Graco 313882C User Manual

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Page 1

Operation

ProMix

3KS

313882C

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 and 3KS Power Supply Module).

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.

0359

#53

TI14543a

II 2 G

Page 2

Contents

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

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

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

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

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

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . 10

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Component Identification and Definition . . . . . . 12

Booth Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

EasyKey Display and Keyboard . . . . . . . . . . . . . . 17

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

EasyKey and 3KS Power Supply Module

Connection Ports . . . . . . . . . . . . . . . . . . . . . . 18

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

3KS Power Supply Module AC Power Switch . . 19

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

3KS Power Supply Module I/S Power . . . . . . . . 19

EasyKey Potlife Exceeded Audible Alarm . . . . . 19

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

EasyKey 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 . . . . . . . . . . . . . . . . . . . . . . . . . 23

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 . . . . . . . . . . . . . . . . . . . . . . . 42

Calibration Screen . . . . . . . . . . . . . . . . . . . . . . . 44

System Operation . . . . . . . . . . . . . . . . . . . . . . . . . 45

Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . 45

Sequential Dosing . . . . . . . . . . . . . . . . . . . . . . . 45

Recipe (Color) Change . . . . . . . . . . . . . . . . . . . 45

General Operating Cycle, Sequential Dosing . . 45

Mix Manifold Valve Settings . . . . . . . . . . . . . . . . 48

Air Flow Switch (AFS) Function . . . . . . . . . . . . . 49

Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Pressure Relief Procedure . . . . . . . . . . . . . . . . 52

Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Color Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Color Change Procedures . . . . . . . . . . . . . . . . . 64

Color Change Sequences . . . . . . . . . . . . . . . . . 64

Alarms and Warnings . . . . . . . . . . . . . . . . . . . . . . 77

System Alarms . . . . . . . . . . . . . . . . . . . . . . . . . 77

System Warnings . . . . . . . . . . . . . . . . . . . . . . . 77

Alarm Troubleshooting . . . . . . . . . . . . . . . . . . . . . 78

Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . 90

System Pneumatic Schematic . . . . . . . . . . . . . . 90

System Electrical Schematic . . . . . . . . . . . . . . . 92

Power Supply Module Electrical Schematic . . . 96

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 98

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 98

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Page 3

Related Manuals

Component Manuals in English

Manual Description

313881 ProMix 3KS Kit Installation 313883 ProMix 3KS Kit Repair-Parts 312775 ProMix 2KS Manual System Installation 312776 ProMix 2KS Manual System Operation 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 Power Supply Module. See F

Power Supply Module and Fluid Station Label

ProMix® 3KS

Electronic Proportioner

FM08ATEX0074 II 2 G Ex ia IIA T3

MAX AIR WPR

.7 7 100

MPa bar PSI

MAX FLUID WPR

MPa bar PSI

MAX TEMP 50°C (122°F)

PART NO. SERIES SERIAL MFG. YR.

Intrinsically safe equipment for Class I, Div 1, Group D, T3

CUS

Ta = -20°C to 50°C Install per 289833

IG. 1 on page 4 for label locations.

ATEX Certificate is listed here

Intrinsically Safe (IS) System. Install per IS Control Drawing No. 258682. EasyKey Interface IS Associated Apparatus for use in non hazardous

CUS

Intrinsically safe

equipment for Class I,

Div 1, Group D, T3

Ta = -20°C to 50°C

location, with IS Connection to Smart Fluid Plate IS Apparatus for use in: Class I, Division 1, Group D T3 C Hazardous Locations

Read Instruction Manual

Warning: Substitution of components may impair intrinsic safety.

PART NO. SERIES

MFG. YR.

Fluid Station Label

ProMix 3KS

FM08ATEX0073 II 2 G Ex ia IIA T3

FLUID PANEL

MAX AIR WPR

.7 7

MPa bar PSI

SERIAL

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

TI14376a

100

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

TI14374a

ATEX Certificate is listed here

Power Supply Module Label

ProMix 3KS

PART NO.

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

SERIES NO. MFG. YR.

Intrinsically safe connections for Class I, Div 1, Group D

CUS

Ta = -20°C to 50°C Install per 258682

Um: 250 V

POWER REQUIREMENTS

VOLTS

AMPS

85-250 ~

2 AMPS MAX

50/60 Hz

II (2) G [Ex ia] IIA FM08ATEX0072

TI14375a

ATEX Certificate is listed here

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Page 4

System Configuration and Part Numbers

Configurator Key

The configured part number for your equipment is printed on the equipment identification labels. See F each of the following categories, depending on the configuration of your system.

IG. 1 for location of the identification labels. The part number includes digits from

3K System

Component C Fluid Meter Component C Change

TK 0 = No Meter

1 = G3000 2 = G3000HR 3 = 1/8 in. Coriolis 4 = Solvent Meter

Label Location on Fluid Station

Maximum Fluid

Working Pressure

is listed here

0 = No Valves (single component C) 1 = Two Valves (low pressure) 2 = Four Valves (low pressure) 3= Two Valves (high pressure) 4= Four Valves (high pressure)

ProMix® 3KS

Electronic Proportioner

FM08ATEX0074 II 2 G Ex ia IIA T3

CUS

Intrinsically safe

equipment for Class I,

Div 1, Group D, T3

Ta = -20°C to 50°C

MAX AIR WPR

.7 7 100

MPa bar PSI

MAX FLUID WPR

MPa bar PSI

MAX TEMP 50°C (122°F)

Intrinsically Safe (IS) System. Install per IS Control Drawing No. 258682. EasyKey Interface IS Associated Apparatus for use in non hazardous location, with IS Connection to Smart Fluid Plate IS Apparatus for use in: Class I, Division 1, Group D T3 C Hazardous Locations

Read Instruction Manual

Warning: Substitution of components may impair intrinsic safety.

PART NO. SERIES

MFG. YR.

Not Designated

SERIAL

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

Not Designated

Label Location on Power Supply Module

TI14370aTI14361a

Configured Part Number

TI14376a

FIG. 1: Identification Label

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System Configuration and Part Numbers

Hazardous Location Approval

Models using a G3000, G3000HR, or intrinsically safe Coriolis meter for A, B, and C 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 TK1400 has a maximum working pressure of 3000 psi (21 MPa, 210 bar).

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

ProMix Fluid Components Maximum Working Pressure

Base System (no meters [option 0], no color/component C change [option 0]) . . . . .3000 psi (21.0 MPa, 210 bar)

Meter Option 1, 2, and 4 (G3000 or G3000HR, Solvent Meter) . . . . . . . . . . . . . . . . .3000 psi (21.0 MPa, 210 bar)

Meter Option 3 (Coriolis Meter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2300 psi (15.86 MPa, 158.6 bar)

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

Color Change Option 3 and 4 (high pressure valves). . . . . . . . . . . . . . . . . . . . . . . . . . 3000 psi (21 MPa, 210 bar)

IG. 1.

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

ProMix 3KS Power Supply Module Wall Mount Fluid Station, 50 cc Integrator and Static Mixer IS Power Cable, red color coded, 50 ft (15.25 m) CAN Communication Cable, green color coded, 10 ft (3.05 m) Meter and Solenoid Cable, 10 ft (3.05 m) Third Component Network Cable, yellow color coded, 6 ft (1.83 m) C Side Dump Valve, if color valve(s) selected

313882C 5

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System Configuration and Part Numbers

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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) 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

Accessories

313882C 7

Page 8

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 symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found 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

Only models with a G3000, G250, G3000HR, G250HR, or intrinsically safe Coriolis meter for A, B, and C meters are approved for installation in a Hazardous Location - Class I, Div I, Group D, T3 or Zone I Group IIA T3. To help prevent fire and explosion:

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

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

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• 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.

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Warnings

WARNING

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 impervious 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

313882C 9

Page 10

Glossary of Terms

Air Chop - the process of mixing air and solvent

together during the flush cycle to help clean the lines and reduce solvent usage.

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.

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

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.

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), catalyst (B), and reducer (C) 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.

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

Fiber Optic Communication - the use of light to transmit communication signals.

Fill Time - the amount of time that is required to load mix material to the applicator.

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.

Grand Total - a non-resettable value that shows the

total amount of material dispensed through the system.

Gun Trigger Input Signal - used to manage ratio 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.

K-factor - a value that refers to the amount of material that passes through a meter. The assigned value refers to an amount of material per pulse.

Ki - refers to the degree fluid flow over shoots its set point.

Kp - refers to the speed in which the fluid flow reaches its set point.

10 313882C

Page 11

Glossary of Terms

Manual Mode - when the proportioning or flow control system is controlling the inputs without any input from an outside control.

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

Mix Input Signal- refers to system mode status where system begins a dose sequence each time the mix signal is made “High”.

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.

Overdose Alarm - when either the resin (A), 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.

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

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

Purge Time - the amount of time required to flush all mixed material from the system.

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, B, and C dispense sequentially in the necessary volumes to attain the mix ratio.

Solvent Fill - the time required to fill the mixed material line with solvent.

Standby - refers to the status of the system.

Third Purge Valve - refers to the use of three purge

valves used to flush some waterborne materials. The valves are used to flush with water, air and solvent.

V/P - refers to the voltage to pressure device in the flow control module.

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

313882C 11

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Overview

Usage

The Graco ProMix 3KS Kit adapts a ProMix 2KS system to be an electronic 3-component paint proportioner. It can blend most 3-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 25 color change valves and up to 4 catalyst and 4 component C change valves.

NOTE: Optional accessories are available for in field installation to achieve 25 colors or for component C change.

Component Identification and Definition

See FIG. 2 and Table 1 for the system components. Components marked with a star (★) are available as part of the ProMix 3KS Kit. All other components are part of the ProMix 2KS System or are available as accessories.

PSM★

CCM

PS◆ PS★◆

BCV

ACV

2KS

2KM

◆ See the ProMix 3KS Repair-Parts manual for optional cable lengths.

IG. 2. ProMix 3KS System, shown with G3000 Meters and Color/Catalyst/Component C Change

12 313882C

6 ft (1.83 m) fluid hose (supplied)

3KS★

CCV★

MC★

3KM★

TI14543a

Page 13

Table 1: Component Descriptions

Component Description

Overview

EasyKey (EK)

★ 3KS Power Supply Module (PSM)

Booth Control (BC)

2KS Fluid Station (2KS)

★ 3KS Fluid Station (3KS)

2K Fluid Manifold (2KM)

★ 3K Fluid Manifold (3KM)

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.

Accepts 85-250 VAC, 50/60 Hz line power and converts that power to acceptable low voltage 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 A, B, and solvent flow meters and the 2K fluid manifold assembly. Its control board manages all proportioning functions.

Includes air control solenoids, flow switches, and mountings for the C and solvent flow meters and the 3K 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.

• Pneumatically Operated Dose Valve for component C

• Purge Valve for solvent

• Sampling Valve for calibrating the flow meter and performing ratio check

• Shutoff Valve for component C to close the fluid passage to the mix manifold, to

allow for accurate calibration and ratio check

• Mix Manifold, which includes the fluid integrator and static mixer. ➜ Fluid Integrator is the chamber where component C aligns with blended

components A/B at the selected ratio and begins to mix.

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

of the fluid integrator.

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Page 14

Overview

Table 1: Component Descriptions

Component Description

Flow Meters (MA, MB, ★MC, MS)

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

Catalyst Change Valves (BCV)

★ Component C Change Valves (CCV)

Four 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.

• 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 25 color change valves. Each stack includes one additional valve for solvent to clean the fluid line between color changes.

An optional component. It is available as a catalyst change valve stack for either low or high pressure with up to 4 catalyst change valves. Each stack includes one additional valve for solvent to clean the fluid line between catalyst changes.

An optional component. It is available as a component C change valve stack for either low or high pressure with up to 4 component C change valves. Each stack includes one additional valve for solvent to clean the fluid line between component C changes.

Dual Fiber Optic

Used to communicate between the EasyKey and Wall Mount Fluid Station.

Cable (FO)

★ Fluid Station

Used to provide power to the Wall Mount Fluid Station.

Power Supply Cable (PS)

Applicator

Not shown. See ProMix 2KS manuals for details.

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

14 313882C

Page 15

Overview

RVA

APV

DVC

DVA

SVA SVB

DVB

Key: ProMix 2KS Fluid Station

MA Component A Meter DVA Component A Dose Valve RVA Component A Sampling

Val ve

SVA Component A Shutoff

Val ve MB Component B Meter DVB Component B Dose Valve RVB Component B Sampling

Val ve

RVB

TI12556a

SPV

SVB Component B Shutoff

Val ve MS Solvent Meter SPV Solvent Purge Valve APV Air Purge Valve SM Static Mixer FI Fluid Integrator AT Air Purge Valve Air Supply

Tu b e

Key: ProMix 3KS Fluid Station

CPV

RVC

SVC

MC Component C Meter DVC Component C Dose Valve RVC Component C Sampling Valve SVC Component C Shutoff Valve CPV Component C Purge Valve SM Static Mixer FI Fluid Integrator

3KS fluid inlet. Connect fluid supply line from 2KS fluid manifold outlet here.

Connect fluid supply line to gun.

TI14382a

FIG. 3. ProMix 2KS and ProMix 3KS Wall Mount Fluid Stations

313882C 15

Page 16

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 E31) and red Alarm indicator blinks.

• Recipe number displays after alarm is reset.

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

IG. 4)

(see F

Key/Indicator Definition and Function Down Key Scrolls recipe numbers down.

Mix Mode Key • Starts Mix mode*.

• Green LED remains lit while in Mix mode or in Idle mode.

* After doing a purge, press key

once. The system will do a mixed material fill sequence, then go to Standby. Press again to start Mix mode.

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.

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, B, and C totalizers.

• Green LED blinks once after key is pressed.

Enter Key Enters selected recipe and starts color

change sequence.

Up Key Scrolls recipe numbers up.

Alarm Indicator (red)

Recipe Indicator (green)

IG. 4. Booth Control (see Table 2)

Display

TI11614A

16 313882C

Page 17

EasyKey Display and Keyboard

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.

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 alarms.

313882C 17

Page 18

EasyKey and 3KS Power Supply Module Connection Ports

EasyKey

AC Power

Audible AlarmFiber Optic Strain

Relief Port

Main Power Access Port

Switch

Ground Screw

I/S Power to 2KS Panel

I/S Power to 3KS Panel

Graco Web Interface

Discrete I/O Cable Connector Ports

TI12638a TI12657a

3KS Power Supply Module

TI14366a TI14372a

AC Power Switch

Main Power Access Port

FIG. 6. Connections and AC Power Switches

18 313882C

Page 19

EasyKey and 3KS Power Supply Module Connection Ports

EasyKey AC Power Switch

Turns system AC power on or off.

3KS Power Supply Module AC Power Switch

Turns 3KS AC power on or off.

EasyKey I/S Power

Power circuit to 2KS Fluid Station.

3KS Power Supply Module I/S Power

Power circuit to 3KS Fluid Station.

EasyKey Potlife Exceeded Audible Alarm

Alerts the user when a Potlife Exceeded alarm occurs.

EasyKey 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.

EasyKey Ethernet Connection

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

Clear by pressing the Alarm Reset

key.

313882C 19

Page 20

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 ProMix 2KS 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 313882C

Page 21

Run Mode Screens

Press the Setup key to

enter Setup mode.

TI12783a

FIG. 9. Run Screens Map

313882C 21

Page 22

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.

2 3 4

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, B, or C hose lights up, showing which component dose valve is open.

Current Date and Time

Screen Number and Screen 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.

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

Stage 1 Actual Ratio (A:B): in hundredths, calculated after each dose of A and B.

Stage 2 Target Ratio (A+B):C: for the active recipe. The ratio can be from 0.0:1–50.0:1, in 0.1 increments.

Stage 2 Actual Ratio (A+B):C: in hundredths, calculated after each dose of C.

22 313882C

Page 23

Run Mode Screens

Totals Screen

IG. 11. Totals Screen

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

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

Screen 5 on page 31.

Reset Solvent Screen

FIG. 13. Reset Solvent Total Screen

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

Alarms Screens

NOTE: Grand totals are not resettable.

Reset Total Screen

IG. 12. Reset Total Screen

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

IG. 14. Alarms Screen

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

Down keys to scroll between the two screens.

See Table 9 on page 77 for a list of alarm codes.

313882C 23

Page 24

Run Mode Screens

Level Control Screen

IG. 15. Level Control Screen

This screen shows the current volume for each fluid. Adjust the actual volumes on this screen, or use the tab to go to Usage (Totals Screen, page 23).

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 occur after 25% of the remaining volume is mixed.

Refill tank volume to clear the alarm.

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

24 313882C

Page 25

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

313882C 25

Page 26

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 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 returning 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 34-41) 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 313882C

Page 27

Setup Mode

Table 4: Component Software Versions

Display (may vary from examples

Component

shown) Description

EK (EasyKey) 2.00.012 EasyKey software version. FP (Fluid Plate) 2.00.012 Fluid Plate software version. BC (Booth Control) -.- Booth Control not installed, not detected, or not oper-

ational.

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) 2K-Manual No AutoKey installed or detected. System operates in

2K Manual Mode only

2K-Auto 2K AutoKey detected. System can operate in 2K Man-

ual, Semi-automatic, or Automatic Mode.

3K-Auto 3K AutoKey detected. System can operate in 3K Man-

ual, Semi-automatic, or Automatic Mode.

XP (XPORT) V6.6.0.2 Example of XPORT network module software version.

Other versions are acceptable.

MC (Micro Controller) 1042.0198 Example of fluid plate micro controller version. Other

versions are acceptable.

IP (Internet Address) 192.168.178.5 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.

313882C 27

Page 28

Setup Mode

System Configuration Screens

NOTE: See FIG. 21 for a map of the System Configura- tion 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 313882C

Page 29

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, and Chinese (Simplified).

Password

The password is only used to enter Setup mode. The default is 0, which means no password is required to enter Setup. If a password is desired, enter a number from 1 to 9999.

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

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

Date Format

Select mm/dd/yy or dd/mm/yy.

313882C 29

Page 30

Setup Mode

Configure Screen 3

IG. 24. Configure Screen 3

Run Mode

Indicates that this is a Manual system.

Dump Valve A

This field only appears if the system includes an optional dump valve A. If dump valve A is included, set to On.

Dump Valve B

This field only appears if the catalyst change option is detected from the cc board, meaning that dump valve B is present. On is the only setting.

Dump Valve C

Dose Size

Select the total dose size (cc) from the pulldown menu: 100, 50, 25, or 10.

NOTE: Selection DD is for dynamic dosing, which is not used with ProMix 3KS.

FIG. 26. Dose Size Menu

Example:

To calculate the dose size of each component, you must first calculate the A+B:C dose sizes. For example, if the total dose size is 50 cc and the A+B:C ratio is 1:1, the dose size of A+B is 25 cc and the dose size of C is also 25 cc. Then use the ratio of A:B (2:1 in this example) to calculate the dose size of A as 16.67 cc (2/3 of 25) and the dose size of B as 8.33 cc (1/3 of 25).

This field only appears if the component C change option is detected from the cc board, meaning that dump valve C is present. On is the only setting.

3rd Flush Valve

Off is default. If optional 3rd flush valve is used, set to On.

Configure Screen 4

IG. 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.

Number of Guns

Enter the number of spray guns (1 or 2).

Gun Flush Box

Enter the number of gun flush boxes (Off, 1, or 2).

30 313882C

Page 31

Configure Screen 5

IG. 27. Configure Screen 5

Special Outputs

Select special outputs (0-4). Each output has two different start times and durations.

Setup Mode

Solvent Monitor

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

Web Browser IP

The default web browser IP address prefix is

192.168.178.__ Assign a unique number for each EasyKey in your system (1-99) and enter it here.

Control Network ID

Used for the Graco Gateway network system. See Graco Gateway manual 312785 for further information.

313882C 31

Page 32

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. 28. Option Screen 1

Flush Volume Check

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

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

ipe Setup Screen 2, page 39.

Stage Fill Volume

This field refers to the amount of material that is required to fill the mixed material line from the A/B fluid panel to the C fluid panel, before adding component C. This value must be the same as the selected dose size. Default is 50 cc.

Verification Screen

FIG. 29. 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.

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 40-41.

K-Factor Input

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

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

Minimum Material Fill Volume

Enter 0-9999 cc.

32 313882C

Page 33

Option Screen 2

IG. 30. Option Screen 2

Auto Dump

If the auto dump feature is being used, set to “On”. Once the auto dump is enabled, the gun flush box is enabled and the potlife alarm is active for 2 minutes, the system will automatically flush out the old material.

Setup Mode

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.

313882C 33

Page 34

Setup Mode

Advanced Setup Screens

NOTE: See FIG. 31 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. 31. Advanced Setup Screens Map

34 313882C

Page 35

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. 32. 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/catalyst/component C module to the dose valve or dump valve.

Advanced Setup Screen 2

FIG. 33. 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/catalyst/component C 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).

313882C 35

Page 36

Setup Mode

Advanced Setup Screen 3

IG. 34. 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 (Stage 1)

Enter the first purge time (0 to 999 seconds) for components A and B.

Advanced Setup Screen 4

FIG. 35. 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

C First Purge Time (Stage 2)

Enter the component C first purge time (0 to 999 seconds).

Total Chop Time (Stage 1)

Enter the total chop time (0 to 999 seconds) for components A and B.

Final Purge Time (Stage 1)

Enter the final purge time (0 to 999 seconds) for components A and B.

C Final Purge Time (Stage 2)

Enter the component C final purge time (0 to 999 seconds).

Mixed Fill Time

Enter the mixed fill time (0 to 999 seconds). It refers to the amount of material that is required to fill from the dose valves to the applicator/gun.

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

K-factor C Meter

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

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.

36 313882C

Page 37

Advanced Setup Screen 5

IG. 36. 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 Outputs is set to 1, 2, 3, or 4 in Configure Screen 5, page

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

Setup Mode

313882C 37

Page 38

Setup Mode

Recipe Setup Screens

NOTE: See FIG. 37 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. 37: Recipe Screens Map

38 313882C

Page 39

Setup Mode

Option Screens.

Recipe Setup Screen 1

IG. 38. Recipe Setup Screen 1

Ratio

Enter the mix ratio of component A over component B (0.0:1 to 50:1) and the ratio of A+B over C (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.

Recipe Setup Screen 2

FIG. 39. 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 999 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, catalyst, or component C module to the dose valve or dump valve.

Component A (Color) Valve (if present)

This field only appears if the system includes a color change module. Enter the component A valve number (1 to 25).

Component B (Catalyst) Valve (if present)

This field only appears if the system includes a color change module. Enter the component B valve number (1 to 4).

Component C (Reducer) Valve (if present)

This field only appears if the system includes a color change module. Enter the component C valve number (1 to 4).

313882C 39

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, catalyst, or component C module to the dose valve or dump valve.

Page 40

Setup Mode

Recipe Setup Screen 3

IG. 40. 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

Recipe Setup Screen 4

FIG. 41. 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 (Stage 1)

Enter the first purge time (0 to 999 seconds) for components A and B.

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).

C First Purge Time (Stage 2)

Enter the component C first purge time (0 to 999 seconds).

Total Chop Time (Stage 1)

Enter the total chop time (0 to 999 seconds) for components A and B.

Final Purge Time (Stage 1)

Enter the final purge time (0 to 999 seconds) for components A and B.

C Final Purge Time (Stage 2)

Enter the component C 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 material that is required to fill from the dose valves to the applicator/gun.

40 313882C

Page 41

Setup Mode

Recipe Setup Screen 5

IG. 42. 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. 43. 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 C Meter

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

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).

Recipe Setup Screen 7

IG. 44. 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, or 4 in Configure Screen 5, page

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

313882C 41

Page 42

Setup Mode

Recipe 0 Screens

NOTE: See FIG. 37 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. 46. Recipe 0 Screen 2

IG. 45. 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

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.)

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. Enter the purge time (0 to 999 seconds).

First Purge Time (Stage 1)

Enter the first purge time (0 to 999 seconds) for components A and B.

C First Purge Time (Stage 2)

Enter the component C first purge time (0 to 999 seconds).

Total Chop Time

Enter the total chop time (0 to 999 seconds) for components A and B.

Final Purge Time (Stage 1)

Enter the final purge time (0 to 999 seconds) for components A and B.

C Final Purge Time (Stage 2)

Enter the component C final purge time (0 to 999 seconds).

42 313882C

Page 43

Setup Mode

Recipe 0 Screen 3

IG. 47. 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 999 cc).

Recipe 0 Screen 4

FIG. 48. Recipe 0 Screen 4

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, or 4 in Configure Screen 5, page

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

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.”

Exiting Fill Time

This field only appears if Exiting Fill Source is set to “Air,” “Solvent,” or “3rd Valve.” Enter the time in seconds.

313882C 43

Page 44

Setup Mode

Calibration Screen

IG. 49. Calibration Screen

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

• Start - start calibration

• Abort - stop calibration

• Purge - purge sampling valves after calibration

See Meter Calibration, page 62, for when and how to calibrate a meter.

44 313882C

Page 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, B, and C dispense sequentially in the necessary volumes to attain the mix ratio.

Recipe (Color) Change

The process when the system automatically flushes out the old color and loads a new color. See pages 64-76.

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 controller sends signals to activate the solenoid valves. The solenoid valves activate Dose Valves A, B, and C. Fluid flow begins when the gun is triggered.

Stage 1 (see FIG. 50, ProMix 2KS Detail)

4. Components A and B are introduced into the 2KS fluid integrator (FI) one at a time as follows.

a. Dose Valve B (DVB) opens, and fluid flows into

the integrator.

b. Flow Meter B (MB) 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

B closes.

NOTE: The dispense volume of component A and B is based on the mix ratio and dose size set by the user and calculated by the ProMix 2KS controller.

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

the 2KS integrator and is aligned proportionately with component B.

e. Flow Meter A (MA) monitors the fluid volume

dispensed and sends electrical pulses to the ProMix 2KS controller.

f. When the target volume is dispensed, Dose

Valve A closes.

313882C 45

Page 46

System Operation

5. Components A and B are pre-mixed in the 2KS integrator, then uniformly blended in the 2KS static mixer (SM) before flowing through the hose to the 3KS Fluid Manifold inlet.

Stage 2 (see FIG. 50, ProMix 3KS Detail)

6. Dose Valve C (DVC) opens, and fluid flows into the 3KS integrator and is aligned proportionately with components A+B (mixed in Stage 1).

7. Flow Meter C (MC) monitors the fluid volume dispensed and sends electrical pulses to the ProMix 3KS controller.

8. When the target volume is dispensed, Dose Valve C closes.

9. Components A+B and C are pre-mixed in the 3KS integrator, then uniformly blended in the 3KS static mixer (SM).

Table 5: Sequential Dosing Operation

Dose 1 Dose 2

NOTE: To control output from the 3KS static mixer

to the gun, install an optional fluid pressure regulator.

10. Components A+B and C are alternately fed into the 2KS integrator as long as the gun is triggered.

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

12. When the gun is triggered again, the ProMix 3KS continues the process where it left off.

NOTE: Operation can be stopped at any time by

pressing the Standby key or shutting off the

main power switch.

Ratio = 2.0:1 A = 2 B = 1 C = 1

Stage 1 (A:B)

Stage 2

(A+B):C Stage 1 (A:B)

Stage 2

(A+B):C

46 313882C

Page 47

System Operation

RVA

APV

DVC

DVA

SVA SVB

DVB

Key: ProMix 2KS Fluid Station

MA Component A Meter DVA Component A Dose Valve RVA Component A Sampling

Val ve

SVA Component A Shutoff

Val ve MB Component B Meter DVB Component B Dose Valve RVB Component B Sampling

Val ve

RVB

TI12556a

SPV

SVB Component B Shutoff

Val ve MS Solvent Meter SPV Solvent Purge Valve APV Air Purge Valve SM Static Mixer FI Fluid Integrator AT Air Purge Valve Air Supply

Tu b e

Key: ProMix 3KS Fluid Station

CPV

RVC

SVC

MC Component C Meter DVC Component C Dose Valve RVC Component C Sampling Valve SVC Component C Shutoff Valve CPV Component C Purge Valve SM Static Mixer FI Fluid Integrator

3KS fluid inlet. Connect fluid supply line from 2KS fluid manifold outlet here.

Connect fluid supply line to gun.

TI14382a

FIG. 50. ProMix 2KS and ProMix 3KS Wall Mount Fluid Stations

313882C 47

Page 48

System Operation

Mix Manifold Valve Settings

To open dose or purge valves, turn hex nut (E) counterclockwise. To close, turn clockwise. See Table 6 and

IG. 51.

TI11581a

IG. 51. Valve Adjustment

Table 6: Mix Manifold Valve Settings

Valve Setting Function

Dose (F

IG. 51)

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

Limits maximum fluid flow rate into integrator and minimizes valve response time.

closed

Purge

IG. 51)

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

Limits maximum fluid flow rate into integrator and minimizes valve response time.

closed

Shutoff (SVA and SVB, F

IG. 60)

Sampling (RVA, RVB, and RVC, F

IG. 60)

Fully open during Run/Mix operation

Fully closed during Run/Mix operation

Closes component A, B, and C ports to integrator during ratio check or meter calibration. Open ports during Run/Mix operation.

Open to dispense component A, B, and C while calibrating meters. Do not open sampling valves unless fluid shutoff valves are closed.

48 313882C

Page 49

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 3KS. Two issues can arise from operating without an air flow switch:

• Without a gun trigger/air flow switch input the ProMix 3KS 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 3KS 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. 52: 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.

313882C 49

Page 50

System Operation

Start Up

1. Go through the Pre-Operation Checklist in Table 7.

Table 7: Pre-Operation Checklist

✓ Checklist

System grounded

Verify all grounding connections were made. See the ProMix 3KS Installation manual.

All connections tight and correct

Verify all electrical, fluid, air, and system connections are tight and installed according to the Installation manual.

Fluid supply containers filled

Check component A, B, and C 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 48, then adjust as needed.

Fluid supply valves open and pressure set

Component A, B, and C fluid supply pressures should be equal unless one component is more viscous and requires a higher pressure setting.

Solenoid 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 displays,

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

FIG. 54. Status Screen

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

75-100 psi inlet air supply (0.5-0.7 MPa, 5.2-7 bar)

2. Turn the AC Power Switch on the EasyKey and on the Power Supply Module ON (I = ON, 0 = OFF).

I = ON

TI12656a TI14372a

IG. 53. 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 59. 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.

50 313882C

Page 51

System Operation

6. Adjust component A, B, and C 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.

11. Adjust the flow rate.

The fluid flow rate shown on the EasyKey Status screen is for either component A, B, and C, depending on which dose valve is open. The fluid supply lines on the screen highlight to show which dose valve is open.

Watch the fluid flow rate displayed on the Status screen while the gun is fully open. Verify that the flow rate of components A, B, and C are within 10% of each other.

If the fluid flow rate is too low: increase air pressure to component A, B, and C 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, B, and C, then adjust as needed.

NOTICE

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.

NOTICE

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.

IG. 55. Status Screen Flow Rate Display

313882C 51

Page 52

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 52.

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

3. Shut OFF the Power Switch on the EasyKey and on the Power Supply Module (0 position). F

4. If servicing the EasyKey or Power Supply Module, also shut off power at main circuit breaker.

0 = OFF

IG. 56.

Pressure Relief Procedure

NOTE: The following procedures relieve all fluid and air

pressure in the ProMix 3KS 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, B, and C 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, B, and C dose valve solenoids to relieve pressure. See F

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

IG. 57.

TI12657a TI14372a

IG. 56. Power Switch

3. Do a complete system purge, following the instructions under Purging Using Recipe 0, page 59.

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, B, and C purge valve solenoids to relieve air and solvent pressure. See F vent pressure is reduced to 0.

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

IG. 60.

IG. 57. Verify that sol-

52 313882C

Page 53

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 52.

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. 59. 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.

IG. 60. Open

6. See F

IG. 59. Using the solenoid identification labels

as a guide, press and hold the override button on each catalyst solenoid until flow from dump valve B stops.

7. Press and hold the dump valve C solenoid override, F

IG. 57.

8. See F

IG. 59. 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 C stops.

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

IG. 57.

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

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

IG. 57.

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

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

IG. 60. Close

the A side sampling valve (RVA).

Systems with Color/Catalyst/Component C Change and Dump Valves

NOTE: This procedure relieves pressure through the

dump valves.

1. Complete all steps under Single Color Systems, page 52.

2. Shut off all color/catalyst/component C supplies to the valve stacks.

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

IG. 57.

4. See F

IG. 59. 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.

13. Press and hold the dump valve C solenoid override, F

IG. 57.

14. Press and hold the C side solvent solenoid override until clean solvent comes from the dump valve, then release.

15. Shutoff the solvent supply to the color/catalyst/component C change stack solvent valves.

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

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

IG. 57.

313882C 53

Page 54

System Operation

Valve Overrides

AFS #1

AFS #2 SOLV SW GFB 1 PS

GFB 2 PS

Not Used

Flow Solv

Flow C

Flow A

Flow B

Dose A

Dose B

Dose C

J13

J12

+ G s

+ +

Dump C

Air

Solvent

+++

Purge C

Dump A

3rd Flush

++++++

J14 J15 J8

Power

Fiber Optic

CAN

Dump B

GFB 2

GFB 1

Dump Valve A

Dump Valve B

Optional Solenoid

Dose Valve A

Solenoid

Dose Valve B

Solenoid

Purge Valve A Solenoid

Purge Valve B Solenoid

GFB 1

GFB 2

3rd Purge Valve Solenoid

Locations

TI12652a

FIG. 57. Component A and B Solenoids

54 313882C

Page 55

(Communication)

(Power Input)

(Color Change

Module)

System Operation

Valve Overrides

VDC

(Booth Control)

FIG. 58. Component C Solenoids

Dose Valve C Solenoid

Purge Valve C

Solenoid Dump Valve C location (optional)

TI14704a

313882C 55

Page 56

System Operation

Solenoid

Identification

Label

Module #1

Color Catalyst

Solenoid Identification Label

Color

TI12826a

Solenoid

Identification

Label

Solvent Solenoid Overrides

Module #2

Color Catalyst

Solenoid Identification Label

Color

Mount Component C Valves Here

Solvent Solenoid Overrides

TI12826a

FIG. 59: Color Change Solenoids

56 313882C

Page 57

RVA

APV

DVA

System Operation

DVB

RVB

TI12556a

DVC

SVA SVB

Key: ProMix 2KS Fluid Station

MA Component A Meter DVA Component A Dose Valve RVA Component A Sampling

Val ve

SVA Component A Shutoff

Val ve MB Component B Meter DVB Component B Dose Valve RVB Component B Sampling

Val ve

Key: ProMix 3KS Fluid Station

CPV

MC Component C Meter DVC Component C Dose Valve RVC Component C Sampling Valve SVC Component C Shutoff Valve CPV Component C Purge Valve SM Static Mixer FI Fluid Integrator

SPV

SVB Component B Shutoff

Val ve MS Solvent Meter SPV Solvent Purge Valve APV Air Purge Valve SM Static Mixer FI Fluid Integrator AT Air Purge Valve Air Supply

Tu b e

3KS fluid inlet. Connect fluid supply line from 2KS fluid manifold outlet here.

RVC

SVC

Connect fluid supply line to gun.

TI14382a

FIG. 60. ProMix 2KS and ProMix 3KS Wall Mount Fluid Stations

313882C 57

Page 58

System Operation

Purging

Read Warnings, page 8. Follow the Grounding instructions in your system Installation manual.

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

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

2. Set the solvent supply pressure regulator at a pressure high enough to completely purge the system in a reasonable amount of time but low enough to avoid splashing or an injection injury. Generally, a setting of 100 psi (0.7 MPa, 7 bar) is sufficient.

There are 4 purging procedures in this manual:

• Purging Mixed Material (below)

• Purging Using Recipe 0 (page 59)

• Purging Fluid Supply System (page 59)

• Purging Sampling Valves and Tubes (page 61)

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.

In the first stage fluid manifold (2KS), 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. This air/solvent chop purges the hose connecting the 2KS static mixer to the 3KS fluid manifold.

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.

NOTE: After doing a purge, press the Mix key once. The system will do a mixed material fill

sequence, then go to Standby. Press again to start Mix mode.

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

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

In the second stage fluid manifold (3KS), solvent purges the component C (right) side of the mix manifold and the inner tube of the integrator. The air/solvent chop from the 2KS purges the left side of the 3KS fluid manifold and the outer tube of the 3KS integrator.

1. Press the Standby

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.

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.

58 313882C

Page 59

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/single compo- nent C systems: disconnect the component A, B, and C fluid supplies at the flow meter inlets, and connect regulated solvent supply lines.

• Multiple color/multiple catalyst/multiple component C systems: connect the solvent supply lines to the designated solvent valve on the appropriate color, catalyst, or component C valve stack. Do not connect a solvent supply to any flow meter.

313882C 59

Page 60

System Operation

3. Adjust the solvent fluid supply pressure. Use the lowest possible pressure to avoid splashing.

4. Remove the Fluid Station cover to access the solenoid valves. See F

IG. 57.

5. Purge as follows:

• Single color/single catalyst/single compo-

nent C 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.

Purge component C side. Press the manual override on the Dose Valve C 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/multiple

component C systems: Select Recipe 0 and press Enter to purge the complete system.

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, B, and C fluid supplies.

9. See page 50 for Start Up procedure.

60 313882C

Page 61

System Operation

Purging Sampling Valves and Tubes

Follow this procedure after meter calibration.

1. Press the Standby

2. See F

IG. 60. 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), component C purge valve, and color change solvent valves (if

used) will open.

IG. 61. 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.

313882C 61

Page 62

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.

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. Press the Right Arrow key to select the Calibra-

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.

• 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.

tion Screen. Press either Dose Valve A, B, C, or Solvent. Press the

Down Arrow Start only one at a time.

7. Dispense component A, B, C, or Solvent into beaker.

the Enter key to select

key and select Start from the menu.

• 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, B, or C, prime the system with material. For a color/catalyst/component C change system, make sure the color/catalyst/component C valve is open.

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

3. Close all fluid shutoff valves and sampling valves.

62 313882C

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 volumes do not have to be equal or at any particular ratio.

d. Close sampling valve tightly.

Page 63

Meter Calibration

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

9. 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.

10. If the screen and actual volumes are different, enter the actual dispensed volume in cc for A, B, C, or

Solvent 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

11. After the volume for A, B, C, or Solvent is entered, the ProMix 3KS 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).

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

• Follow the Purging Sampling Valves and

Tubes procedure, page 61.

• 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.

13. Make sure all sampling valves are closed and all fluid shutoff valves are fully open.

14. 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 50.

313882C 63

Page 64

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. 62 through FIG. 71 illustrate various color change sequences. See Table 8 to determine which figure to reference, based on the recipe change and system configuration. The time sequences are detailed in the following paragraphs.

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 begins after the Color/Catalyst/Component C Change steps are completed.

• Dump Valve B is required for a Catalyst Change

8. Press the Mix key to start spraying.

Single Color Systems

1. Follow procedure for Purging Fluid Supply System, page 59.

2. Load the new color. See Start Up, page 50.

3. Press the Mix key to start spraying.

64 313882C

system.

• Dump Valve C is required for a Component C Change 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 X, only the fill cycle data from Recipe X is used.

Page 65

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.

Component C Fill

• This sequence fills the line with the new component C all the way to the Dump C valve.

• The new component C valve and the Dump C valve open during the Fill Time.

• The new component C valve and the Dump C valve close when the Fill Time expires.

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.

First Purge C

Select the First Purge C Source (solvent or water) and First Purge C Time. For most applications, solvent is selected.

• 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.

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

Component C Purge/Dump

• This sequence flushes out component C with solvent, from the component C valve to the Dump C valve.

• The component C change solvent valve and the Dump C valve open during the Purge Time.

The system purges the old material from the dose valves to the gun, using only the selected purge media. The purge C valve opens during the First Purge C 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.

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

313882C 65

Page 66

Color Change

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.

Final Purge C

Select the Final Purge C Source (solvent or water) and Final Purge C 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. The purge C valve opens during the Final Purge C Time and closes when the time expires.

Table 8: ProMix 3KS Color Change Chart Reference

Starting

Recipe

Ending

Recipe

Change

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, B, and C until the Fill Time expires.

Purge Active

The system turns on the Purge/Recipe Change Purge Active output during these steps.

Fill Active

The system turns on the Recipe Change Fill Active output during this step.

A/B/C

3rd Purge

Valve Refer to Fig.

XYYesYesF XYYesNoF XYNoYesF X Y No No F XYExternalYesF XYExternalNoF X0n/aYesF X0n/aNoF

0 or 61 X Yes Yes F

IG. 62 IG. 63 IG. 64 IG. 65 IG. 70 IG. 71 IG. 66 IG. 67 IG. 68

0 or 61 X Yes No FIG. 69 0 or 61 0 n/a Yes F 0 or 61 0 n/a No F

IG. 66 IG. 67

66 313882C

Page 67

Color Change

Recipe Change X -> Y A1 to A2, B1 to B2, C1 to C2 3rd Flush Valve

Dump A If any component isn't changing, that time segment is skipped. Dump B Dump C

Solvent A Solvent B Solvent C

Component A Component B Component C

A Purge Time A Fill Time B Purge Time B Fill Time C Purge Time C Fill Time

Purge A (Air) For first pur ge and final purge, Purge B (Solvent) only one of the purge valves are used Purge D (3rd/Water) Purge C (Solvent/Water)

Dose A Dose B Dose C

No Gun Flush Boxes:

Gun Trigger(s) by Operator

1 Gun Fluxh Box:

Gun Flush Box Output 1 Gun Flush Box Output 2

2 Gun Flush Boxes:

Gun Flush Box Output 1 Gun Flush Box Output 2

Two Second Initial Purge Ti me First Purge Time First Purge C Time Chop Time Final Purge Time Final Purge C Time Mixed Fill Time

Valve

Time Sequence

FIG. 62: ProMix 3KS Color Change Chart 1

313882C 67

Page 68

Color Change

Recipe Change X -> Y A1 to A2, B1 to B2, C1 to C2 No 3rd Flush Valve

Dump A If any component isn't changing , that time segment is sk ipped. Dump B Dump C

Solvent A Solvent B Solvent C

Component A Component B Component C

A Purge Time A Fill Time B Purge Time B Fill Time C Purge Time C Fill Time

Purge A (Air) For first purge and final purge, Purge B (Solvent) only one of the purge valves are used Purge D (3rd/Water) Purge C (Solvent/Water)

Dose A Dose B Dose C

No Gun Flush Boxes:

Gun Trigger(s) by Operator

1 Gun Fluxh Box:

Gun Flush Box Output 1 Gun Flush Box Output 2

2 Gun Flush Boxes:

Gun Flush Box Output 1 Gun Flush Box Output 2

First Purge Time First Purge C Time Chop Time Final Purge Time Final Purge C Time Mixed Fill Time

Valve

Time Sequence

FIG. 63: ProMix 3KS Color Change Chart 2

68 313882C

Page 69

Recipe Change X -> Y No components change 3rd Flush Valve

Dump A Dump B Dump C

Solvent A Solvent B Solvent C

Component A Component B Component C

A Purge Time A Fill Time B Purge Time B Fill Time C Purge Time C Fill Time

Purge A (Air) For first pur ge and final purge, Purge B (Solvent) only one of the purge valves are used Purge D (3rd/Water) Purge C (Solvent/Water)

Dose A Dose B Dose C

No Gun Flush Boxes:

Gun Trigger(s) by Operator

1 Gun Fluxh Box:

Gun Flush Box Output 1 Gun Flush Box Output 2

2 Gun Flush Boxes:

Gun Flush Box Output 1 Gun Flush Box Output 2

Two Second Initial Purge Ti me First Purge Time First Purge C Time Chop Time Final Purge Time Final Purge C Time Mixed Fill Time

Valve

Time Sequence

Color Change

FIG. 64: ProMix 3KS Color Change Chart 3

313882C 69

Page 70

Color Change

Recipe Change X -> Y No components change No 3rd Flush Valve

Dump A Dump B Dump C

Solvent A Solvent B Solvent C

Component A Component B Component C

A Purge Time A Fill Time B Purge Time B Fill Time C Purge Time C Fill Time

Purge A (Air) For first purge and final purge, Purge B (Solvent) only one of the purge valves are used Purge D (3rd/Water) Purge C (Solvent/Water)

Dose A Dose B Dose C

No Gun Flush Boxes:

Gun Trigger(s) by Operator

1 Gun Fluxh Box:

Gun Flush Box Output 1 Gun Flush Box Output 2

2 Gun Flush Boxes:

Gun Flush Box Output 1 Gun Flush Box Output 2

First Purge Time First Purge C Time Chop Time Final Purge Time Final Purge C Time Mixed Fill Time

Valve

Time Sequence

FIG. 65: ProMix 3KS Color Change Chart 4

70 313882C

Page 71

Recipe Change

X, 0, 61 -> 0 No more A, B, C 3rd Flush Valve

Dump A Dump B Dump C

Solvent A Solvent B Solvent C

Component A Component B Component C

A Purge Time B Purge Time C Purge Time

Purge A (Air) For first pur ge and final purge, Purge B (Solvent) only one of the purge valves are used Purge D (3rd/Water) 3rd flush valve is only used if enabled in EasyKe Purge C (Solvent/Water)

Dose A Dose B Dose C

No Gun Flush Boxes:

Gun Trigger(s) by Operator

1 Gun Fluxh Box:

Gun Flush Box Output 1 Gun Flush Box Output 2

2 Gun Flush Boxes:

Gun Flush Box Output 1 Gun Flush Box Output 2

Two Second Initial Purge Ti me Two second initial purge onlty happens if First Purge Time 3rd flush valve is enabled First Purge C Time Chop Time Final Purge Time Final Purge C Time

Valve

Time Sequence

Color Change

FIG. 66: ProMix 3KS Color Change Chart 5

313882C 71

Page 72

Color Change

Recipe Change X, 0, 61 -> 0 No more A, B, C No 3rd Flush Valve

Dump A Dump B Dump C

Solvent A Solvent B Solvent C

Component A Component B Component C

A Purge Time B Purge Time C Purge Time

Purge A (Air) For first purge and final purge, Purge B (Solvent) only one of the purge valves are used Purge D (3rd/Water) Purge C (Solvent/Water)

Dose A Dose B Dose C

No Gun Flush Boxes:

Gun Trigger(s) by Operator

1 Gun Fluxh Box:

Gun Flush Box Output 1 Gun Flush Box Output 2

2 Gun Flush Boxes:

Gun Flush Box Output 1 Gun Flush Box Output 2

First Purge Time First Purge C Time Chop Time Final Purge Time Final Purge C Time

Valve

Time Sequence

FIG. 67: ProMix 3KS Color Change Chart 6

72 313882C

Page 73

Recipe Change 0,61 -> X New A, B, C 3rd Flush Valve

Dump A Dump B Dump C

Solvent A Solvent B Solvent C

Component A Component B Component C

A Purge Time A Fill Time B Purge Time B Fill Time C Purge Time C Fill Time

Purge A (Air) Only one of these three valves is used depending on the "Exiting F ill Source" Purge B (Solvent) selected in EasyKey. Purge D (3rd/Water) Purge C (Solvent/Water)

Dose A Dose B Dose C

No Gun Flush Boxes:

Gun Trigger(s) by Operator

1 Gun Fluxh Box:

Gun Flush Box Output 1 Gun Flush Box Output 2

2 Gun Flush Boxes:

Gun Flush Box Output 1 Gun Flush Box Output 2

Exiting Fill Time Mixed Fill Time

Valve

FIG. 68: ProMix 3KS Color Change Chart 7

Color Change

Time Sequence

313882C 73

Page 74

Color Change

Recipe Change 0,61 -> X New A, B, C No 3rd Flush Valve

Dump A Dump B Dump C

Solvent A Solvent B Solvent C

Component A Component B Component C

A Purge Time A Fill Time B Purge Time B Fill Time C Purge Time C Fill Time

Purge A (Air) Purge B (Solvent) Purge D (3rd/Water) Purge C (Solvent/Water)

Dose A Dose B Dose C

No Gun Flush Boxes:

Gun Trigger(s) by Operator

1 Gun Fluxh Box:

Gun Flush Box Output 1 Gun Flush Box Output 2

2 Gun Flush Boxes:

Gun Flush Box Output 1 Gun Flush Box Output 2

Exiting Fill Time Mixed Fill Time

Valve

Time Sequence

FIG. 69: ProMix 3KS Color Change Chart 8

74 313882C

Page 75

Recipe Change X -> Y External Color Change 3rd Flush Valve

Dump A Dump B Dump C

Solvent A Solvent B Solvent C

Component A Component B Component C

A Purge Time A Fill Time B Purge Time B Fill Time C Purge Time C Fill Time

Purge A (Air) For first purge and final purge, Purge B (Solvent) only one of the purge valves are used Purge D (3rd/Water) Purge C (Solvent/Water)

Dose A Dose B Dose C

No Gun Flush Boxes:

Gun Trigger(s) by Operator

1 Gun Fluxh Box:

Gun Flush Box Output 1 Gun Flush Box Output 2

2 Gun Flush Boxes:

Gun Flush Box Output 1 Gun Flush Box Output 2

Two Second Initial Purge Time First Purge Time First Purge C Time Chop Time Final Purge Time Final Purge C Time Wait for External CC Input Mixed Fill Time

Valve

Time Sequence

FIG. 70: ProMix 3KS Color Change Chart 9

Color Change

313882C 75

Page 76

Color Change

Recipe Change X -> Y External Color Change No 3rd Flush Valve

Dump A Dump B Dump C

Solvent A Solvent B Solvent C

Component A Component B Component C

A Purge Time A Fill Time B Purge Time B Fill Time C Purge Time C Fill Time

Purge A (Air) For first purge and final purge, Purge B (Solvent) only one of the purge valves are used Purge D (3rd/Water) Purge C (Solvent/Water)

Dose A Dose B Dose C

No Gun Flush Boxes:

Gun Trigger(s) by Operator

1 Gun Fluxh Box:

Gun Flush Box Output 1 Gun Flush Box Output 2

2 Gun Flush Boxes:

Gun Flush Box Output 1 Gun Flush Box Output 2

First Purge Time First Purge C Time Chop Time Final Purge Time Final Purge C Time Wait for External CC Input Mixed Fill Time

Valve

Time Sequence

FIG. 71: ProMix 3KS Color Change Chart 10

76 313882C

Page 77

Alarms and Warnings

NOTICE

Do not use the fluid in the line that was dispensed 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-31. See F

IG. 72.

• Alarm sounds.

• Status bar on the EasyKey Display shows the alarm E-Code with a description (see Table 9).

Alarm Indicator (red)

Recipe Indicator (green)

IG. 72. Booth Control

Display

TI11614A

System Warnings

Table 9 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 9. If you forget which E-Code occurred, use the Alarms Screens (page

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

To reset alarms, see Table 10. Many alarms can be

cleared by simply pressing the Alarm Reset

Table 9: System Alarm/Warning Codes

Code Description Details

E-1 Communication Error Alarm Page 78 E-2 Potlife Alarm Page 78 E-3 Ratio High Alarm Page 79 E-4 Ratio Low Alarm Page 80 E-5 Overdose A/B Dose Too Short Alarm Page 81 E-6 Overdose B/A Dose Too Short Alarm Page 81 E-7 Dose Time A Alarm Page 82 E-8 Dose Time B Alarm Page 82 E-9 Mix in Setup Alarm Page 83 E-10 Remote Stop Alarm Page 83 E-11 Purge Volume Alarm Page 83 E-12 CAN Network Communication Error

Alarm E-13 High Flow Alarm Page 85 E-14 Low Flow Alarm Page 85 E-15 System Idle Warning Page 85 E-16 Setup Change Warning Page 85 E-17 Power On Warning Page 85 E-18 Defaults Loaded Warning Page 85 E-19 I/O Alarm Page 86 E-20 Purge Initiate Alarm Page 87 E-21 Material Fill Alarm Page 87 E-22 Tank A Low Alarm Page 88 E-23 Tank B Low Alarm Page 88 E-24 Tank S Low Alarm Page 88 E-25 Auto Dump Complete Alarm Page 88 E-26 Color/Catalyst Purge Alarm Page 88 E-27 Color/Catalyst Fill Alarm Page 88 E-29 Tank C Low Alarm Page 88 E-30 Overdose C Alarm Page 81 E-31 Dose Time C Alarm Page 82

key.

Page 84

313882C 77

Page 78

Alarm Troubleshooting

Table 10. Alarm Troubleshooting

E-1: COMM_ERROR

Cause Solution

No power to the EasyKey. Connect power to EasyKey. 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 mate-

rial, or a new color:

• Solvent Purge - See Purging Mixed Material on

page 58. 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 64.

78 313882C

Page 79

Alarm Troubleshooting

Table 10. Alarm Troubleshooting

E-3: RATIO_HIGH_ALARM

Sequential Dosing System

The mix ratio is higher than the set tolerance on the previous dose cycle.

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

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

Manually operate the Dispense A, B, and C solenoid valves as instructed in the ProMix 3KS 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 6: Mix Manifold Valve Settings,

page 50, for adjustment guidelines.

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

313882C 79

Page 80

Alarm Troubleshooting

Table 10. Alarm Troubleshooting

E-4: RATIO_LOW_ALARM

Sequential Dosing System

The mix ratio is lower than the set tolerance on the previous dose cycle.

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.

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

Manually operate the Dispense A, B, and C solenoid valves as instructed in the ProMix 3KS 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 6: Mix Manifold Valve Settings,

page 50, for adjustment guidelines.

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

80 313882C

Page 81

Alarm Troubleshooting

Table 10. Alarm Troubleshooting

E-5: OVERDOSE_A/B_DOSE_TOO_SHORT_ALARM, E-6: OVERDOSE_B/A_DOSE_TOO_SHORT_ALARM, and E-30: OVERDOSE_C_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.

E-30: the C dose overshoots and, when combined with A+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 Scree n on page 23. If A, B, or C 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 3KS is reading any fluid flow.

4. If the ProMix 3KS 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 3KS to reduce the fluid supply pressure. Contact your Graco distributor for information.

Slow actuation of component A, B, or C valves. See E-3: RATIO_HIGH_ALARM and E-4:

RATIO_LOW_ALARM, pages 79-80.

Running a high mix ratio and a high flow rate. It may be necessary to restrict the flow rate through the

component B or C dose valve by adjusting its hex nut (E). See page 48.

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Page 82

Alarm Troubleshooting

Table 10. Alarm Troubleshooting

E-7: DOSE_TIME_A_ALARM, E-8: DOSE_TIME_B_ALARM, and E-31: DOSE_TIME_C_ALARM

E-7: gun trigger input is active (AFS or Integration) and no A meter pulses are detected during the dose time selected.

E-8: gun trigger input is active (AFS or Integration) and no B meter pulses are detected during the dose time selected.

E-31: gun trigger input is active (AFS or Integration) and no C meter pulses are 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 62.

Slow actuation of component A, B, or C valves. See E-3: RATIO_HIGH_ALARM and E-4:

RATIO_LOW_ALARM, pages 79-80.

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.

82 313882C

Page 83

Alarm Troubleshooting

Table 10. Alarm Troubleshooting

E-9: MIX_IN_SETUP_ALARM

Cause Solution

Attempt to operate system while in Setup mode. System must be in Standby to change current recipe,

and cannot be operated.

E-10: REMOTE_STOP_ALARM

Cause Solution

Automation has requested that the system abort all oper-

Abort operations. Troubleshoot automation system.

ations.

E-11: PURGE_VOLUME_ALARM

Cause Solution

ProMix 3KS 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 set too high. 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.

313882C 83

Page 84

Alarm Troubleshooting

E-12: CAN_COMM_ERROR_ALARM

Cause Solution

Table 10. 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 ProMix 3KS 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 ProMix 3KS 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.

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

Verify that the cable is correctly connected.

84 313882C

Page 85

Alarm Troubleshooting

Table 10. 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_WARNING

Cause Solution

The power to the system has been cycled. 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.

313882C 85

Page 86

Alarm Troubleshooting

Table 10. Alarm Troubleshooting

E-19: I/O ALARM

Cause Solution

The Mix and Purge digital inputs are on at the same time. Ensure that only one input is on at a time. At least 1 sec

delay is required when switching from Mix to Purge or vice versa.

NOTE: The I/O alarm incorporates several sub-alarms relating to internal data issues, as detailed below. These alarms may not apply to all software versions.

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.

86 313882C

Page 87

E-20: PURGE_INITIATE_ALARM

Cause Solution

Alarm Troubleshooting

Table 10. 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.

313882C 87

Page 88

Alarm Troubleshooting

Table 10. Alarm Troubleshooting

E-22: TANK_A_LOW_ALARM, E-23: TANK_B_LOW_ALARM, E-24: TANK_S_LOW_ALARM, or E-29: TANK_C_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.

E-25: AUTO_DUMP_COMPLETE_ALARM

Cause Solution

A potlife alarm is active for more than 2 minutes, the gun

Be sure to spray all mixed material before potlife expires. flush box is enabled and gun is in the gun flush box, and an auto dump flush sequence is complete.

E-26: COLOR/CATALYST_PURGE_ALARM

Cause Solution

System detects no meter pulses, or a disruption in meter

Check that meter cable is connected. 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. Fuse F1, F2, or both are blown. Verify condition of fuses and replace if necessary. See

Repair-Parts manual.

E-29: TANK_C_LOW_ALARM (see above) E-30: OVERDOSE_C_ALARM (see page 81) E-31: DOSE_TIME_C_ALARM (see page 82)

88 313882C

Page 89

Alarm Troubleshooting

313882C 89

Page 90

Schematic Diagrams

System Pneumatic Schematic

AIR INPUT

PURGE AIR

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

AIR INPUT

CONTROL AIR

TO MANIFOLD 1/4 TUBE

AIR EXHAUST MUFFLER

4-WAY SOLENOID

3-WAY SOLENOID

12 VDC

AIR EXHAUST MUFFLER

12 VDC

COLOR CHANGE CONTROL

DOSE A

OPEN

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)

FLUSH AIR TO FLUID INLET 1/4 TUBE

MAC

36 SERIES SOLENOID VALVES

5/32 TUBE

OPEN

5/32 TUBE

OPEN

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

3-WAY SOLENOID

MANIFOLD

12 VDC

GFB 1 VALV E

5/32 TUBE

OPEN

(OPTIONAL)

GFB 2 VALV E (OPTIONAL)

90 313882C

Page 91

System Pneumatic Schematic

Schematic Diagrams

TO MANIFOLD 1/4 TUBE

AIR EXHAUST MUFFLER

4-WAY SOLENOID

3-WAY SOLENOID

12 VDC

COLOR CHANGE CONTROL

DOSE C

OPEN

5/32 TUBE

OPEN

VALV E

PURGE C VALV E

DUMP C VALV E (OPTIONAL)

MAC

36 SERIES SOLENOID VALVES

5/32 TUBE

COLOR VALV E STACKS

3RD COMP. 1

3RD COMP. 2

3RD COMP. 3

3RD COMP. 4

3RD COMP. SOLVENT

COLOR 13 (OPTIONAL)

COLOR 14 (OPTIONAL)

COLOR 15 (OPTIONAL)

COLOR 16 (OPTIONAL)

COLOR 17 (OPTIONAL)

COLOR 18 (OPTIONAL)

COLOR 19 (OPTIONAL)

COLOR 20 (OPTIONAL)

COLOR 21 (OPTIONAL)

COLOR 22 (OPTIONAL)

COLOR 23 (OPTIONAL)

COLOR 24 (OPTIONAL)

COLOR 25 (OPTIONAL)

MANIFOLD

313882C 91

Page 92

Schematic Diagrams

System Electrical Schematic

NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 3KS system. Some compo-

nents shown are not included with all systems.

Non-Hazardous Area

85-250

VAC

L1NGND

GND

PROMIX 2KS EASYKEY INTERFACE

TERMINAL

BLOCK

L1NGND

GND

LINE

FILTER

85-250 VAC

POWER

DC OK

SUPPLY

+24 VDC

COMMON

GND LUG

123

COMMON

POWER

ROCKER

SWITCH

121A1B2A

OPEN OPEN

UNUSED

12345

POWER HARNESS

UNUSED

BARRIER

BOARD

HARNESS

+12VDC I/S (RED)

123

COM (BLACK)

SHIELD

+24VDC

OPEN

123

MIX INPUT

PURGE INPUT

JOB COMPLETE INPUT

EXTERNAL CLR CHG READY

RESET ALARM INPUT

DIGITAL INPUT COMMON

RECIPE BIT 0 INPUT

12345

1234567

RJ45

ALARM

COMMON

1234

DISPLAY

BOARD

1234567891011J412345678910111213141516171819

RJ45

POWER DIST.

TERMINAL

BLOCKS

RJ45

RECIPE BIT 1 INPUT

RECIPE BIT 2 INPUT

RECIPE BIT 3 INPUT

RECIPE BIT 4 INPUT

RECIPE BIT 5 INPUT

RECIPE CHANGE INPUT

REMOTE

I/O

INTEGRATION

DIGITAL OUTPUT COMMON/POWER

PURGE/RECIPE CHG ACTIVE OUTPUT

MIX ACTIVE OUTPUT

MIX READY OUTPUT

FILL ACTIVE

1234567

BOARD

SHIELD

DIGITAL OUTPUT COMMON/POWER

SPECIAL OUTPUT #1

SPECIAL OUTPUT #2

FLOW CAL. ACTIVE

FLOW RATE ALARM OUTPUT

DIGITAL OUTPUT COMMON/POWER

12345

123456789

FLOW CONTROL CAL. (BLK)

GUN TRIGGER (WHT )

DIGITAL IN COMMON (RED)

REMOTE STOP (GRN)

123456789

SPECIAL OUTPUT #3

SPECIAL OUTPUT #4

DIGITAL OUTPUT COMMON/POWER

ALARM RESET (BRN)

ALARM OUTPUT (BLU)

DIGITAL OUTPUT COMMON (ORG)

POT LIFE (YEL)

FLOW RATE ANALOG IN (PUR)

FLOW RATE ANALOG COMMON (GRAY)

(+24) YEL

I/O HARNESSES

BEACON

(COM) GRAY

ORG

RED

BRN

TERMINAL

BLOCKS

12345

RS485 INTEGRATION A (WHT/BLU)

RS485 INTEGRATION B (BLU/WHT)

RS485 INTEGRATION GROUND (SHIELD)

12345

J10

RS485 NETWORK A (WHT/ORG)

RS485 NETWORK B (ORG/WHT)

RS485 NETWORK GROUND (SHIELD)

CABLE

WEB SERVER

RJ45

BULKHEAD

(25'-200' OPTIONS)

RJ45

MODULE

RJ45

FO IN (BLK)

FO OUT (BLU)

RJ45

MEMBRANE

SWITCH

WITH

RIBBON

CABLE

DISPLAY

92 313882C

Page 93

Schematic Diagrams

System Electrical Schematic

NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 3KS system. Some compo-

nents shown are not included with all systems.

Non-Hazardous Area

TO FO IN - J6

(BLK)

TO FO OUT - J4

(BLU)

TO J3

3RD COMPONENT

FLUID PANEL

HAZARDOUS

AREA

SMART FLUID PANEL

TO J10

CONTROL BOX

NON-HAZARDOUS

AREA

85-250

VAC

L1NGND

50' STD.

123

TERMINAL

BLOCK

GND LUG

POWER

ROCKER

123

121A1B2A

OPEN OPEN

NL1L1 NGND

12345

SWITCH

HARNESS

BARRIER

BOARD

123

85-250 VAC

POWER

SUPPLY

COMMON

+24 VDC

DC OK

PROMIX 3KS BARRIER/PS ENCLOSURE

(10'-100' OPTIONS)

+12VDC I/S (RED)

COM (BLACK)

SHIELD

+24VDC

OPEN

COMMON

123

POWER

HARNESS

313882C 93

Page 94

Schematic Diagrams

System Electrical Schematic

NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 3KS system. Some compo-

nents shown are not included with all systems.

Hazardous Area

TECNO

V/P

FLUID

PRESS.

SENS.

SIG (RED)

COM (BLK)

+ PRESSURE (GRN)

COM (RED)

EX+ (WHT)

- PRESSURE (BLK)

SHIELD (BARE)

12345

FLOW

CONTROL

BOARD

12345

10' STD.

V/P ANALOG OUT (WHT)

PRESS. (GRN)

+12 V (RED)

GND (BLK)

CHASSIS (BARE)

I.S. METERS

(25'-100' OPTIONS) - GREEN COLOR CODED

(10')/

(40')

12345

SMART FLUID PANEL

CONTROL BOX

BLUE

CABLE

HAZARDOUS

AREA

(50' STD.)/

DUMP B

MANIFOLD

BLACK

RED

65432

MH2

J10

+12VDC I/S

COM

SHIELD

123

(100' OPTION)

GFB #1

BLACK

RED

12 VDC

3-WAY SOLENOID

GFB #2

BLACK

RED

DUMP A 3RD FLUSH

BLACK

RED

BLUE

BLACK

RED

65432

J15

FO IN

FO OUT

(BLU)

CABLE

12 VDC

4-WAY SOLENOID

PURGE B

BLACK

65432

(BLK)

RED

PURGE A

BLACK

RED

YELLOW

J14

BLACK

12 VDC

DOSE B

GREEN

BLACK

65432

4-WAY SOLENOID

DOSE A

SIG

RED

BLACK

RED

12345678910

AIR FLOW SWITCH 1

50' STD.

(10'-100' OPTIONS) - RED COLOR CODED

SIG (WHITE)

SHIELD/GRN

PWR (RED)

FLOW METER B

COM (BLACK)

SIG (WHITE)

FLOW METER SOLVENT

SHIELD/GRN

PWR (RED)

COM (BLACK)

SIG (WHITE)

12345

J12

SHIELD/GRN

GROUND

TERMINAL

UNUSED

12345

J13

UNUSED

GRD (BLK)

UNUSED

32541

+12VDC (RED)

SHIELD (BARE)

CAN H (WHT)

CAN L (BLU)

J11

UNUSED

32541

UNUSED

FLOW METER A

3X CABLE

AIR FLOW SWITCH 2

SOLVENT FLOW SWITCH

GFB 2 PRESSURE SWITCH

GFB 1 PRESSURE SWITCH

PWR (RED)

COM (BLACK)

COM

SIG

COM

SIG

COM

SIG

COM

SIG

COM

12345

SMART

FLUID

PANEL

CONTROL

BOARD

NON-HAZARDOUS

AREA

PROMIX 2KS

EASYKEY

INTERFACE

TO FO OUT (BLU) - J8

PROMIX 3KS

PS & BARRIER

INTERFACE

TO FO IN (BLK) - J7

94 313882C

Page 95

Schematic Diagrams

System Electrical Schematic

NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 3KS system. Some compo-

nents shown are not included with all systems.

Hazardous Area

12 VDC

4-WAY SOLENOID

12 VDC

3-WAY SOLENOID

1 4 5 2 3

COLOR

J7/J11

BOARD 1

FLOW METER C

CABLE

PWR (RED)

COM (BLACK)

SIG (WHITE)

SHIELD/GRN

CLR 25

3RD COMP. 4

3RD COMP. 3

3RD COMP. 2

3RD COMP. 1

3RD COMP. SOLVENT

+12VDC

COM

65432

12345

+12VDC

CLR 15

COM

+12VDC

COM

+12VDC

J10

J14

COM

CLR 14

COM

+12VDC

COM

+12VDC

CLR 13

4 5 6 7 8

123456789

DIN RAIL MOUNTED

TERMINAL BLOCKS

UNUSED (BLK) -

METER SIG (WHT ) -

METER PWR (RED) -

METER COM (BLK) -

CLR 12

CAT 4

CAT 3

CAT 2

CAT 1

SOL CAT

+12VDC

COM

CLR 3

COM

65432

12345

+12VDC

COM

CLR 2

COM

+12VDC

J10

J14

+12VDC

CLR 1

COM

+12VDC

COM

+12VDC

SOL CLR

6' STD.

(BLUE COLOR CODED)

1 4 5 2 3

J7/J11

1 4 5 2 3

J7/J11

CLR 9

CLR 10

CLR 11

MANIFOLD

COM

+12VDC

COM

+12VDC

CLR 7

+12VDC

COM

+12VDC

CLR 6

65432

12345

+12VDC

COM

CLR 5

+12VDC

J16

J15

COM

+12VDC

CLR 4

COM

+12VDC

65432

(COLORS

1 THRU 12,

CATALYST

1 THRU 4)

12345

COM

+12VDC

MANIFOLD

CLR 8

CLR 22

CLR 23

CLR 24

MANIFOLD

COM

+12VDC

COM

+12VDC

COM

+12VDC

CLR 19

12345

+12VDC

CLR 18

+12VDC

65432

J16

J15

COM

+12VDC

CLR 17

+12VDC

COM

+12VDC

CLR 16

+12VDC

65432

COLOR

BOARD 2

(COLORS

13 THRU 30)

12345

COM

+12VDC

MANIFOLD

CLR 21

CLR 20

GROUND

TERMINAL

DOSE C "-" (GRN) -

DOSE C "+" (BLK) -

DOSE C

PURGE C

DUMP C

MANIFOLD

BLACK

RED

BLACK

RED

BLACK

RED

GRD (BLK)

+12VDC (RED)

SHIELD (BARE)

6' STD.

(10'-100' OPTIONS) - YELLOW COLOR CODED

32541

3RD COMPONENT

DUMP C "-" (YEL) -

PURGE C "-" (BLU) -

PURGE C "+" (BLK) -

DUMP C "+" (BLK) -

FLUID PANEL

32541

CAN H (WHT)

CAN L (BLU)

CAN

50' STD.

(6'-100' OPTIONS)

YELLOW COLOR CODED

ISOLATION

BOARD

BOOTH

CONTROL

32541

GRD (BLK)

+12VDC (RED)

32541

235

+12VDC (RED)

COM (BLK)

BOARD

SHIELD (BARE)

CAN H (WHT)

CAN L (BLU)

SHIELD (BARE)

313882C 95

Page 96

Schematic Diagrams

Power Supply Module Electrical Schematic

GND L1 N

RED 16 AWG BROWN 16 AWG

GRN/YEL 16 AWG

RED 16 AWG BROWN 16 AWG

TERMINAL BLOCKS

POWER ROCKER SWITCH

L L N N

HIGH

VOLTAGE

24 VDC+

OUTPUT

COMMON

24 VDC+

- - + DC OK

BLACK 18 AWG RED 18 AWG

J4-3 J4-2 J4-1

24 VDC+

POWER SUPPLY

UNUSED

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

UNUSED

COMMON (BLACK)

+12 VDC I/S (WHITE)

J5-3 J5-2 J5-1

SHIELD/GRND

GND LUG

IS POWER

12 VDC

BARRIER BOARD

96 313882C

Page 97

Technical Data

Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . Base system: 3000 psi (21 MPa, 210 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stage 1 (A:B): 0.1:1- 50:1*

Stage 2 (A+B:C): 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 . . . . . . . . . . . . . . .

3KS Fluid Station . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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) 1/4 npt(m)

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 flow rate, dose size, and meter resolution.

See individual component manuals for additional technical data.

313882C 97

Page 98

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.

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

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

Graco reserves the right to make changes at any time without notice.

Original instructions. This manual contains English. MM 313882

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441

www.graco.com

Revised June 2012

Graco 313882C User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Related Manuals

Equipment Approvals

System Configuration and Part Numbers

Accessories

Warnings

Glossary of Terms

Overview

Booth Control

EasyKey Display and Keyboard

EasyKey and 3KS Power Supply Module Connection Ports

Run Mode Screens

Setup Mode

System Operation

Meter Calibration

Color Change

Alarms and Warnings

Alarm Troubleshooting

Schematic Diagrams

Technical Data

Graco Standard Warranty

Graco Information