaminated mix material. Do a manual purge and resume the recipe just tested, or do Recipe 0 then go on to the next recipe.

Dose A, solvent purge valve (B side), and color change solvent valves (if used) will open.

IG. 68. Calibration Screen

7. To 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.

62 312776F

Solvent Push Feature

System Operation

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 35. If there are 2 guns, the smaller potlife volume is used.

Solvent Push requires an accessory solvent meter (MS). Order Graco Part No. 16D329 S3000 Solvent Meter Kit. See manual 308778.

1. See F

IG. 69. Install the solvent meter (MS) on the

side of the fluid station, as explained in the ProMix 2KS Installation Manual.

2. To enable Solvent Push, select “Solvent” or “3rd

Valve,” as desired. See Option Screen 2, page 33.

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.

NOTE: The system must be in Mix to initiate Solvent Push.

close the Dose Valves (DVA, DVB) and open the Solvent Purge Valve (SPV).

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.

NOTE: To manually interrupt Solvent Push, press the

Standby key. The Solvent Purge Valve (SPV) or

3rd purge valve will close. To re-enter Solvent Push,

press the Mix key.

5. When the total solvent dispensed exceeds 50% of the potlife volume, the system will go into Standby

mode.

6. Perform a manual purge or recipe change to purge the remaining mixed material. This will clear the system out of Solvent Push, allowing you to resume Mix mode.

3. Press and hold the Mix key for 5 seconds

to turn on Solvent Push. The green Mix LED will light and the Recipe LED will blink. The system will

Key:

DVA Component A 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

DVA is closed

NOTE: Once the system senses that solvent exceeds

50% of potlife volume, attempts to re-enter Solvent Push will cause an Overdose A/B Alarm (E-5, E-6).

DVB is closed

SMC

TI12556b

SPV is open

FIG. 69. Solvent Push Setup

312776F 63

System Operation

Mix Fill Push Feature

The Mix Fill Push feature enables the user to prevent potlife expiration of material by mixing and flowing new material through the Gun Flush Box.

Mix Fill Push requires an accessory Gun Flush Box for each gun that will use this feature. Order Graco Part No. 15V826 Fun Flush Box Kit. See manual 312784.

NOTE: If the gun is not in the box the Mix Fill Push feature will not operate.

NOTE: The Mix Fill Push operation will run every time the Potlife alarm occurs with the gun in the box. Unattended systems can therefore repeatedly perform this operation as the potlife keeps happening.

Mix Fill Push requires a Gun Flush Box for the gun. If two guns are used, each requires a Fun Flush Box for this feature to operate. The second Gun Flush Box must be configured as a Special Output. See Configure Screen 5 on page 31.

To enable Mix Fill Push, select “Mix Fill Push” in the Auto Dump field. See Option Screen 2, page 33.

1. The system gets a Potlife alarm.

2. The buzzer will do a double "chirp" every 4 seconds to indicate an impending Mix Fill Push.

3. After waiting for the 2-minute Auto Dump time the system will run the Mix Fill Push.

NOTE: On a one-gun system the gun must be in the GFB. On a 2-gun system both guns must be in the GFBs.

4. If one of the guns in not in the GFB, the system will not perform any of the Mix Fill Push or Auto Dump operations. The system will retry every 30 seconds in case the gun is then installed in the GFB.

5. With the guns in the GFBs, the system will proportion mixed material through the guns in order to reset the potlife volume.

6. The alarm is cleared.

7. The event is logged in the Alarm Log as two alarms: E-5 Overdose A and E-6 Overdose B.

IG. 70. Mix Fill Push Timing Chart

64 312776F

Meter Calibration

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.

Calibrate the meter:

• The first time the system is operated.

• Whenever new materials are used in the system, especially if the materials have viscosities that differ significantly.

Meter Calibration

4. Place the beakers (minimum size - 250 cc) in holders. Put the sampling tubes into the beakers.

NOTE: If tubes need replacing, use 5/32 in. or 4 mm OD tubing.

5. On the EasyKey, press the Setup key to access

setup screens.

6. Select Recipe & Advanced Setup and press the

Enter key to select.

• At least once per month as part of regular maintenance.

• Whenever a flow meter is serviced or replaced.

NOTE:

• K-factors on the Calibration Screen are

updated automatically after the calibration procedure is completed.

• K-factor values on the screen are viewable only.

If needed, you can manually edit the K-factors in Advanced Setup Screen 4 (page 36) or Recipe Setup Screen 5 (page 41).

• All values on this screen are in cc, independent

of the units set in Configure Screen 1.

• 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.

7. Press the Right Arrow key to select the Calibra-

tion Screen. Press either A Meter, B Meter, or Solvent. Press the Down

Arrow only one at a time.

key and select Start from the menu. Start

the Enter key to select

2. Shut off all spray or dispense devices connected to the ProMix.

3. Close both fluid shutoff valves and sampling valves.

312776F 65

Meter Calibration

8. Dispense component A, B, or Solvent into beaker.

a. To avoid splashing, slowly open sampling

valves.

b. For more accurate calibration, adjust the valve

to dispense at a flow rate similar to your production 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 volumes do not have to be equal or at any particular ratio.

d. Close sampling valve tightly.

9. The volume that the ProMix measured displays on the EasyKey.

12. After the volume for A, B, 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 36) or Recipe Setup Screen 5 (page 41).

13. Always purge sampling valves after calibrating meters. Use one of the following methods.

•Follow the Purging Sampling Valves and

Tubes procedure, page 62.

• 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.

14. Make sure both sampling valves are closed and both fluid shutoff valves are fully open.

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 dispensed.

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 calibration procedure, scroll to Abort on the Calibration

Screen menu and press the Enter key

15. Before you begin production, clear the system of solvent and prime it with material.

a. Go to 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 53.

66 312776F

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.

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. 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 change operation aborts. The Booth Control enters Standby

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.

mode at the Booth Control.

or , to select the new

to begin the color change

Color Change Sequences

FIG. 71 through FIG. 80 illustrate various color change sequences. See Table 9 to determine which figure to reference, based on the recipe change and system configuration. The time sequences are detailed in the following paragraphs.

NOTE: For software version 2.04.xxx and older, the system uses the color/catalyst purge and fill times from the new recipe.

NOTE: See Setup Mode on page 25 to select purge sources and set desired purge, chop, and fill times.

NOTES:

• The system uses old recipe data for the purge cycle. However, it opens the new color/catalyst valve based on the new recipe data.

• The system uses the new recipe data for the fill cycle.

• For the one gun flush box (GFB) option, the spray gun must be inserted in the GFB during the entire color change cycle (purge and fill). The GFB trigger output will be on during the recipe change cycle.

• For the two gun flush box (GFB) option, both spray guns must be inserted in the GFBs during the entire color change cycle (purge and fill). The system will turn each GFB trigger output on and off based on the preset time for each gun.

• 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.

• For systems without dump valves, the First Purge

8. Press the Mix key to start spraying.

begins after the Color/Catalyst Change steps are completed.

Single Color Systems

• Dump Valve B is required for a Catalyst Change

1. Follow procedure for Purging Fluid Supply Sys- tem, page 60.

2. Load the new color. See Start Up, page 53.

3. Press the Mix key to start spraying.

312776F 67

system.

• When going from Recipe X to Recipe 0, only the purge cycle data from Recipe 0 is used.

• When going from Recipe 0 to Recipe Y, only the fill cycle data from Recipe Y is used.

Color Change

Color Purge/Dump

• 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

• 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.

• The new color valve and the Dump A valve close when the Fill Time expires.

Catalyst Purge/Dump

• This sequence flushes out the catalyst with solvent, from the catalyst valve to the Dump B valve.

• The catalyst change solvent valve and the Dump B valve open during the Purge Time.

• The catalyst change solvent valve closes when the Purge Time expires.

Catalyst Fill

• This sequence fills the line with the new catalyst all the way to the Dump B valve.

• The new catalyst valve and the Dump B valve open during the Fill Time.

First Purge

Select the First Purge Source (air, solvent, or 3rd valve) and First Purge Time. For most applications, air is selected.

The system purges the old material from the dose valves to the gun, using only the selected purge media (usually air). The selected purge valve opens during the First Purge Time and closes when the time expires.

Chop Cycle

Select the Chop Type (air/solvent or air/3rd 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 solvent chop cycle. The number of chop cycles is determined by dividing the Total Chop Time by the sum of the Air and Solvent Chop Times.

Final Purge

Select the Final Purge Source (air, solvent, or 3rd valve) and Final Purge Time. For most applications, solvent is selected.

The system fills the line with solvent from the dose valves to the gun, using only the selected purge media (usually solvent). The selected purge valve opens during the Final Purge Time and closes when the time expires.

Fill

This sequence fills the line from the dose valves to the gun, and is also referred to as the mixed material fill. The system begins mixing components A and B until the Fill Time expires.

• The new catalyst valve and the Dump B valve close when the Fill Time expires.

68 312776F

Table 9: Color Change Chart Reference

Color Change

Starting

Recipe

Ending Recipe

Change

Type Dump A Exiting Fill Refer to Fig.

X Y Change Yes NA F

X Y Change No NA FIG. 72

0YFillYesYesF

0YFillYesNoF

0YFillNoYesFIG. 75

0 Y Fill No No F

X0PurgeYesNAF

X0PurgeNoNAFIG. 78

00PurgeYesNAF

00PurgeNoNAF

NOTE: For manual systems, the Digital I/O signals identified in the color charts on the following pages represent internal states.

IG. 71

IG. 73

IG. 74

IG. 76

IG. 77

IG. 79

IG. 80

312776F 69

70 312776F

ProMix 2KS Recipe Change Chart #1 X to Y

Stack Valves A1 to A2, B1 to B2

Dump A Enabled, 3rd Flush Valve Enabled

Color/Catalyst/(Reducer)

Solvent A If a component is not changing, that time segment is skipped Dump A Flush out old color and fill with new color Component A Solvent B Dump B Flush out old catalyst and fill with new catalyst Component B

Separate Gun 1 and Gun 2

First Purge Selection Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A Purge A (Air) Purge B (Solvent) If Chop Type is "Air/Solvent" 3rd Purge Valve on A If Chop Type is "Air/3rd Purge" 2 s B Purge after Chop Fixed Purge B. Enabled in Options Screen 2 Final Purge Selection Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A

Separate Gun 1 and Gun 2

Dose A Dose B

Purge from X, Fill from Y -->

Stack Valves

Purge Valves

Dose Valves

Purge from X -->

Fill from Y -->

A FillA Purge

Color Change Stack Flush Sequence Color Change Stack Components

Dose Valve and Integrator Flush Sequence Purge Operation Details

Color Change Stack Purge and Fill Operations by Time

Dose Valve and Integrator Flush Purge and Chop Operations by Time

Dose Valve and Integrator Mix Fill Operations by Time

2 s B

B FillB Purge

Final PurgeFirst Purge Total Chop

Waiting

Fixed for Purge A (Air)

Mixed Fill Time using Sequential Dosing

Mixed Fill Time using Dynamic Dosing

Color Change

GFB Outputs

Gun Trigger(s) by Operator

Gun Flush Box Output 1 Gun Flush Box Output 2

Color Change Input <- Start of Color Change Purge Active Output Fill Active Output End of Color Change -> Mix Ready Output

Special Output #1 <- Length -> <- Length -> Special Output #2 <- Length -> <- Length -> Special Output #3 <- Length -> <- Length -> Special Output #4 <- Length -> <- Length -> 3 + GFB on #4

If No Gun Flush Boxes

1 Gun

2 Guns

Digital I/O

Special Outputs <- Start of On-Purge <- Start of On-Fill

Gun and Hose Flush Operations by Time Gun and Hose Mix Material Fill Operations by Time

This happens on the same time scale as the Dose Valve and Integrator Flush Sequence

Each Integrator Flush Purge, Chop, and Mix Material Fill operation runs sequentially for Gun 1 then for Gun 2

Discrete I/O Signals by Time

FIG. 71: ProMix 2KS Recipe Change Chart #1 X to Y

2KS X to Y K15

312776F 71

ProMix 2KS Recipe Change Chart #2 X to Y

Stack Valves A1 to A2, B1 to B2

No Dump A, 3rd Flush Valve Enabled

Color/Catalyst/(Reducer)

Purge from X, Fill from Y -->

Dose A Dose B

Stack Valves

No Dump A

Separate Gun 1 and Gun 2

Purge from X -->

Purge Valves

Separate Gun 1 and Gun 2

Fill from Y -->

Dose Valves

A FillA Purge B FillB Purge

Color Change Stack Flush Sequence Color Change Stack Components

Dose Valve and Integrator Flush Sequence Purge Operation Details

<- A Purge and A Fill through Dose A with no Dump

Color Change Stack Purge and Fill Operations by Time

Dose Valve and Integrator Flush Purge and Chop Operations by Time

Total ChopFirst PurgeWaiting

Dose Valve and Integrator Mix Fill Operations by Time

Waiting

Final Purge2 s B

Fixed for Purge A (Air)

Mixed Fill Time using Sequential Dosing

Mixed Fill Time using Dynamic Dosing

GFB Outputs

Gun Trigger(s) by Operator

Gun Flush Box Output 1 Gun Flush Box Output 2

Color Change Input <- Start of Color Change Purge Active Output Fill Active Output End of Color Change -> Mix Ready Output

Special Output #1 <- Length -> <- Length -> Special Output #2 <- Length -> <- Length -> Special Output #3 <- Length -> <- Length -> Special Output #4 <- Length -> <- Length -> 3 + GFB on #4

If No Gun Flush Boxes

1 Gun

2 Guns

GFB 1 Only

Digital I/O

Special Outputs <- Start of On-Purge <- Start of On-Fill

Gun and Hose Flush Operations by Time Gun and Hose Mix Material Fill Operations by Time

This happens on the same time scale as the Dose Valve and Integrator Flush Sequence

Each Integrator Flush Purge, Chop, and Mix Material Fill operation runs sequentially for Gun 1 then for Gun 2

Discrete I/O Signals by Time

FIG. 72: ProMix 2KS Recipe Change Chart #2 X to Y

Color Change

2KS X to Y K13

72 312776F

ProMix 2KS Recipe Fill Chart #3 0 to Y

Stack Valves A1, B1

Dump A Enabled, 3rd Flush Valve Enabled

Color/Catalyst/(Reducer)

Solvent A Dump A Push out solvent and fill with new color Component A Solvent B Dump B Push out solvent and fill with new catalyst Component B

Separate Gun 1 and Gun 2

Exiting Fill Selection Recipe 0: Purge A (Air), Purge B (Solvent), or 3rd Valve on A First Purge Selection Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A Purge A (Air) Fixed for Purge A (Air) Purge B (Solvent) If Chop Type is "Air/Solvent" 3rd Purge Valve on A If Chop Type is "Air/3rd Purge" 2 s B Purge after Chop Fixed Purge B. Enabled in Options Screen 2 Final Purge Selection Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A

Separate Gun 1 and Gun 2

Dose A Dose B

No Purge, Fill from Y -->

Stack Valves

Purge Valves

Dose Valves

No Purge -->

Fill from Y -->

Waiting

Exit. Fill Waiting

From Recipe 0

Color Change Stack Fill Sequence Color Change Stack Components

Dose Valve and Integrator Flush Sequence Purge Operation Details

Exiting Fill Enabled

Color Change Stack Purge and Fill Operations by Time

B FillA Fill

Only active components are filled

Dose Valve and Integrator Flush Purge and Chop Operations by Time

Dose Valve and Integrator Mix Fill Operations by Time

Mixed Fill Time using Sequential Dosing

Mixed Fill Time using Dynamic Dosing

Color Change

GFB Outputs

Gun Trigger(s) by Operator

Gun Flush Box Output 1 Gun Flush Box Output 2

Color Change Input <- Start of Color Change Purge Active Output Fill Active Output End of Color Change -> Mix Ready Output

Special Output #1 <- Length -> <- Length -> Special Output #2 <- Length -> <- Length -> Special Output #3 <- Length -> <- Length -> Special Output #4 <- Length -> <- Length -> 3 + GFB on #4

If No Gun Flush Boxes

1 Gun

2 Guns

Digital I/O

Special Outputs <- Start of On-Purge <- Start of On-Fill

Gun and Hose Flush Operations by Time Gun and Hose Mix Material Fill Operations by Time

This happens on the same time scale as the Dose Valve and Integrator Flush Sequence

Each Integrator Flush Purge, Chop, and Mix Material Fill operation runs sequentially for Gun 1 then for Gun 2

Discrete I/O Signals by Time

FIG. 73: ProMix 2KS Recipe Fill Chart #3 0 to Y

2KS 0 to Y K15

312776F 73

ProMix 2KS Recipe Fill Chart #4 0 to Y

Dump A Enabled, 3rd Flush Valve Enabled

Color/Catalyst/(Reducer)

Solvent A Only active components are filled Dump A Push out solvent and fill with new color Component A Solvent B Dump B Push out solvent and fill with new catalyst Component B

Separate Gun 1 and Gun 2

First Purge Selection Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A Purge A (Air)

Purge B (Solvent) If Chop Type is "Air/Solvent" 3rd Purge Valve on A If Chop Type is "Air/3rd Purge" 2 s B Purge after Chop Fixed Purge B. Enabled in Options Screen 2 Final Purge Selection Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A

Separate Gun 1 and Gun 2

Dose A Dose B

No Purge, Fill from Y -->

Stack Valves

Purge Valves

Dose Valves

A Fill B Fill

Color Change Stack Flush Sequence Color Change Stack Components

No Purge -->

Dose Valve and Integrator Flush Sequence Purge Operation Details

Fill from Y -->

Stack Valves A1, B1

No Exiting Fill

Color Change Stack Purge and Fill Operations by Time

Dose Valve and Integrator Flush Purge and Chop Operations by Time

Waiting

Fixed for Purge A (Air)

Dose Valve and Integrator Mix Fill Operations by Time

Mixed Fill Time using Sequential Dosing

Mixed Fill Time using Dynamic Dosing

GFB Outputs

Gun Trigger(s) by Operator

Gun Flush Box Output 1 Gun Flush Box Output 2

Color Change Input <- Start of Color Change Purge Active Output Fill Active Output End of Color Change -> Mix Ready Output

Special Output #1 <- Length -> <- Length -> Special Output #2 <- Length -> <- Length -> Special Output #3 <- Length -> <- Length -> Special Output #4 <- Length -> <- Length -> 3 + GFB on #4

If No Gun Flush Boxes

1 Gun

2 Guns

Digital I/O

Special Outputs <- Start of On-Purge <- Start of On-Fill

Gun and Hose Flush Operations by Time Gun and Hose Mix Material Fill Operations by Time

This happens on the same time scale as the Dose Valve and Integrator Flush Sequence

Each Integrator Flush Purge, Chop, and Mix Material Fill operation runs sequentially for Gun 1 then for Gun 2

Discrete I/O Signals by Time

FIG. 74: ProMix 2KS Recipe Fill Chart #4 0 to Y

Color Change

2KS 0 to Y K14

74 312776F

ProMix 2KS Recipe Fill Chart #5 0 to Y

Stack Valves A1, B1

No Dump A, 3rd Flush Valve Enabled

Exiting Fill Enabled

Color/Catalyst/(Reducer)

No Purge, Fill from Y -->

Solvent A Only active components are filled Dump A Push out solvent and fill with new color Component A Solvent B Dump B Push out solvent and fill with new catalyst Component B

Exiting Fill Selection Recipe 0: Purge A (Air), Purge B (Solvent), or 3rd Valve on A First Purge Selection Purge A (Air) Fixed for Purge A (Air) Purge B (Solvent) If Chop Type is "Air/Solvent" 3rd Purge Valve on A 2 s B Purge after Chop Fixed Purge B. Enabled in Options Screen 2 Final Purge Selection Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A

Dose A <- A Fill through Dose A with no Dump A Dose B

Stack Valves

Separate Gun 1 and Gun 2

Purge Valves

Separate Gun 1 and Gun 2

Dose Valves

No Purge -->

Fill from Y -->

Waiting A Fill B Fill

Exit. Fill Waiting

From Recipe 0

Color Change Stack Fill Sequence Color Change Stack Components

No Dump A

Dose Valve and Integrator Flush Sequence Purge Operation Details

Color Change Stack Purge and Fill Operations by Time

Dose Valve and Integrator Flush Purge and Chop Operations by Time

Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A

If Chop Type is "Air/3rd Purge"

Dose Valve and Integrator Mix Fill Operations by Time

Mixed Fill Time using Sequential Dosing

Mixed Fill Time using Dynamic Dosing

Color Change

GFB Outputs

Gun Trigger(s) by Operator

Gun Flush Box Output 1 Gun Flush Box Output 2

Color Change Input <- Start of Color Change Purge Active Output Fill Active Output End of Color Change -> Mix Ready Output

Special Output #1 <- Length -> <- Length -> Special Output #2 <- Length -> <- Length -> Special Output #3 <- Length -> <- Length -> Special Output #4 <- Length -> <- Length -> 3 + GFB on #4

If No Gun Flush Boxes

1 Gun

2 Guns

Digital I/O

Special Outputs <- Start of On-Purge

Gun and Hose Flush Operations by Time Gun and Hose Mix Material Fill Operations by Time

This happens on the same time scale as the Dose Valve and Integrator Flush Sequence

Each Integrator Flush Purge, Chop, and Mix Material Fill operation runs sequentially for Gun 1 then for Gun 2

GFB 1 Only

Discrete I/O Signals by Time

<- Start of On-Fill

FIG. 75: ProMix 2KS Recipe Fill Chart #5 0 to Y

2KS 0 to Y K13

312776F 75

ProMix 2KS Recipe Fill Chart #6 0 to Y

Stack Valves A1, B1

No Dump A, 3rd Flush Valve Enabled

Color/Catalyst/(Reducer)

No Purge, Fill from Y -->

Solvent A Only active components are filled Dump A Push out solvent and fill with new color Component A Solvent B Dump B Push out solvent and fill with new catalyst Component B

First Purge Selection Purge A (Air) Fixed for Purge A (Air) Purge B (Solvent) If Chop Type is "Air/Solvent" 3rd Purge Valve on A 2 s B Purge after Chop Fixed Purge B. Enabled in Options Screen 2 Final Purge Selection Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A

Dose A <- A Fill through Dose A with no Dump A Dose B

Stack Valves

Separate Gun 1 and Gun 2

No Purge -->

Purge Valves

Separate Gun 1 and Gun 2

Fill from Y -->

Dose Valves

A Fill B Fill

Color Change Stack Flush Sequence Color Change Stack Components

No Dump A

Waiting

Dose Valve and Integrator Flush Sequence Purge Operation Details

No Exiting Fill

Color Change Stack Purge and Fill Operations by Time

Dose Valve and Integrator Flush Purge and Chop Operations by Time

Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A

If Chop Type is "Air/3rd Purge"

Dose Valve and Integrator Mix Fill Operations by Time

Mixed Fill Time using Sequential Dosing

Mixed Fill Time using Dynamic Dosing

GFB Outputs

If No Gun Flush Boxes

Gun Trigger(s) by Operator

Gun Flush Box Output 1 Gun Flush Box Output 2

Color Change Input <- Start of Color Change Purge Active Output Fill Active Output End of Color Change -> Mix Ready Output

Special Output #1 <- Length -> <- Length -> Special Output #2 <- Length -> <- Length -> Special Output #3 <- Length -> <- Length -> Special Output #4 <- Length -> <- Length -> 3 + GFB on #4

1 Gun

2 Guns

GFB 1 Only

Digital I/O

Special Outputs <- Start of On-Purge

Gun and Hose Flush Operations by Time Gun and Hose Mix Material Fill Operations by Time

This happens on the same time scale as the Dose Valve and Integrator Flush Sequence

Each Integrator Flush Purge, Chop, and Mix Material Fill operation runs sequentially for Gun 1 then for Gun 2

Discrete I/O Signals by Time

<- Start of On-Fill

FIG. 76: ProMix 2KS Recipe Fill Chart #6 0 to Y

Color Change

2KS 0 to X K12

76 312776F

Color Change

ProMix 2KS Recipe Purge Chart #7 X to 0

Dump A Enabled, 3rd Flush Valve Enabled

Color/Catalyst/(Reducer)

Purge from 0, No Fill -->

Solvent A Every recipe 0 entry will flush all components Dump A Flush out old color Component A Solvent B Dump B Flush out old catalyst Component B

Dose A Dose B

Gun Trigger(s) by Operator

Gun Flush Box Output 1 Gun Flush Box Output 2

Color Change Input <- Start of Color Change Purge Active Output End of Color Change -> Fill Active Output Mix Ready Output

Special Output #1 <- Length -> Special Output #2 <- Length -> Special Output #3 <- Length -> Special Output #4 <- Length -> 3 + GFB on #4

Stack Valves

Separate Gun 1 and Gun 2

Purge from 0 -->

Purge Valves

Separate Gun 1 and Gun 2

No Fill -->

Dose Valves

GFB Outputs

If No Gun Flush Boxes

1 Gun

2 Guns

Digital I/O

Special Outputs <- Start of On-Purge

A Purge B Purge

Color Change Stack Flush Sequence Color Change Stack Components

First Purge Total Chop Final Purge

Dose Valve and Integrator Flush Sequence Purge Operation Details

Gun and Hose Flush Operations by Time Gun and Hose Mix Material Fill Operations by Time

This happens on the same time scale as the Dose Valve and Integrator Flush Sequence

Each Integrator Flush Purge, Chop, and Mix Material Fill operation runs sequentially for Gun 1 then for Gun 2

This activates for Autodump operations only

Stack Valves Off

Color Change Stack Purge and Fill Operations by Time

Dose Valve and Integrator Flush Purge and Chop Operations by Time

2 s B

Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A

If Chop Type is "Air/3rd Purge"

Dose Valve and Integrator Mix Fill Operations by Time

Mixed Fill Time using Sequential Dosing

Mixed Fill Time using Dynamic Dosing

Discrete I/O Signals by Time

2KS X to 0 K15

FIG. 77: ProMix 2KS Recipe Purge Chart #7 X to 0

312776F 77

ProMix 2KS Recipe Purge Chart #8 X to 0

Color/Catalyst/(Reducer)

Purge from X, Fill from Y -->

Solvent A Every recipe 0 entry will flush all components Dump A Flush out old color Component A Solvent B Dump B Flush out old catalyst Component B

Dose A Dose B

Gun Trigger(s) by Operator

Gun Flush Box Output 1 Gun Flush Box Output 2

Color Change Input <- Start of Color Change Purge Active Output End of Color Change -> Fill Active Output Mix Ready Output

Special Output #1 <- Length -> Special Output #2 <- Length -> Special Output #3 <- Length -> Special Output #4 <- Length -> 3 + GFB on #4

Stack Valves

Separate Gun 1 and Gun 2

Purge Valves

Separate Gun 1 and Gun 2

Dose Valves

GFB Outputs

If No Gun Flush Boxes

Digital I/O

Special Outputs <- Start of On-Purge

Purge from 0 -->

No Fill -->

1 Gun

2 Guns

No Dump A

Waiting First Purge Total Chop 2 s B Final Purge

GFB 1 Only

Color Change Stack Flush Sequence Color Change Stack Components

Dose Valve and Integrator Flush Sequence Purge Operation Details

<- A Purge through Dose A with no Dump A

Gun and Hose Flush Operations by Time Gun and Hose Mix Material Fill Operations by Time

This happens on the same time scale as the Dose Valve and Integrator Flush Sequence

Each Integrator Flush Purge, Chop, and Mix Material Fill operation runs sequentially for Gun 1 then for Gun 2

This activates for Autodump operations only

Stack Valves Off

No Dump A, 3rd Flush Valve Enabled

B PurgeA Purge

Color Change Stack Purge and Fill Operations by Time

Dose Valve and Integrator Flush Purge and Chop Operations by Time

Dose Valve and Integrator Mix Fill Operations by Time

Waiting

Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A

If Chop Type is "Air/3rd Purge"

Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A

Discrete I/O Signals by Time

Mixed Fill Time using Sequential Dosing

Mixed Fill Time using Dynamic Dosing

Color Change

2KS X to 0 K13

FIG. 78: ProMix 2KS Recipe Purge Chart #8 X to 0

78 312776F

Color Change

ProMix 2KS Recipe Purge Chart #9 0 to 0

Dump A Enabled, 3rd Flush Valve Enabled

Color/Catalyst/(Reducer)

Purge from 0, No Fill -->

Solvent A Every recipe 0 entry will flush all components Dump A Flush out old color Component A Solvent B Dump B Flush out old catalyst Component B

Dose A Dose B

Gun Trigger(s) by Operator

Gun Flush Box Output 1 Gun Flush Box Output 2

Color Change Input <- Start of Color Change Purge Active Output End of Color Change -> Fill Active Output Mix Ready Output

Special Output #1 <- Length -> Special Output #2 <- Length -> Special Output #3 <- Length -> Special Output #4 <- Length -> 3 + GFB on #4

Stack Valves

Separate Gun 1 and Gun 2

Purge Valves

Separate Gun 1 and Gun 2

GFB Outputs

If No Gun Flush Boxes

Special Outputs <- Start of On-Purge

Dose Valves

1 Gun

2 Guns

Digital I/O

Purge from 0 -->

No Fill -->

Waiting A Purge B Purge

Exit. Fill Total Chop 2 s B

From Recipe 0

Color Change Stack Flush Sequence Color Change Stack Components

Dose Valve and Integrator Flush Purge and Chop Operations by Time - From Recipe 0

Dose Valve and Integrator Flush Sequence Purge Operation Details

Gun and Hose Flush Operations by Time Gun and Hose Mix Material Fill Operations by Time

This happens on the same time scale as the Dose Valve and Integrator Flush Sequence

Each Integrator Flush Purge, Chop, and Mix Material Fill operation runs sequentially for Gun 1 then for Gun 2

Stack Valves Off

Exiting Fill Enabled

Color Change Stack Purge and Fill Operations by Time - From Recipe 0

Dose Valve and Integrator Mix Fill Operations by Time

Waiting

Final PurgeFirst Purge

Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A

If Chop Type is "Air/3rd Purge"

Discrete I/O Signals by Time

Mixed Fill Time using Sequential Dosing

Mixed Fill Time using Dynamic Dosing

FIG. 79: ProMix 2KS Recipe Purge Chart #9 0 to 0

2KS 0 to 0 K3

312776F 79

ProMix 2KS Recipe Purge Chart #10 0 to 0

Color/Catalyst/(Reducer)

Purge from 0, No Fill -->

Solvent A Every recipe 0 entry will flush all components Dump A Flush out old color Component A Solvent B Dump B Flush out old catalyst Component B

Dose A <- A Purge through Dose A with no Dump A Dose B

Gun Trigger(s) by Operator

Gun Flush Box Output 1 Gun Flush Box Output 2

Color Change Input <- Start of Color Change Purge Active Output End of Color Change -> Fill Active Output Mix Ready Output

Special Output #1 <- Length -> Special Output #2 <- Length -> Special Output #3 <- Length -> Special Output #4 <- Length -> 3 + GFB on #4

Stack Valves

Separate Gun 1 and Gun 2

Purge Valves

Separate Gun 1 and Gun 2

GFB Outputs

If No Gun Flush Boxes

Special Outputs <- Start of On-Purge

Dose Valves

1 Gun

2 Guns

Digital I/O

Purge from 0 -->

No Fill -->

Waiting

From Recipe 0

Color Change Stack Flush Sequence Color Change Stack Components

No Dump A

Dose Valve and Integrator Flush Purge and Chop Operations by Time - From Recipe 0

Dose Valve and Integrator Flush Sequence Purge Operation Details

Gun and Hose Flush Operations by Time Gun and Hose Mix Material Fill Operations by Time

This happens on the same time scale as the Dose Valve and Integrator Flush Sequence

Each Integrator Flush Purge, Chop, and Mix Material Fill operation runs sequentially for Gun 1 then for Gun 2

Stack Valves Off

No Dump A, 3rd Flush Valve Enabled

Exiting Fill Enabled

Color Change Stack Purge and Fill Operations by Time - From Recipe 0

Dose Valve and Integrator Mix Fill Operations by Time

WaitingB PurgeA Purge

Final Purge2 s BTotal ChopFirst PurgeExit. Fill Waiting

Discrete I/O Signals by Time

Mixed Fill Time using Sequential Dosing

Mixed Fill Time using Dynamic Dosing

FIG. 80: ProMix 2KS Recipe Purge Chart #10 0 to 0

Color Change

2KS 0 to 0 K1

Alarms and Warnings

NOTE: Do not use the fluid in the line that was dis-

pensed off ratio as it may not cure properly.

System Alarms

System alarms alert you of a problem and help prevent off-ratio spraying. If an alarm occurs, operation stops and the following occurs:

• A red LED illuminates steadily or blinks on the Booth Control.

• Booth Control displays an alarm E-Code, E-1 to E-28. See F

IG. 81.

• Buzzer sounds (for E-2 only; see page 29 to set for all alarms).

• Status bar on the EasyKey Display shows the alarm E-Code with a description (see Table 10).

Alarm Indicator (red)

Recipe Indicator (green)

IG. 81. Booth Control

Display

TI11614A

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

313386).

To Reset Alarm and Restart

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

24) to view the last 10 alarms, with date and time stamps.

To reset alarms, see Table 11. Many alarms can be

cleared by simply pressing the Alarm Reset

Table 10: System Alarm/Warning Codes

Code Description Details

E-1 Communication Error Alarm Page 81

E-2 Potlife Alarm Page 81

E-3 Ratio High Alarm Page 82

E-4 Ratio Low Alarm Page 83

E-5 Overdose A/B Dose Too Short Alarm Page 84

E-6 Overdose B/A Dose Too Short Alarm Page 84

E-7 Dose Time A Alarm Page 85

E-8 Dose Time B Alarm Page 85

E-9 Not used NA

E-10 Remote Stop Alarm Page 86

E-11 Purge Volume Alarm Page 86

E-12 CAN Network Communication Error

Alarm

E-13 High Flow Alarm Page 88

E-14 Low Flow Alarm Page 88

E-15 System Idle Warning Page 88

E-16 Setup Change Warning Page 88

E-17 Power On Warning Page 88

E-18 Defaults Loaded Warning Page 88

E-19 I/O Alarm Page 89

E-20 Purge Initiate Alarm Page 90

E-21 Material Fill Alarm Page 90

E-22 Tank A Low Alarm Page 90

E-23 Tank B Low Alarm Page 90

E-24 Tank S Low Alarm Page 90

E-25 Auto Dump Complete Alarm Page 91

E-26 Color/Catalyst Purge Alarm Page 91

E-27 Color/Catalyst Fill Alarm Page 91

E-28 Mix Fill Push Complete Page 91

key.

Page 87

80 312776F

Alarm Troubleshooting

Table 11. Alarm Troubleshooting

E-1: COMM ERROR

Cause Solution

No power to the EasyKey. Connect power to EasyKey.

Alarm Troubleshooting

No power to Fluid Station. The intrinsically safe power cable between the EasyKey and Fluid Station is not connected.

No power to Fluid Station. The fluid control board fuse is blown.

The fiber optic cable between the EasyKey and Fluid Station is not connected.

The fiber optic cable is cut or bent. Verify that the cable has not been cut or bent at a radius

Dirty fiber optic cable ends. Disconnect fiber optic cable ends and clean with a

A communication cable or connector failed. Replace cable.

E-2: POTLIFE ALARM

Cause Solution

The potlife time has been exceeded for the mixed material.

NOTICE

To prevent mixed material from curing in the equipment, do not shut off power. Follow one of the solutions at right.

Verify that the cable is correctly connected. See Installation manual.

Verify condition of fuse and replace if necessary. See Repair-Parts manual.

Verify that the cable is correctly connected. See Installation manual.

smaller than 1.6 in. (40 mm).

lint-free cloth.

Press the Alarm Reset

alarm. Purge the system with solvent, fresh mixed material, or a new color:

• Solvent Purge - See Purging Mixed Material on

page 59. The system purges until the preset purge time is complete.

key to stop the audible

• New Mixed Material Purge - Go to Mix mode and

spray the required volume to restart the timer.

• Color Change - Perform a color change, page 67.

312776F 81

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 Solution

There is too little restriction in the system. • Check that the system is fully loaded with material.

• Check that the supply pump’s cycle rate is set properly.

• 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 rate was probably too high.

If the alarm occurred after you were spraying for some time, the pressures from the fluid supplies could be unbalanced.

Restrict gun needle travel to slow down the initial fluid delivery rate until fluid hoses are loaded with material.

Adjust component A and B fluid supply regulator pressures until they are about equal. If the pressures are already about equal, verify that component A and B dose valves are operating properly.

Slow actuation of the component A or B valves. This can be caused by:

Manually operate the Dispense A and B solenoid valves as instructed in the ProMix 2KS Repair-Parts manual to check operation.

• Air pressure to the valve actuators is too low. • Increase air pressure. Air pressure must be 75-120 psi (0.52-0.84 MPa, 5.2-8.4 bar); 120 psi is recommended.

• Something is restricting the solenoid or tubing and

interrupting valve actuation air.

• There may be dirt or moisture in the air supply. Filter appropriately.

• A dose valve is turned in too far. • Refer to Table 7: Mix Manifold Valve Settings,

page 53, for adjustment guidelines.

• Fluid pressure is high and air pressure is low. • Adjust air and fluid pressure. See recommended air pressure above.

82 312776F

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 Solution

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 properly.

• 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 rate was probably too high.

If the alarm occurred after you were spraying for some time, the pressures from the fluid supplies could be unbalanced.

Restrict gun needle travel to slow down the initial fluid delivery rate until fluid hoses are loaded with material.

Adjust component A and B fluid supply regulator pressures until they are about equal. If the pressures are already about equal, verify that component A and B dose valves are operating properly.

Slow actuation of the component A or B valves. This can be caused by:

Manually operate the Dispense A and B solenoid valves as instructed in the ProMix 2KS Repair-Parts manual to check operation.

• Air pressure to the valve actuators is too low. • Increase air pressure. Air pressure must be 75-120 psi (0.52-0.84 MPa, 5.2-8.4 bar); 120 psi is recommended.

• Something is restricting the solenoid or tubing and

interrupting valve actuation air.

• There may be dirt or moisture in the air supply. Filter appropriately.

• A dose valve is turned in too far. • Refer to Table 7: Mix Manifold Valve Settings,

page 53, for adjustment guidelines.

• Fluid pressure is high and air pressure is low. • Adjust air and fluid pressure. See recommended air pressure above.

312776F 83

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 F

IG. 11

Repair the valve (see valve manual 312782).

Totals Screen on page 23. If A and B are dosing simultaneously (sequential dosing only), there is a leak.

Sampling valve is leaking. Tighten or replace valve.

Flow meter fluctuations caused by pressure pulsations. Check for pressure pulsations:

1. Close all the manifold valves.

2. Turn on the circulating pumps and all the booth equipment (such as fans and conveyors).

3. Check if the ProMix 2KS is reading any fluid flow.

4. If the ProMix 2KS shows there is fluid flow and there are no leaks from the gun or any other seals or fittings, the flow meters are probably being affected by pressure pulsations.

5. Close the fluid shutoff valve between the fluid supply system and the flow meter. The flow indication should stop.

6. 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 distributor for information.

Slow actuation of component A or B valves. See E-3: RATIO HIGH ALARM and E-4: RATIO LOW

ALARM, pages 82-83.

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 page 51.

84 312776F

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 fewer than 31 A meter pulses were detected during the dose time selected.

E-8: gun trigger input is active (AFS or Integration) and fewer than 31 B meter pulses were detected during the dose time selected.

Cause Solution

System is in Mix mode and gun is only partially

Fully trigger the gun.

triggered, allowing air but no fluid to pass through gun.

Fluid flow rate is too low. Increase flow rate.

Dose time setting is too short for the current flow rate. Increase the dose time setting.

Flow meter or cable failed or flow meter clogged. To check meter sensor operation, remove meter cap to

expose sensor. Pass a ferrous metal tool in front of the sensor.

TI12792a

If there is a meter or cable failure, you will see a large difference 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 65.

Slow actuation of component A or B valves. See E-3: RATIO HIGH ALARM and E-4: RATIO LOW

ALARM, pages 82-83.

The supply pump is not turned on. Turn on the supply pump.

There is an air leak downstream from the air flow switch. Check the air lines for leaks and repair.

The air flow switch is stuck open. Clean or replace air flow switch.

System is in Mix mode with 0 volume entered for Min Material Fill Volume (see Option Screen 1, page 32),

Verify condition of fuse and replace if necessary. See Repair-Parts manual.

and Fuse F1 is blown.

312776F 85

Alarm Troubleshooting

E-9: Not used

E-10: REMOTE STOP ALARM

Cause Solution

Table 11. Alarm Troubleshooting

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.

Verify that the gun is not shut off and that the solvent flow 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.

86 312776F

E-12: CAN COMM ERROR ALARM

Cause Solution

Alarm Troubleshooting

Table 11. Alarm Troubleshooting

Communication between the Color Change Module and the Fluid Station is interrupted.

• 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. 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.

• Check the color change board DIP switch settings. See the Installation manual.

• 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 electrical noise. See the Installation manual.

• 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.

• The sticker on the color change board shows the software part number and version, for example 15T270 1.01. If the version is older than 1.01, replace the board.

Communication between the Color Change Module and the Fluid Station is interrupted. The fluid control board fuse is blown.

Communication between the Booth Control and the Fluid Station is interrupted.

• If all software versions and DIP switch settings are correct and you still have E-12 alarms, then the system 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.

• Appears on the EasyKey display if the unit is programmed for Manual Mode, and a booth control is not connected.

• The dip switch settings on the Color Change Module were changed (see manual 312787) while the power was on. Cycle the power to clear the alarm.

• The dip switch configuration on the Color Change Control Module (see manual 312787) is setup incorrectly.

Verify condition of fuse and replace if necessary. See Repair-Parts manual.

Verify that the cable is correctly connected.

312776F 87

Alarm Troubleshooting

Table 11. Alarm Troubleshooting

E-13: HIGH FLOW ALARM or E-14: LOW FLOW ALARM (may also be set as Warnings)

Cause Solution

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

Cause Solution

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

Cause Solution

The system setup parameters have been changed. No action required. See Event Log available through

advanced web interface.

E-17: POWER ON/POWER OFF WARNING

Cause Solution

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 contact.

Reset button has been pushed (S1 on EasyKey display board, S3 on Autokey).

Check that all wires are securely connected. Ensure that wires are not stretched too tightly.

No action required. See Event Log available through 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

Cause Solution

The factory defaults have been installed on the system. No action required. See Event Log available through

advanced web interface.

88 312776F

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 are only seen in the Alarm log or through BWI or AWI, and may not apply to all software versions.

Fluid Plate Reboot (FP Reboot): Occurs if the system detects a fluid plate control board reboot or power cycle not triggered from the EasyKey. The system reverts to Recipe 61, and mixed material may be in the lines.

Autokey Lost: Occurs if the Autokey is lost or changed after having been detected. (A short term loss of the Autokey will not be registered.) Some system functions may become unavailable. For example, an automatic system will not respond to PLC or robot control.

Illegal Source: Occurs if a recipe outside of the range 1-60 is detected as the source data for global recipe data copies. This is possible if an invalid configuration file is sent to the EasyKey.

2K/3K Error: Occurs if the recipe data is incompatible with the current Autokey setting (2K or 3K). This is possible 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 a configuration 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.

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 configuration file is valid.

Verify that the configuration file is valid.

Verify that the configuration file specifications and the hardware conform.

Range Error: Occurs if a valve used in a recipe is not present in the current hardware setup. For example, a

Verify that the recipe specifications and the hardware

conform. recipe calls for valve 30 but the system has only 12 valves.

Level Control (LC) Error: Occurs if level control data is

Verify that the Autokey is set properly. received by the EasyKey, and the current Autokey setting (2K or 3K) has changed since the level control data was originally initialized.

Level Control (LC) Range Error: Occurs if level control

Set level control data correctly. data includes a valve range exceeding the capability of the machine.

Modbus (MB) Overflow: Occurs if the Modbus connec-

Verify the Modbus protocol to the EasyKey. tion to a PLC experiences data overflow.

312776F 89

Alarm Troubleshooting

E-20: PURGE INITIATE ALARM

Cause Solution

Table 11. Alarm Troubleshooting

System detects atomizing air to the gun when purge is

Shut off gun air.

selected.

For systems with a gun flush box, gun is not in the box when purge is selected.

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.

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

Cause Solution

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:

• Adjust fill volume.

• Adjust fill time.

For systems without color change and with minimum mixed material fill volume entered, Fuse F1 is blown.

Verify condition of fuse and replace if necessary. See

Repair-Parts manual.

E-22: TANK A LOW ALARM, E-23: TANK B LOW ALARM, or E-24: TANK S LOW ALARM

Cause Solution

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:

• Refill tank volume to clear the alarm.

• Resume mixing by selecting “Spray 25% of remaining 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.

90 312776F

Table 11. Alarm Troubleshooting

E-25: AUTO DUMP COMPLETE ALARM

Cause Solution

Alarm Troubleshooting

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. pulses lasting longer than 1 second throughout the Color/Catalyst purge time duration.

Clean or repair meter.

E-27: COLOR/CATALYST FILL ALARM

Cause Solution

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.

Gun, dump valve, or correct color/catalyst valve not

Clean or repair meter.

Open the valve. open.

Exhausted fluid supply. Check fluid level and refill if necessary.

Switch settings (S3-S6) on color change board do not match hardware configuration.

Verify that color change board switches are set correctly.

See installation manual.

Fuse F1, F2, or both are blown. Verify condition of fuses and replace if necessary. See

Repair-Parts manual.

E-28: MIX FILL PUSH COMPLETE

Cause Solution

Mix fill push has been completed. Potlife expired material has been purged.

312776F 91

Schematic Diagrams

System Pneumatic Schematic

AIR INPUT

COLOR CHANGE

AIR EXHAUST MUFFLER

12 VDC

4-WAY SOLENOID

12 VDC

4-WAY SOLENOID

12 VDC

4-WAY SOLENOID

12 VDC

4-WAY SOLENOID

12 VDC

4-WAY SOLENOID

AIR EXHAUST MUFFLER

12 VDC

3-WAY SOLENOID

3/8 AIR FILTER MANUAL DRAIN 5 MICRON WALL MOUNT ONLY

AIR INPUT

TO MANIFOLD 1/4 TUBE

CONTROL AIR

PURGE AIR

12 VDC

3-WAY SOLENOID

12 VDC

3-WAY SOLENOID

12 VDC

3-WAY SOLENOID

MANIFOLD

5/32 TUBE

OPEN

5/32 TUBE

OPEN

5/32 TUBE

OPEN

5/32 TUBE

OPEN

5/32 TUBE

OPEN

5/32 TUBE

OPEN

5/32 TUBE

OPEN

5/32 TUBE

OPEN

5/32 TUBE

OPEN

DOSE A VALV E

DOSE B VALV E

PURGE A VALV E

PURGE B VALV E

PURGE C VALV E (OPTIONAL)

DUMP A VALV E (OPTIONAL)

DUMP B VALV E (OPTIONAL)

GFB 1 VALV E (OPTIONAL)

GFB 2 VALV E (OPTIONAL)

FLUSH AIR TO FLUID INLET 1/4 TUBE

CONTROL

36 SERIES SOLENOID VALVES

COLOR VALV E STACKS

COLOR 1 COLOR 2 COLOR 3 COLOR 4 COLOR 5 COLOR 6 COLOR 7 COLOR 8 COLOR SOLVENT COLOR 9 COLOR 10 COLOR 11 COLOR 12 CATALYST 1 CATALYST 2 CATALYST 3 CATALYST 4 CATALYST SOLVENT

COLOR 13 COLOR 14 COLOR 15 COLOR 16 COLOR 17 COLOR 18 COLOR 19 COLOR 20 COLOR 21 COLOR 22 COLOR 23 COLOR 24 COLOR 25 COLOR 26 COLOR 27 COLOR 28 COLOR 29 COLOR 30

MAC

92 312776F

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

MEMBRANE SWITCH WITH RIBBON CABLE

DISPLAY

1 2 3 4 5 6 7 8 9 10 11

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

POWER HARNESS

DISPLAY BOARD

RJ45

J10

LINE

NON-HAZARDOUS AREA

DC OK

+24 VDC

COMMON COMMON

OPERATOR INTERFACE

POWER

SUPPLY

BARRIER BOARD

12L1

UNUSED

1 2 3

+24VDC

OPEN

COMMON

85-250 VAC

+12VDC I/S (RED) COM (BLACK) SHIELD

HARNESS

L1 N

ALARM

3 4

RJ45

POWER DIST. TERMINAL BLOCKS

FLOW CONTROL CAL. (BLK)

GUN TRIGGER (WHT )

DIGITAL IN COMMON (RED)

REMOTE STOP (GRN)

ALARM RESET (BRN)

ALARM OUTPUT (BLU)

DIGITAL OUTPUT COMMON (ORG)

POT LIFE (YEL)

FLOW RATE ANALOG IN (PUR)

FLOW RATE ANALOG COMMON (GRAY)

SHIELD

RJ45

REMOTE I/O INTEGRATION BOARD

1 2 3 4 5 6 7 8 9 10

I/O HARNESSES

RS485 INTEGRATION A (WHT/BLU)

RS485 INTEGRATION B (BLU/WHT)

RS485 INTEGRATION GROUND (SHIELD)

RS485 NETWORK A (WHT/ORG)

RS485 NETWORK B (ORG/WHT)

RS485 NETWORK GROUND (SHIELD)

1 2 3 4 5 6

TERMINAL BLOCKS

FILTER

OPEN

L1 N GND

GND LUG

2 3

POWER

ROCKER

SWITCH

1B 2A 2B

CABLE

(50' STD.)/

(100' OPTION)

MIX INPUT

PURGE INPUT

JOB COMPLETE INPUT

EXTERNAL CLR CHG READY

RESET ALARM INPUT

DIGITAL INPUT COMMON

RECIPE BIT 0 INPUT

RECIPE BIT 1 INPUT

RECIPE BIT 2 INPUT

RECIPE BIT 3 INPUT

RECIPE BIT 4 INPUT

RECIPE BIT 5 INPUT

RECIPE CHANGE INPUT

DIGITAL OUTPUT COMMON/POWER

PURGE/RECIPE CHG ACTIVE OUTPUT

MIX ACTIVE OUTPUT

MIX READY OUTPUT

FILL ACTIVE

FLOW CAL. ACTIVE

FLOW RATE ALARM OUTPUT

DIGITAL OUTPUT COMMON/POWER

SPECIAL OUTPUT #1

SPECIAL OUTPUT #2

SPECIAL OUTPUT #3

SPECIAL OUTPUT #4

DIGITAL OUTPUT COMMON/POWER

L1 N GND

(+24) YEL

(COM) GRAY

ORG BRN

RED

TERMINAL BLOCK

L1 N GND

BEACON

GND N L1

85-250 VAC

FO IN (BLK)

FO OUT (BLU)

RJ45

RJ45 BULKHEAD

3' (25'-200' OPTIONS)

RJ45

WEB SERVER

RJ45

MODULE

312776F 93

CABLE

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

FO OUT (BLU)

FO IN (BLK)

FLUID PANEL CONTROL BOX

FLUID PANEL CONTROL BOARD

J10

+12VDC I/S

COM

SHIELD

J15

J14

HAZARDOUS AREA

1 2 3

4 5 6

1 2 3

J12

4 5 6

1 2 3

J13

4 5 6

1 2 3

4 5 6

MH2

3 2

J11

5 4 1

3 2

5 4 1

6 5 4

3 2 1

6 5 4 3 2 1

6 5 4

3 2 1

1 2 3 4 5 6

7 8 9 10

UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED

6' STD. (3'-100' OPTIONS)

50' STD.

GRD (BLK) +12VDC (RED) SHIELD (BARE)

CAN H (WHT)

CAN L (BLU)

BLACK RED BLACK RED BLACK RED

SIG COM SIG COM SIG COM SIG COM SIG COM

PWR (RED) COM (BLACK) SIG (WHITE) SHIELD/GRN PWR (RED) COM (BLACK) SIG (WHITE) SHIELD/GRN PWR (RED) COM (BLACK) SIG (WHITE) SHIELD/GRN

GROUND TERMINAL

MANIFOLD

3X CABLE

(10')/ (40')

GRD (BLK) +12VDC (RED) SHIELD (BARE) CAN H (WHT) CAN L (BLU)

BOOTH

CONTROL

BOARD

5 4 1

DUMP B

GFB #1

GFB #2

DUMP A

NOT USED

PURGE C

PURGE B

PURGE A

NOT USED

DOSE B

DOSE A

AIR FLOW SWITCH 1

AIR FLOW SWITCH 2

SOLVENT FLOW SWITCH

GFB 1 PRESSURE SWITCH

GFB 2 PRESSURE SWITCH

FLOW METER A

FLOW METER B

FLOW METER SOLVENT

12 VDC

3-WAY SOLENOID

12 VDC

4-WAY SOLENOID

V/P ANALOG OUT (WHT) PRESS. (GRN) +12 V (RED) GND (BLK) CHASSIS (BARE)

MANIFOLD

CLR 8

CLR 7

CLR 6

CLR 5

CLR 4

CLR 3

CLR 2

CLR 1

SOL CLR

MANIFOLD

CLR 21

CLR 20

CLR 19

CLR 18

CLR 17

CLR 16

CLR 15

CLR 14

CLR 13

I.S. METERS

+12VDC

COM

1 2 3 4 5

J7/J11

FLOW CONTROL BOARD

1 2 3 4 5 6

J7/J11

1 2 3 4 5 6

1 2

J4 1 2 3 4 5

1 4 5 2 3

COLOR BOARD 1 (COLORS 1 THRU 12, CATALYST 1 THRU 4)

J16

J15

J10

J14

1 4 5 2 3

COLOR BOARD 2 (COLORS 13 THRU 30)

J15

J16

J14

J10

SIG (RED) COM (BLK)

+ PRESSURE (GRN) COM (RED) EX+ (WHT)

- PRESSURE (BLK) SHIELD (BARE)

6 5 4 3

2 1

6 5 4 3 2 1

6' STD.

6 5 4

3 2 1

6 5 4 3 2 1

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

MANIFOLD

TECNO V/P

FLUID PRESS. SENS.

CLR 9

CLR 10

CLR 11

CLR 12

CAT 4

CAT 3

CAT 2

CAT 1

SOL CAT

CLR 22

CLR 23

CLR 24

CLR 25

CLR 26

CLR 27

CLR 28

CLR 29

CLR 30

94 312776F

EasyKey Electrical Schematic

Schematic Diagrams

GND L1 N

TERMINAL BLOCKS

ALARM

- +

L L N N

COMMON

- - + DC OK

HIGH

VOLTAGE

24 VDC+

OUTPUT

24 VDC+

GRN/YEL 16 AWG

RED 16 AWG BROWN 16 AWG

GND L1 N

L1 N

RED 16 AWG BROWN 16 AWG

1 2

1A 2A

RED 16 AWG BROWN 16 AWG

LINE FILTER

POWER

ROCKER SWITCH

RJ45 BULKHEAD

RJ45

POWER SUPPLY

GND LUG

GREEN/BLACK/WHITE 22 AWG RED/BLACK/WHITE 22 AWG BLACK 18 AWG RED 18 AWG

432

DISPLAY BOARD

RED 18 AWG

BLACK 18 AWG

IS POWER

12 VDC

UNUSED

BARRIER BOARD

UNUSED

COMMON (BLACK)

+12 VDC I/S (WHITE)

J5-3 J5-2 J5-1

SHIELD/GRND

RJ45

DISPLAY BOARD

UNUSED

J1-5 J1-4 J1-3 J1-2 J1-1

BLACK 18 AWG RED 18 AWG

J4-3 J4-2 J4-1

24 VDC+

312776F 95

Meter Performance Data (G3000 on A and B)

50cc Dose

25cc Dose

Ratio

10cc Dose

1:1 2:1 3:1 4:1 5:1 6:1 7:1 8:1 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

3500

NOTE: Maximum system flow is 3800 cc/min.

3800

3000

2500

2000

1500

1000

Flow Rate (cc/min)

500

Test Conditions

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

96 312776F

Meter Performance Data (G3000 on A, Coriolis on B)

50cc Dose

25cc Dose

NOTE: Maximum system flow is 3800 cc/min.

3800

3500

3000

50cc Dose

2500

25cc Dose

2000

1500

10cc Dose

Ratio

1:1 2:1 3:1 4:1 5:1 6:1 7:1 8:1 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

1000

500

Flow Rate (cc/min)

Test Conditions

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

312776F 97

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, 5.2 - 7 bar)

Air filter inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 npt(f)

Air filtration for air logic and purge air (Graco-supplied). . 5 micron (minimum) filtration required; clean and dry air

Air filtration for atomizing air (user-supplied) . . . . . . . . . . 30 micron (minimum) filtration required; clean and dry air

Mixing ratio range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1:1- 50:1*

On-ratio accuracy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . up to +

Fluids handled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . one or two component:

• solvent and waterborne paints

• polyurethanes

• epoxies

• acid catalyzed varnishes

• moisture sensitive isocyanates

Viscosity range of fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 20- 5000 cps*

Fluid filtration (user-supplied) . . . . . . . . . . . . . . . . . . . . . . 100 mesh minimum

Fluid flow rate range*

G3000, G250 Meter . . . . . . . . . . . . . . . . . . . . . . . . . .

G3000HR, G250HR Meter. . . . . . . . . . . . . . . . . . . . .

Coriolis Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

S3000 Solvent Meter (accessory) . . . . . . . . . . . . . . .

Fluid inlet sizes

Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dose Valve/Color Valve Adapters . . . . . . . . . . . . . . .

Fluid outlet size (static mixer). . . . . . . . . . . . . . . . . . . . . . 1/4 npt(f)

External Power Supply Requirements . . . . . . . . . . . . . . . 85 - 250 Vac, 50/60 Hz, 2 amps maximum draw

Operating temperature range . . . . . . . . . . . . . . . . . . . . . . 41- 122° F (5-50° C)

Environmental Conditions Rating. . . . . . . . . . . . . . . . . . . indoor use, pollution degree (2), installation category II

Noise Level

Sound pressure level . . . . . . . . . . . . . . . . . . . . . . . . .

Sound power level . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wetted parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303, 304 SST, Tungsten carbide (with nickel binder),

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)

15 amp maximum circuit breaker required 8 to 14 AWG power supply wire gauge

below 70 dBA below 85 dBA

perfluoroelastomer; PTFE

1%, user selectable

* 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 distributor.

See individual component manuals for additional technical data.

98 312776F

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is 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 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 rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com.

For patent information, see www.graco.com/patents.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

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

www.graco.com

Revision F, April 2015

Graco 312776F User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Related Manuals

Equipment Approvals

System Configuration and Part Numbers

Accessories

Warnings

Important Two-Component Material Information

Glossary of Terms

Overview

Booth Control

EasyKey Display and Keypad

Run Mode Screens

Setup Mode

System Operation

Meter Calibration

Color Change

Alarms and Warnings

Alarm Troubleshooting

Schematic Diagrams

Meter Performance Data (G3000 on A and B)

Meter Performance Data (G3000 on A, Coriolis on B)

Technical Data

Graco Standard Warranty

Graco Information