Graco 313882C User Manual

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

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

2 313882C

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

313882C 3

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

4 313882C

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

System Configuration and Part Numbers

6 313882C

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

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.

8 313882C

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

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

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

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

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.

313882C 13

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

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

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

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

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

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

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

Run Mode Screens

Press the Setup key to

enter Setup mode.

TI12783a

FIG. 9. Run Screens Map

313882C 21

Run Mode Screens

Status Screen

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

• Press the Setup key to enter the Setup screens from the Status screen.

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

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

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

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

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

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

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

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

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

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

+ 68 hidden pages