Graco 313885C User Manual

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Operation

ProMix

3KS

313885C

Plural Component Proportioner

Automatic 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

TI14826a

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

EasyKey Display and Keyboard . . . . . . . . . . . . . . 16

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

EasyKey and 3KS Power Supply Module

Connection Ports . . . . . . . . . . . . . . . . . . . . . . 17

EasyKey AC Power Switch . . . . . . . . . . . . . . . . 18

3KS Power Supply Module AC Power Switch . . 18

EasyKey I/S Power . . . . . . . . . . . . . . . . . . . . . . 18

3KS Power Supply Module I/S Power . . . . . . . . 18

EasyKey Potlife Exceeded Audible Alarm . . . . . 18

EasyKey Graco Web Interface Port . . . . . . . . . . 18

EasyKey Ethernet Connection . . . . . . . . . . . . . 18

Run Mode Screens . . . . . . . . . . . . . . . . . . . . . . . . 19

Splash Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Manual Override Screen . . . . . . . . . . . . . . . . . . 22

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

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

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

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

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

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

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

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

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

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

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

Recipe Setup Screens . . . . . . . . . . . . . . . . . . . 39

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

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

ProMix 3KS Integration Specifics . . . . . . . . . . . . 46

Discrete I/O vs Network Communications . . . . . 46

Discrete I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Automation Flow Charts . . . . . . . . . . . . . . . . . . 51

System Operation . . . . . . . . . . . . . . . . . . . . . . . . . 63

Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . 63

Sequential Dosing . . . . . . . . . . . . . . . . . . . . . . . 63

Recipe (Color) Change . . . . . . . . . . . . . . . . . . . 63

Flow Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Typical PLC Interaction with ProMix 3KS . . . . . 64

General Operating Cycle, Sequential Dosing . . 66

Mix Manifold Valve Settings . . . . . . . . . . . . . . . . 68

Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Pressure Relief Procedure . . . . . . . . . . . . . . . . 71

Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Color Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Color Change Procedures . . . . . . . . . . . . . . . . . 83

Color Change Sequences . . . . . . . . . . . . . . . . . 83

Alarms and Warnings . . . . . . . . . . . . . . . . . . . . . . 96

System Alarms . . . . . . . . . . . . . . . . . . . . . . . . . 96

System Warnings . . . . . . . . . . . . . . . . . . . . . . . 96

Alarm Troubleshooting . . . . . . . . . . . . . . . . . . . . . 97

Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . 108

System Pneumatic Schematic . . . . . . . . . . . . . 108

System Electrical Schematic . . . . . . . . . . . . . . 110

Power Supply Module Electrical Schematic . . 114

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Graco Standard Warranty . . . . . . . . . . . . . . . . . . 116

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 116

2 313885C

Related Manuals

Component Manuals in English

Manual Description

313881 ProMix 3KS Kit Installation 313883 ProMix 3KS Kit Repair-Parts 312778 ProMix 2KS Automatic System Installation 312779 ProMix 2KS Automatic System Operation 312780 ProMix 2KS Automatic 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 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

313885C 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 313885C

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: A Model with Flow Control has a maximum working pressure of 190 psi (1.31 MPa, 13.1 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],

and no flow control [Optional with ProMix 2KS Base Unit]) . . . . . . . . . . . . . . . . . . . .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)

Flow Control (Optional with ProMix 2KS Automatic Base Unit) . . . . . . . . . . . . . . . . . 190 psi (1.31 MPa, 13.1 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

313885C 5

System Configuration and Part Numbers

6 313885C

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

313885C 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 313885C

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

313885C 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 313885C

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.

313885C 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 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★

PS◆

PS★◆

CCM

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 313885C

6 ft (1.83 m) fluid hose (supplied)

3KS★

CCV★

MC★

3KM★

TI14826a

Component Description

Overview

EasyKey (EK)

★ 3KS Power Supply Module (PSM)

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.

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.

313885C 13

Overview

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)

Flow Control

Not shown. See ProMix 2KS manuals for details.

Regulator Assembly (FC)

Applicator

Not shown. See ProMix 2KS manuals for details.

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

14 313885C

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

313885C 15

EasyKey Display and Keyboard

LCD Display

IG. 4. 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 1.

Table 1: EasyKey Keypad Functions (see FIG. 4)

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.

16 313885C

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

Graco Web Interface

Discrete I/O Cable Connector Ports

TI12638a TI12657a

3KS Power Supply Module

AC Power Switch

Ground Screw

I/S Power to 3KS Panel

TI14366a TI14372a

FIG. 5. Connections and AC Power Switches

313885C 17

Main Power Access Port

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

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.

NOTE: If using the Graco Gateway in your system, disconnect its cable from the EasyKey before updating the ProMix 3KS software.

Alerts the user when a Potlife Exceeded alarm occurs.

Clear by pressing the Alarm Reset

key.

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.

18 313885C

Run Mode Screens

NOTE: See FIG. 8 for a map of the Run screens.

Detailed screen descriptions follow.

Splash Screen

At power up, the Graco logo and software revision will display for approximately 5 seconds, followed by the

Status Screen (see page 21).

Run Mode Screens

IG. 6. 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 man-

ual).

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. 7. Fluid Plate Programming Screen

313885C 19

Run Mode Screens

Press the Setup key to

enter Setup mode.

TI12802a

FIG. 8. Run Screens Map

20 313885C

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

IG. 9. Status Screen

Key to F

IG. 9:

Active Recipe: shows the active recipe.

NOTE: At power up the system defaults to Recipe

61, which is not a valid recipe number.

Potlife Timer: shows remaining potlife time in min-

utes. Two times are shown if there are two guns (manual or semi-automatic mode only).

Status Bar: shows current alarm or operation mode

(standby, mix, purge, recipe change, or the current alarm).

NOTE: If the auto key board is removed from the EasyKey display board, the Status Bar will read “Auto key not found.” This indicates that the automatic mode is not operable.

Target Flow Rate and 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 Scroll Arrows: displays the

current screen number and the total number of screens in a group. The Up and Down arrows on the right edge of the screen indicate the scroll feature. The total number of screens in some groups may vary depending on system configuration selections.

Current Flow Control Data: fluid output pressure

and percentage of analog signal range used for driving the fluid regulator V/P.

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, calcu-

lated 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, cal-

culated after each dose of C.

313885C 21

Lock Symbol: indicates that Setup screens are

password protected. See page 26.

Run Mode Screens

Manual Override Screen

IG. 10. Manual Override Screen

This screen will appear if Manual Override is set to “On” in Advanced Setup Screen 1 (page 35). It shows the active recipe, new/go to recipe, and manual override mode.

If Flow Control is set to “On” in Configure Screen 5 on page 31, this screen will also display Flow Rate Range, Flow Set Point, Flow Control Calibration (Start/Abort), and Global Flow Control Data Copy (Start/Abort).

Manual Override Menu

This field allows you to set the operating mode from the EasyKey. Press the Enter key to view the menu,

then select the desired operating mode (Standby, Mix, Purge, or Recipe Change). See F

IG. 11.

Flow Rate Range

This screen displays the flow rate range selected on

Advanced Setup Screen 5 (see page 37).

Flow Set Point

The Flow Set Point is user settable. If Flow Control Override is set to “Off” or “Pressure” in Advanced Setup Screen 1 on page 35, the Flow Set Point will display as cc/min. Enter the desired flow set point within the range.

If Flow Control Override is set to “% Open,” the Flow Set Point will display as % Open. This percentage relates to the flow control V/P ratio which translates to a fluid flow rate. Set the initial percentage at 35% and increase as necessary to reach the desired flow rate.

Flow Control Calibration

This field allows you to calibrate flow control for each recipe. The system must be in Mix mode and receiving a

Gun Trigger signal. Press the Enter key to view the menu, then select Start or Abort. See F

The flow rate will drop to 0, then incrementally increase until it reaches the maximum flow rate. To view the progress, go to the Status Screen, page 21. The system will populate the data for the current recipe. To copy this data to all recipes, see Global Flow Control Data

Copy, page 23.

IG. 12.

FIG. 12. Flow Control Calibration

IG. 11. Manual Override Menu

22 313885C

Run Mode Screens

Global Flow Control Data Copy

This field allows you to copy flow control data from the active recipe to all recipes. Press the Enter key to

view the menu, then select Start or Abort. See F

IG. 13. Global FC Data Copy

IG. 13.

Totals Screen

Reset Total Screen

FIG. 15. Reset Total Screen

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

Reset Solvent Screen

IG. 14. 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.

NOTE: Grand totals are not resettable.

IG. 16. Reset Solvent Total Screen

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

313885C 23

Run Mode Screens

Alarms Screens

IG. 17. Alarms Screen

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

IG. 19. If the tank volume reaches the low-level

See F 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.

Down

See Table 13 on page 96 for a list of alarm codes.

keys to scroll between the two screens.

Level Control Screen

IG. 18. 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).

FIG. 19. Tank Level Low Screen (Tank A Shown)

24 313885C

Setup Mode

Press the Setup key to enter Setup mode.

Press the Setup key to

enter Setup mode.

NOTE: See F

IG. 20 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 39.

To access System Configuration Screens,

page 28.

Press the Setup key to exit

Setup mode and return to the Status

FIG. 20. Setup Screens Map

screen.

This screen appears momentarily

if a password is activated.

TI12803a

313885C 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. 21. 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. 23. Set Up Home Screen

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

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

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

IG. 23 are only examples and may vary on your screen.

See Table 2 for further information.

on the Status Screen.

Setup Locked

IG. 22. Setup Locked Screen

26 313885C

Setup Mode

Table 2: 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.

313885C 27

Setup Mode

System Configuration Screens

NOTE: See FIG. 24 for a map of the System Configura- tion Screens. Detailed screen descriptions follow.

Automatic

NOTE: Each screen displays the current screen number and the total number of screens in the group.

IG. 24. System Configuration and Option Screens Map

TI12804a

28 313885C

Setup Mode

Configure Screen 1

IG. 25. 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.

NOTE: Be sure to write down the password and keep it in a secure location.

Configure Screen 2

FIG. 26. Configure Screen 2

Month

Enter current month.

Day

Enter current day.

Year

Enter current year (four digits).

Time

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

Display Units

Select the desired display units:

• cc/liter (default)

• cc/gallon

Date Format

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

313885C 29

Setup Mode

Configure Screen 3

Automatic

IG. 27. Configure Screen 3

Run Mode

Select the Run mode application from the pulldown menu: Automatic (default), Semi-Automatic (uses a manual spray gun), or Manual.

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.

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 available with ProMix 3KS.

IG. 29. 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).

Dump Valve C

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. 28. 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).

NOTE: Only 1 gun is used in automatic mode.

Gun Flush Box (manual or semi-automatic mode)

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

30 313885C

Setup Mode

Configure Screen 5

IG. 30. Configure Screen 5 FIG. 31. Configure Screen 6 (Automatic mode shown)

Flow Control

This field only appears if Run Mode is set to “Automatic” in Configure Screen 3, page 30. Select On or Off.

If set to “On,” Advanced Setup Screen 5, page 37 is added.

Special Outputs

Configure Screen 6

Flow Control

This field only appears if Run Mode is set to “Automatic” in Configure Screen 3, page 30. Select “Discrete” or “Network.”

Proportioning

Select “Discrete” or “Network.”

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

Solvent Monitor

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

Web Browser IP

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.

Gun 1 Trigger

Displays AFS if Run Mode is set to “Semi-automatic” in Configure Screen 3, page 30.

Select “Discrete” or “Network” if Run Mode is set to “Automatic” in Configure Screen 3, page 30.

Gun 2 Trigger Displays AFS if Number of Guns is set to “2” in Config-

ure Screen 4, page 30.

Control Network ID

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

313885C 31

Setup Mode

Option Screens

NOTE: See FIG. 24 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. 32. 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 40.

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. 33. 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 36-38.

If set to “Recipe”, Color/Catalyst Purge and Color/Catalyst Fill are added to Recipe Setup Screen 2, page 40. Recipe Setup Screen 3, 4, and 7 are added. See pages 41-42.

K-Factor Input

If set to “Global,” Advanced Setup Screen 4, page 37 is added.

If set to “Recipe,” Recipe Setup Screen 5, page 42, is added.

Minimum Material Fill Volume

Enter 0-9999 cc.

32 313885C

Option Screen 2

IG. 34. Option Screen 2

External Color Change

If set to “Off”, Color/Catalyst Purge Time and Color/Catalyst Fill Time appear in Advanced Setup Screen 1, page 35 or Recipe Setup Screen 2, page 40 (depending on whether Flush and Fill Inputs are set to “Global” or “Recipe”).

Setup Mode

If set to “On”, these fields are removed from the screens.

Auto Dump

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

Flow Rate Monitor

This field only appears if Flow Control is set to “Off” in Configure Screen 5, page 31.

If set to “On,” Recipe Setup Screen 6 on page 42 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 42 will not appear.

313885C 33

Setup Mode

Advanced Setup Screens

NOTE: See FIG. 35 for a map of the Advanced Setup Screens. Detailed screen descriptions follow.

Advanced Setup screens 2, 3, 4, and 8 appear depending on

selections made in Option

screens 1 and 2. Screen 5

appears if Flow Control is set

to “On” in Configure screen 5.

4 / 8

TI12805a

IG. 35. Advanced Setup Screens Map

34 313885C

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. 36. Advanced Setup Screen 1

Flow Control Override

This field only appears if Flow Control is set to “On” in Configure Screen 5 on page 31. The selections made will affect the display in Totals Screen on page 23.

Choose the desired selection as defined below:

Selection Description

Off Normal operation % Open Flow control regulator is opened to a

desired percentage.

Pressure Flow control regulator is opened to a

calibrated pressure.

Manual Override

This field only appears if Run Mode is set to “Automatic” or “Semi-automatic” in Configure Screen 3, page 30. Set to “On” to override all outside control. If selected, the

Totals Screen (page 23) will be added.

Gun 1/Gun2 Potlife Volume

Enter the potlife volume (1 to 1999 cc) for each gun. This is the amount of material required to move through the mix manifold, hose and applicator/gun before the potlife timer is reset.

Use the following information to determine approximate pot life volume (PLV) in cc:

Hose ID (inches) Volume (cc/foot)*

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.

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.

313885C 35

Setup Mode

Advanced Setup Screen 2

IG. 37. Advanced Setup Screen 2

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

Advanced Setup Screen 3

FIG. 38. 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.

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).

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).

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.

36 313885C

Setup Mode

Advanced Setup Screen 4

IG. 39. 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).

Advanced Setup Screen 5

IG. 40. Advanced Setup Screen 5 (Automatic Mode

F with Flow Control Only)

This screen appears only if Flow Control is set to “On” in

Configure Screen 5, page 31.

Flow Rate Range

Enter the flow rate range (0-300, 0-600, or 0-1200). This determines the flow control PID loop resolution.

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.

Flow Rate Tolerance

Enter the flow rate tolerance (1 to 99%). This is the percentage of variance that the system will allow before a flow rate warning/alarm occurs.

Flow Rate Ki

Enter the flow rate Ki (flow control PID loop integral value). This refers to the degree that fluid flow overshoots its set point.

Flow Rate Kp

Enter the flow rate Kp (flow control PID loop gain value). This refers to the speed at which the fluid flow reaches its set point.

Flow Rate Alarm Time

Enter the flow rate alarm time (1 to 99 seconds).

313885C 37

Setup Mode

Advanced Setup Screen 6

IG. 41. Advanced Setup Screen 6

This screen shows the status of recipe analog inputs and digital outputs. If box is shaded the input recipe is active.

Advanced Setup Screen 7

Advanced Setup Screen 8

FIG. 43. Advanced Setup Screen 8

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.

IG. 42. Advanced Setup Screen 7

This screen shows the status of digital inputs and digital outputs. If box is shaded the input is active. If not, input is off.

38 313885C

Recipe Setup Screens

NOTE: See FIG. 44 for a map of the Recipe screens. Detailed screen descriptions follow.

Recipe 0 Screens

Setup Mode

Recipe screens 3, 4, 5, 6, and

7 appear depending on

selections made in Option

screens 1 and 2

TI12787a

IG. 44: Recipe Screens Map

313885C 39

Setup Mode

Option Screens.

Recipe Setup Screen 1

IG. 45. 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. 46. 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).

40 313885C

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.

Setup Mode

Recipe Setup Screen 3

IG. 47. 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. 48. 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

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.

313885C 41

Setup Mode

Recipe Setup Screen 5

IG. 49. 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. 50. 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. 51. 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.

42 313885C

Recipe 0 Screens

Setup Mode

NOTE: See FIG. 44 on page 39 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. 53. Recipe 0 Screen 2

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

IG. 52. 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.)

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

Enter the first purge time (0 to 999 seconds) for components A and B in stage 1.

C First Purge Time

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 in stage 1.

Final Purge Time

Enter the final purge time (0 to 999 seconds) for components A and B in stage 1.

C Final Purge Time

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

313885C 43

Setup Mode

Recipe 0 Screen 3

IG. 54. 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. 55. 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.

44 313885C

Calibration Screen

IG. 56. 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”).

Setup Mode

• Start - start calibration

• Abort - stop calibration

• Purge - purge sampling valves after calibration

See Meter Calibration, page 81, for when and how to calibrate a meter.

313885C 45

ProMix 3KS Integration Specifics

Discrete I/O vs Network Communications

The ProMix 3KS Automatic system does not use a Booth Control. Instead, it uses Discrete I/O or Network Communications to drive the system. Each method can be used exclusively, or both at the same time.

In Automatic mode, the following fields can be set to “Discrete” or “Network” (see Configure Screen 6 on page 31):

• Flow Control

• Proportioning

• Gun 1 Trigger

NOTE: In Semi-automatic mode, only the Proportioning field is available,

NOTE: The Manual Override function enables you to operate the system before the automation (PLC) is available. Manual Override still requires some communication through Discrete I/O or Network Communications. Although Manual Override is not intended to be the main mode of control, it can be used if proper Gun Trigger Input is provided.

Discrete I/O

Discrete I/O requires a 24 Vdc power supply which must be supplied on site. The ProMix 3KS does not supply power for Discrete I/O.

See Table 3 on page 50, F 7 on page 60 for inputs and outputs. Understanding these inputs and outputs is necessary to properly integrate the ProMix 3KS to the automation.

Input and output connections are made at the Discrete I/O terminal strips (F (F

IG. 60) inside the EasyKey. Also see the System

Electrical Schematic on page 110.

Review the Color Change Charts (F understanding of the color change sequence is necessary to properly drive the inputs and monitor the outputs.

See Advanced Setup Screen 7, page 38. This screen shows the actual status of all inputs and outputs. It is important to ensure that each input from local automation (PLC) is received by the EasyKey and to verify that the ProMix 3KS is sending outputs to the automation.

The following paragraphs describe each discrete I/O function in detail.

IG. 66 on page 59, and Table

IG. 59) and the discrete I/O board

IG. 79-FIG. 88). A full

Display Board Barrier Board

Discrete I/O Board (see FIG. 60)

IG. 57: EasyKey Control Boards

46 313885C

Terminal Strips (see F

IG. 59)

TI12496a

Multiple Station

GND

TI12923a

Integration Control

ProMix 3KS Integration Specifics

RT1

FIG. 58: 255767 EasyKey Display Board

Analog In Common

Analog In Signal

Reset Alarm

Remote Stop

Potlife Alarm

Output Common

General Alarm

Gun Trigger

Input Common

Flow Control Calibrate

TI12924a

313885C 47

ProMix 3KS Integration Specifics

Digital Inputs

See Automation Flow Charts, pages 51-55.

Mix Start: This is a maintained input. When High, the

ProMix 3KS will attempt to enter Mix mode. This Mix Start input should not be attempted unless the Mix_Ready output is recognized. This ensures that there are no alarms and that the Mix Start input is appropriate.

This input stays High at all times when mixing on demand is required. When Low, the intent is to stop mixing material and perform a purge or recipe change.

Do not toggle this input to set the unit to Standby mode during short work stoppages. The ProMix 3KS will automatically go into Idle mode after 2 minutes of inactivity. When a Gun Trigger input is seen, the ProMix 3KS will automatically leave Idle mode and resume mixing material where it left off.

Purge Start: This is a maintained input. When recog- nized by the ProMix 3KS, the Purge Sequence will start, using the Purge Time from the active recipe. This will also include the Solvent Fill Time. Proper monitoring of the Purge/Color Change Output is required to ensure this function has begun. Once this output is removed, the system will immediately go to Standby mode.

Gun Trigger: When High, this input signals the ProMix 3KS that the gun is actually triggered. It should be sent every time the gun is triggered. This input provides timing for alarm functions and also drives the flow control functions. Without it, no flow control functions will start.

Job Complete: This is a momentary input, 100 msec minimum. When recognized by the ProMix 3KS, the Job totals are cleared and a time/date stamp is added for retrieval.

Remote Stop: Use this input when external equipment is used to stop the system. Clear any alarms before using this input. For more information about when this input is needed, contact your Graco distributor.

Alarm Reset: This is a momentary input, 100 msec minimum. When recognized by the ProMix 3KS it clears any active alarms and allows the automation to take the next step.

Common: This is not an input, but the ProMix 3KS expects to have the COM side of the 24 Vdc supply connected as shown in Table 7. This ensures proper opera-

tion of each input and output.

I/O Terminal Strip Detail

Color Change Start: This is a momentary input, 100

msec minimum. When recognized by the ProMix 3KS, the Color Change sequence will begin, starting at the Color/Catalyst Dump.

NOTE: If the new recipe has the same color as the active recipe, then the Color/Catalyst Dump and Color/Catalyst Fill times are skipped and the Color Change Sequence starts with the Purge. Also, the recipe bit configuration for the Color Change must be loaded at least 100 msec before the Color Change Start input is turned on. The recipe bit configuration must remain on while the Color Change Start input is removed. Graco recommends the recipe bits stay active and do not change until a new color is required. The PLC should monitor the Purge/Color Change Output as well as the Fill Active Output to ensure the process happens as required. A complete color change without errors (resulting in a Mix Ready Output state) is a completed color change.

NOTE: This also applies if using the Modbus Registers (see the Modbus Map table in manual 312785).

Pin 1

IG. 59: EasyKey Terminal Strips

RS485 Integration A RS485 Integration B

RS485 Integration Ground RS485 Network A RS485 Network B RS485 Network Ground

Flow Control Calibrate Gun Trigger Digital Common Remote Stop Alarm Reset General Alarm Digital Common Potlife Alarm Flow Rate Analog In Flow Rate Analog Common

INPUTS

OUTPUTS

TI12958a

48 313885C

ProMix 3KS Integration Specifics

JLS

Digital Output

Common/Power

Special Output #4

Special Output #3

Special Output #2

Digital Output

Special Output #1

Common/Power

Digital Output Common/Power

Flow Rate Alarm Output

Flow Control Calibrate Active

Fill Active

Mix Ready Output

Mix Active Output

Purge/Recipe Change Active Output

Digital Output Common/Power

Recipe Change Input

Recipe Bit 5 Input

Recipe Bit 4 Input

FIG. 60: 255766 Discrete I/O Board

Mix Input

Purge Input

Spare

Job Complete Input

External Color Change Ready

Recipe Bit 3 Input

Recipe Bit 2 Input

Recipe Bit 1 Input

Recipe Bit 0 Input

Digital Input Common

313885C 49

ProMix 3KS Integration Specifics

Digital Outputs

See Automation Flow Charts, pages 51-55.

Purge_CC_Active: This output will remain High during

the manual Purge or Color Change purge sequence. See the Color Change Charts (F ther information.

Fill_Active: This output will remain High while the ProMix 3KS is in the Mixed Material Fill at the end of a typical color change sequence.

Mix_Active: This output will remain High while the ProMix 3KS is in Mix mode. There may be alarm outputs while this output is High; these are typically High/Low Flow Warnings. Always monitor this output and the alarm outputs to provide feedback of the actual status of the ProMix 3KS. (See the Modbus Charts in the Graco Gateway manual 312785.)

Mix_Ready: This output will remain High while there are no alarms and the ProMix 3KS is ready to go to Mix mode.

General Alarm: This output will remain High when any alarm is active. See Table 13 on page 96 for a complete list of alarms.

IG. 79-FIG. 88) for fur-

Analog Inputs

Flow Command: This is the positive side of the 0 – 10

Vdc signal. (See Common under Digital Inputs, page

48.) This input corresponds to the Flow Range setting in Advanced Setup Screen 5, page 37. For example, if the setting is 0 – 300 cc/min, the 0 Vdc analog input is 0 cc/min, therefore the 10 Vdc analog input is 300 cc/min.

Table 3: Sourcing/Sinking Inputs and Outputs

Inputs (Automation Sourcing) 1 Flow Control Calibration Black + 2 Gun Trigger White + 3 Digital In Common Red - 4 Remote Stop Green + 5 Alarm Reset Brown +

Outputs (Automation Sourcing) 6 Alarm Output Blue + 7 Digital Out Common Orange - 8 Pot Life Yellow +

Outputs (Automation Sinking)

NOTE: It is important to monitor this output along with

Mix_Active to understand the alarm’s true meaning.

Alarm_Potlife: This output will remain High along with the Alarm output when the potlife time has been reached for the active recipe. The Mix_Active output will drop Low, even if the Mix_Start input is High. This output will remain High until the potlife volume is dispensed or the ProMix 3KS completes a Purge or a Color Change. The Alarm Reset input will not stop this output but will silence the audible alarm on the EasyKey.

NOTE: The Alarm Reset audible alarm.

To dispense the potlife volume, the ProMix 3KS Mix_Start input must be turned Off then back to High to spray material. At this point, Mix_Active, Alarm, and Alarm_Potlife outputs will be High until the potlife volume is sprayed.

Digital Out Supply: This is the supply for the digital outputs. It is the same supply for the digital inputs. (See

Common under Digital Inputs, page 48.)

key will also reset the

6 Alarm Output Blue - 7 +24 Volts Orange + 8 Pot Life Yellow -

Automation 9 Flow Rate Analog In Purple + 10 Flow Rate Analog Common Gray -

50 313885C

Automation Flow Charts

Start Mix Mode Process

See FIG. 61, Table 4, and Table 5.

ProMix 3KS Integration Specifics

Start Mix

Mode Process

YESNO

Is Mix Ready

bit = 1?

Must be Alarm Condi-

tion or Active Recipe

61. See Alarm Pro-

cessing on page 55,

or Startup from Recipe

61 (see NOTE below)

NOTE: 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).

Set Mix bit = 1

Is Mix Active

bit = 1?

YES

ProMix 3KS in Mix

Mode (Complete)

Mix Active = 1 while

the ProMix 3KS is in

Mix mode

IG. 61. Start Mix Mode Process Flow Chart

313885C 51

ProMix 3KS Integration Specifics

Mixing Mode Process

See FIG. 62, Table 4, and Table 5.

Mixing Mode

Process

Mixing Mode is desired. PLC is polling to ensure

Mixing Mode is main-

tained.

Check Alarm

Condition: is Alarm_

General bit = 1?

YES

Is Mix Active

bit = 1?

YESNO

Mixing Process active

Go to Start Mix Mode

Process, page 51

Go to Alarm Process-

ing, page 55

IG. 62. Mixing Mode Process Flow Chart

52 313885C

Purge Mode Process

See FIG. 63, Table 4, and Table 5.

ProMix 3KS Integration Specifics

Start

Must be Alarm

Condition or Active

Recipe 61. See

Alarm Processing

on page 55, or

Startup from Recipe

61 (see NOTE below).

Is Mix Ready

bit = 1?

YESNO

Set Purge bit = 1?

Is Purge_CC_Active

bit = 1?

YES

NOTE: 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).

IG. 63. Purge Mode Process Flow Chart

313885C 53

(Wait for Mix Ready)

Is Mix Ready

bit = 1?

YES

ProMix 3KS in

Purge_CC Mode

(Process Started)

ProMix 3KS Purge

Process (Complete)

ProMix 3KS Integration Specifics

Color Change Mode Process

See FIG. 64, Table 4, and Table 5.

Color Change

Process

(basic)

Do nothing. Spraying at

desired recipe.

Ensure Color-

Change bit is seen

by ProMix 2KS

YES NO

Is Active Recipe =

to desired recipe?

(Register 40005).

Purge_CC_Active

bit = 1?

YES

(Wait for Mix Ready)

Clear ColorChange (CC)

Load ccNewRecipe

(Register 40046) with

recipe number to Color

Change to (0 through

60 is valid).

Set ColorChange (CC)

bit = 1.

bit (momentary input).

CC process started.

Is Mix Ready

bit = 1?

IG. 64. Color Change Mode Process Flow Chart

54 313885C

Check Alarm

Condition: is Alarm_

General bit = 1?

YES

Process Alarm. See Alarm Processing,

page 55.

ProMix 3KS Color

Change Process

(Complete)

Alarm Processing

See FIG. 65, Table 4, Table 5, and Table 6.

ProMix 3KS Integration Specifics

Alarm Processing

An Alarm Condition

has been found

previously.

Alarm_General = 1.

Determine the exact alarm

from Table 6 on page 58

and solve what caused the

alarm, as required.

Reset the alarm.

Reset_Alarm = 1.

NO YES

Is Mix Ready

bit = 1?

Check if Potlife

Alarm: is Alarm_

Potlife bit = 1?

YESNO

Two options:

• Purge or Color Change to remove mixed material in the line.

• Place in Mix mode and spray the Potlife Volume set in the ProMix 2KS.

NOTE: The Reset key only silences the alarm. To clear the alarm you must use one of these two options.

Go to next process,

as desired.

IG. 65. Alarm Processing Flow Chart

313885C 55

ProMix 3KS Integration Specifics

Table 4: ProMix 3KS Digital Inputs (Modbus Register 40040)

Bit Digital Input Binary Name Details

0:5 0000000000XXXXXXRecipe Binary bits for viewing discrete inputs only. 6 000000000

1000000Color Change

Set bit to “1” to initiate Color Change (momentary)

(CC) 7 00000000 8 0000000

10000000Mix Set bit to initiate Mix mode (maintain)

100000000Purge Set bit to “1” to initiate Purge sequence (maintained)

9 0000001000000000Job_Complete Set bit to “1” to initiate Job Complete input (momen-

tary)

10 0000010000000000External CC

Ready

Set bit to “1” to initiate External Color Change

(momentary) 11 0000100000000000Not Used 12 0001000000000000FC _Calibrate Set bit to “1” to initiate a Flow Control Calibrate input

(momentary) 13 0010000000000000Gun_Trigger Set bit to “1” to indicate the gun is actually triggered

(maintain while gun is triggered, remove when gun is

closed) 14 0

100000000000000Reset_Alarm Set bit to “1” to clear an active Alarm (momentary)

15 1000000000000000Remote Stop Set bit to remotely stop unit (momentary)

NOTE: Shaded cells relate to the flow charts on pages 51-55.

56 313885C

Table 5: ProMix 3KS Digital Outputs (Modbus Register 40041)

Bit Digital Input Binary Name Details

ProMix 3KS Integration Specifics

0 000000000000000

1 Purge_CC_Active “1” indicates Purge or Color Change is in prog-

ress 1 00000000000000 2 0000000000000

10Mix_Active “1” indicates Mix is in progress

100Mix_Ready “1” indicates No Alarms and OK to Mix

3 0000000000001000CC_Fill_Active “1” indicates the Fill portion of a Color Change is

in progress 4 0000000000010000FCalActive “1” indicates the Flow Control Calibrate routine is

in progress 5 0000000000100000Flow_Rate_Alarm “1” indicates the Flow Rate Alarm/Warning is

active 6 0000000001000000Special_1 “1” indicates the Special_1 output is on (monitor

only) 7 0000000010000000Special_2 “1” indicates the Special_2 output is on (monitor

only) 8 0000000100000000Special_3 “1” indicates the Special_3 output is on (monitor

only) 9 0000001000000000Special_4 “1” indicates the Special_4 output is on (monitor

only) 10 0000010000000000Not Used 11 0000100000000000Not Used 12 0 0 0

1000000000000Alarm_General “1” indicates a General Alarm is in process. (If

Mix_Active is still High, then a Warning only.) See

the Modbus charts in the Graco Gateway manual

312785 for details on type. 13 0010000000000000Alarm_Potlife “1” indicates a Potlife Alarm is in process.

NOTE: Shaded cells relate to the flow charts on pages 51-55.

313885C 57

ProMix 3KS Integration Specifics

Table 6: ProMix 3KS Active Alarms (Modbus Register 40010)

Bit Digital Input Binary Name Details

Low Byte: 0 0000 0000 0000 0000 No Bits Set No Active Alarms Low Byte: 0 0000 0000 0000 0001 Comm_Error Low Byte: 0 0000 0000 0000 0010 Potlife_Alarm Low Byte: 0 0000 0000 0000 0100 Ratio_High_Alarm Low Byte: 0 0000 0000 0000 1000 Ratio_Low_Alarm Low Byte: 0 0000 0000 0001 0000 Overdose_A_Alarm Low Byte: 0 0000 0000 0010 0000 Overdose_B_Alarm Low Byte: 0 0000 0000 0100 0000 Dose_Time_A_Alarm Low Byte: 0 0000 0000 1000 0000 Dose_Time_B_Alarm Low Byte: 0 0000 0001 0000 0000 Mix_In_Setup_Alarm Low Byte: 0 0000 0010 0000 0000 Remote_Stop_Alarm Low Byte: 0 0000 0100 0000 0000 Purge_Volume_Alarm Low Byte: 0 0000 1000 0000 0000 CAN_Comm_Error_Alarm Low Byte: 0 0001 0000 0000 0000 High_Flow_Alarm Low Byte: 0 0010 0000 0000 0000 Low_Flow_Alarm Low Byte: 0 0100 0000 0000 0000 System_Idle_Alarm Low Byte: 0 1000 0000 0000 0000 Setup_Change_Alarm High Byte: 0 0000 0000 0000 0001 Power_On_Alarm High Byte: 0 0000 0000 0000 0010 Defaults_Loaded_Alarm High Byte: 0 0000 0000 0000 0100 IO_Alarm High Byte: 0 0000 0000 0000 1000 Purge_Initiate_Error High Byte: 0 0000 0000 0001 0000 Material_Fill_Alarm High Byte: 0 0000 0000 0010 0000 Tank_A_Low_Alarm High Byte: 0 0000 0000 0100 0000 Tank_B_Low_Alarm High Byte: 0 0000 0000 1000 0000 Tank_S_Low_Alarm High Byte: 0 0000 0001 0000 0000 Auto_Dump_Complete High Byte: 0 0000 0010 0000 0000 Color/Catalyst_Purge_Alarm High Byte: 0 0000 0100 0000 0000 Color/Catalyst_Fill_Alarm High Byte: 0 0000 1000 0000 0000 Num_Alarm_Desc High Byte: 0 0001 0000 0000 0000 Tank_C_Low_Alarm High Byte: 0 0010 0000 0000 0000 Overdose_C__Alarm High Byte: 0 0100 0000 0000 0000 Dose_Time_C_Alarm High Byte: 0 1000 0000 0000 0000 Potlife_Buzzer

58 313885C

ProMix 3KS E

asyKey

PLC Output

Digital Input

ProMix 3KS Integration Specifics

(Sourcing)

Input Common

ProMix 3KS EasyKey

Digital Output

Output Common

24 Vdc

Output

CommonInput

PLC Input

(Sinking)

Input

ProMix 3KS EasyKey

Digital Output

Output Common

Output

FIG. 66. Automation 24 Vdc Sourcing Input Diagram

24 Vdc

CommonOutput

PLC Input

(Sourcing)

Input

Common

313885C 59

ProMix 3KS Integration Specifics

Table 7: Discrete I/O Terminal Connections

Terminal Terminal Location Name Details (also see pages 56 and 57)

Digital Inputs

1 J2, Remote I/O Board Mix Set Bit to Initiate Mix Mode (maintain) 2 J2, Remote I/O Board Purge Set Bit to “1” to initiate Purge Sequence

(maintained)

3 J2, Remote I/O Board Job_Complete Set Bit to “1” to initiate Job Complete Input

(momentary)

4 J2, Remote I/O Board External CC Ready Set Bit to “1” to initiate External Color

Change (maintained) 5 J2, Remote I/O Board Spare 6* J2, Remote I/O Board Digital Input Common

1* J3, Remote I/O Board Digital Input Common 2 J3, Remote I/O Board Recipe Bit 0 Set Binary Bits for Recipe to Change To (hold

until changing again) 3 J3, Remote I/O Board Recipe Bit 1 Set Binary Bits for Recipe to Change To (hold

until changing again) 4 J3, Remote I/O Board Recipe Bit 2 Set Binary Bits for Recipe to Change To (hold

until changing again) 5 J3, Remote I/O Board Recipe Bit 3 Set Binary Bits for Recipe to Change To (hold

until changing again) 6 J3, Remote I/O Board Recipe Bit 4 Set Binary Bits for Recipe to Change To (hold

until changing again) 7 J3, Remote I/O Board Recipe Bit 5 Set Binary Bits for Recipe to Change To (hold

until changing again) 8 J3, Remote I/O Board Color Change (CC) Set Bit to “1” to initiate Color Change

(momentary)

1 10 Pin Terminal Block Flow Control Calibrate Set Bit to “1” to initiate Flow Control Calibrate

(momentary) 2 10 Pin Terminal Block Gun Trigger Set Bit to “1” to indicate Gun is Triggered

(fluid flow expected) 3† 10 Pin Terminal Block Digital Input Common 4 10 Pin Terminal Block Remote Stop Set Bit to “1” to initiate a Remote Stop

(momentary) 5 10 Pin Terminal Block Reset_Alarm Set Bit to “1” to Clear an Active Alarm

(momentary) * Digital inputs tied together on the I/O board (see F † Digital inputs tied together on the EasyKey Display Board (see F

IG. 60).

IG. 58).

Multiple connection points for convenience.

60 313885C

ProMix 3KS Integration Specifics

Table 7: Discrete I/O Terminal Connections

Terminal Terminal Location Name Details (also see pages 56 and 57)

Digital Outputs

1★ J4, Remote I/O Board Digital Output Common/Power 2 J4, Remote I/O Board Purge_CC Active “1” Indicates Purge or Color Change is in

progress 3 J4, Remote I/O Board Mix_Active “1” Indicates Mix is in progress 4 J4, Remote I/O Board Mix_Ready “1” Indicates No Alarms and OK to Mix 5 J4, Remote I/O Board CC_Fill_Active “1” Indicates the Fill Portion of a Color

Change is in progress 6 J4, Remote I/O Board FCalActive “1” Indicates the Flow Control Calibrate rou-

tine is in progress 7 J4, Remote I/O Board Flow_Rate “1” Indicates the Flow Rate Alarm/Warning is

active 8★ J4, Remote I/O Board Digital Output Common/Power

1★ J5, Remote I/O Board Digital Output Common/Power 2 J5, Remote I/O Board Special_1 “1” Indicates the Special_1 Output is on 3 J5, Remote I/O Board Special_2 “1” Indicates the Special_2 Output is on 4 J5, Remote I/O Board Special_3 “1” Indicates the Special_3 Output is on 5 J5, Remote I/O Board Special_4 “1” Indicates the Special_4 Output is on 6★ J5, Remote I/O Board Digital Output Common/Power

6 10 Pin Terminal Block General Alarm Output “1” Indicates the General Alarm Output is on 7◆ 10 Pin Terminal Block Digital Output Common/Power 8 10 Pin Terminal Block Potlife Alarm “1” Indicates the Potlife Alarm Output is on 9 10 Pin Terminal Block Flow Rate Analog In (0-10

VDC)

0 - 10VDC input for Flow Setpoint relative to

flow range set in 2KS Flow Range Screen 10 10 Pin Terminal Block Flow Rate Common to Pin 9 Common side of Flow Setpoint from Terminal

Communications

1 6 Pin Terminal Block RS485 Integration A 2 6 Pin Terminal Block RS485 Integration B

Communication to External PLC/Controller 3 6 Pin Terminal Block RS485 Integration

Shield/Ground

4 6 Pin Terminal Block RS485 Network A

Communication to Multiple EasyKeys only5 6 Pin Terminal Block RS485 Network B 6 6 Pin Terminal Block RS485 Network Shield/Ground

★ Digital outputs tied together on the I/O board (see F

◆ Digital outputs tied together on the EasyKey Display Board (see F

IG. 60).

IG. 58).

Multiple connection points for convenience.

313885C 61

ProMix 3KS Integration Specifics

Table 8: ProMix 3KS Recipe Bits

Recipe Bits Number Recipe Bits Number

543210 543210

000000 0 100001 33 000001 1 100010 34 000010 2 100011 35 000011 3 100100 36 000100 4 100101 37 000101 5 100110 38 000110 6 100111 39 000111 7 101000 40 001000 8 101001 41 001001 9 101010 42 001010 10 101011 43 001011 11 101100 44 001100 12 101101 45 001101 13 101110 46 001110 14 101111 47 001111 15 110000 48 010000 16 110001 49 010001 17 110010 50 010010 18 110011 51 010011 19 110100 52 010100 20 110101 53 010101 21 110110 54 010110 22 110111 55 010111 23 111000 56 011000 24 111001 57 011001 25 111010 58 011010 26 111011 59 011011 27 111100 60 011100 28 011101 29 011110 30 011111 31 100000 32

62 313885C

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 83-95.

Flow Control

Flow control is an optional feature of the ProMix 3KS automatic system. Flow control regulates the flow of material to a manual or automatic air spray gun, to help ensure adequate coverage and avoid sags or runs in the finish coat. It is not for use with air-assisted or airless spray guns.

See F

IG. 67. The flow regulator (FC) is required to use

flow control in your system. Connect the fluid inlet and outlet lines, air line, and cable as shown.

Set Flow Control to “On” in Configure Screen 5 on page 31. Make the desired selections in Advanced Setup Screen 5, page 37.

See the Graco Gateway manual 312785 for Flow Control Modbus addresses.

Fluid Inlet from

Fluid Station

Cable from

Fluid Station

FIG. 67. Flow Control Regulator

Air Line from Fluid Station

Fluid Outlet to Gun

TI13656a

313885C 63

System Operation

Typical PLC Interaction with ProMix 3KS

This section describes a typical interaction when a local PLC is directly connected to the Discrete I/O connections of the ProMix 3KS.

See ProMix 3KS Integration Specifics on page 46 for a detailed explanation of inputs and outputs.

NOTE: Communications fields of Configure Screen 6 must be set to DISCRETE (see page 31).

Start Mixing

To start the mix process, the PLC will monitor and ensure the Mix_Ready output is High. This provides assurance it is ready to mix. PLC will drive High the Mix_Start input, keep it High and monitor the Mix_Active output to ensure the ProMix 3KS followed through on the request.

Stop Mixing

To stop mixing (to perform a purge or color change), remove the Mix_Start input (the status bar on the EasyKey will show STANDBY). Monitor the Mix_Ready output to ensure the Mix_Active output goes Low.

Color Change

To perform a color change, ensure there are no alarms (except the Potlife Alarm). If alarms are present, the Alarm_Reset input should be sent momentarily to clear the alarm (>100 msec).

During the short On state, the recipe will be read from this binary sequence and the status bar of the EasyKey will display COLOR CHANGE XX. The Purge_CC_Active output will be High for the duration of the color change purge process. During the Mixed Material Load portion at the end of the Color Change sequence, the Fill_Active output will be on, indicating that portion of the color change. These will not be on at the same time. Once the Mix_Ready output goes High with no alarms, then the PLC has assurance that the requested color change has taken place with the requested recipe being the current active recipe. If any error occurs during the process, the requested recipe will not be loaded, and the old recipe will remain active.

NOTE: It is not possible to read the active recipe through Discrete I/O alone. Only by monitoring networked registers through the Gateway is it possible to view the active recipe. Proper management of the alarm status outputs during the color change process will ensure the active recipe is what is expected.

Purge

To start a Purge (no color change), drive the Purge_Start input High (maintained) while ensuring Mix_Ready output is High (ensuring no active alarms). An exception is Potlife alarm (see Color Change above if alarms are present.) The Purge_CC_Active output is High for the entire Purge process. Ensure there are no alarms during this process. Fill_Active is High when Mix is on. When complete, Mix _Ready output will be High, indicating a completed purge.

NOTE: No change is made to the active recipe.

NOTE: Alarm_Reset will not reset a Potlife alarm. Only

dispensing the Potlife Volume or a complete Purge/Color Change will reset a Potlife alarm.

The Alarm Reset Input will silence the audible alarm. Turn the Color_Change_Start input on momentarily (>100 msec) while the proper sequence of recipe bits are set.

NOTE: The Recipe Bits must be presented at least 100 msec before the Color Change Start input is turned on and remain until a new recipe is required.

64 313885C

Gun Trigger Input

This input is sent and expected every time the gun is actually triggered, and this input is turned off when the gun is not triggered. Never tie this input with any other signal. Without this input, some critical mixing alarms are eliminated. This input should be provided through Discrete I/O only for flow control applications to ensure fast coordination with the flow control process. Applications without integrated flow control can use Gun Trigger input through Network Communications or Discrete I/O.

NOTE: This has the same effect as the air flow switch used on manual ProMix 3KS systems.

System Operation

Alarm Monitoring/Reset (Discrete I/O)

Anytime an alarm occurs, the Alarm Reset input will reset the alarms and allow for processing of the next step by automation, except for the following condi-

tions:

• Potlife Alarms cannot be reset by the Alarm Reset

input or through the EasyKey Alarm Reset key. Only a Purge/Color Change or spraying the Pot-

life volume will reset a Potlife alarm. (See Alarm_Potlife output information on page 50.)

• When Flow Control is turned on (see Configure Screen 5 on page 31), the Flow_Rate_Alarm output will be High when the instantaneous flow rate is above or below the Flow Rate tolerance setting. (High Flow or Low Flow will be the condition, indicating in the status bar of the EasyKey.) This output will be High along with the Mix_Active output. The PLC should monitor the amount of time this condition exists and take action at a predetermined time. With Flow Control there will be times (for example during flow rate changes) where the general alarm as described here will be High (typically momentarily). The PLC must read this Alarm output (i.e. general alarm), see if Mix_Active is still High, and if so, start a timer. A typical example would be to ensure all parts are sprayed within a specific flow rate range. A maximum predetermined time would be set to allow a Low or High flow condition to exist continuously.

• Shutdown or go to Standby after the flow rate alarm time expires.

Job_Complete Input

For Applications with Dump Valves (for quick purges/color changes at or near the gun):

ProMix 3KS has four specials that can each be turned off and on twice throughout a color change sequence. See Advanced Setup Screen 8 on page 38 or Recipe Setup Screen 7 on page 42.

For example, a dump valve at a gun on a robot could be opened at the appropriate times to facilitate fast color changes. Another output could be used to automatically drive an air-operated fluid regulator High during the Purge or Color Change process.

NOTE: With integrated Flow Control, the flow control regulator automatically is driven High. See Advanced Setup Screen 5 on page 37 for specifics on setting up these values. Each of the specials can be monitored, but can only be controlled through the times entered within the setup screens of the EasyKey or by managing the proper registers on the network.

The following ProMix 3KS inputs should never be on (High) at the same time:

•Mix_Start

• Purge_Start

• Color_Change_Start

The Recipe Bits (0-6) are always on at the same time. The only time these bits are recognized is when the Color_Change_Start input is High. The Recipe Bits should be loaded and stay loaded for the current recipe. Do not change the Recipe Bits until a color change is required again. Inconsistent results are possible if this is not followed.

Every time a momentary Job_Complete input is seen by the ProMix 3KS, a job log will be recorded, logging the A, B, and C meter volumes (cc) with a time and date stamp. The volumes will then be reset to 0. (Volume totals are accumulated since the last reset.)

NOTE: A Color Change accomplishes the same Job Complete Reset functions. The Job_Complete input is commonly used to record material usage for a specific set of parts. These volumes are sprayed material volumes.

313885C 65

System Operation

General Operating Cycle, Sequential Dosing

1. The system enters and loads the desired color.

2. The system enters Mix mode 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 Trigger input is seen.

Stage 1 (see FIG. 68, 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.

f. When the target volume is dispensed, Dose

Valve A closes.

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. 68, 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).

NOTE: To control output from the 3KS static mixer to the gun, install an optional fluid pressure regulator.

NOTE: The dispense volume of components A and B is based on the mix ratio and dose size set by the user and calculated by the 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.

Table 9: Sequential Dosing Operation

Dose 1 Dose 2

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

Stage 1 (A:B)

10. Components A+B and C are alternately fed into the 3KS integrator as long as the Gun Trigger input is seen.

11. If the Gun Trigger input is not seen for two minutes, the system switches to Idle mode, which closes off the mix manifold dose valves.

12. When the Gun Trigger input is seen again, the ProMix 3KS continues the process where it left off.

NOTE: Operation can be stopped at any time by going to Standby mode (remove Mix input).

Stage 2

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

Stage 2

(A+B):C

66 313885C

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

313885C 67

System Operation

Mix Manifold Valve Settings

To open dose or purge valves, turn hex nut (E) counterclockwise. To close, turn clockwise. See Table 10 and

IG. 69.

TI11581a

IG. 69. Valve Adjustment

Table 10: Mix Manifold Valve Settings

Valve Setting Function

Dose (see F

IG. 69)

Purge (see F

IG. 69)

Shutoff (SVA and SVB, see F

IG. 68)

Sampling (RVA and RVB, see F

IG. 68)

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

Fully open during Run/Mix operation

Fully closed during Run/Mix operation

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

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

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

68 313885C

Start Up

System Operation

1. Go through the Pre-Operation Checklist in Table 11.

Table 11: 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 68, 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 19.

➜ 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.

Mix

FIG. 71. Status Screen

3. Verify that the EasyKey is working. The active recipe number and Standby mode should be displayed.

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. 70. Power Switches

4. If this is the first time starting up the system, purge it

as instructed in Purging Fluid Supply System, page 78. The equipment was tested with lightweight oil, which should be flushed out to avoid contaminating your material.

5. Make sure that the EasyKey is in Standby (remove

Mix input).

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).

313885C 69

System Operation

10. Purge air from the fluid lines.

a. Shut off air to the gun by clos-

ing the air regulator or shutoff valve for the gun atomizing air.

b. Trigger the gun (man-

ual or automatic) into

Manual gun shown

a grounded metal pail.

c. Go to Mix mode.

d. If the flow meters over-run because of air in the

system, an alarm will occur and operation stops.

Press the Alarm Reset

key to clear

alarm.

e. Go to Mix 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. 72. Status Screen Flow Rate Display

70 313885C

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 71.

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 EasyKey or Power Supply Module, also shut off power at main circuit breaker.

0 = OFF

IG. 73.

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. 74.

TI12657a TI14371a

IG. 73. Power Switches

3. Do a complete system purge, following the instructions under Purging Using Recipe 0, page 78.

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. 77.

IG. 74. Verify that sol-

313885C 71

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 71.

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. 76. 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. 77. Open

6. See F

IG. 76. 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. 74.

8. See F

IG. 76. 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. 74.

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. 74.

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. 77. 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 71.

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. 74.

4. See F

IG. 76. 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. 74.

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. 74.

72 313885C

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

+ +

Dump C

Air

Solvent

+++

Purge C

3rd Flush

++++++

J14 J15 J8

Power

Fiber Optic

CAN

Dump A

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. 74. Component A and B Solenoids

313885C 73

System Operation

(Communication)

(Power Input)

(Color Change

Module)

Valve Overrides

VDC

(Booth Control)

FIG. 75. Component C Solenoids

Dose Valve C Solenoid

Purge Valve C

Solenoid Dump Valve C location (optional)

TI14704a

74 313885C

Solenoid

Identification

Label

System Operation

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. 76: Color Change Solenoids

313885C 75

System Operation

RVA

APV

DVA

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

76 313885C

Purging

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

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

There are 4 purging procedures in this manual:

• Purging Mixed Material (below)

• Purging Using Recipe 0 (page 78)

• Purging Fluid Supply System (page 78)

• Purging Sampling Valves and Tubes (page 80)

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

System Operation

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.

3. If using a gun flush box, place the gun into the box and close the lid. Go to Purge mode. The purge sequence automatically starts.

If the gun flush box is not used, trigger the gun (manual or automatic) into a grounded metal pail until the purge sequence is complete.

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.

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. Go to Standby mode (remove Mix input).

When done purging, the EasyKey automatically switches to Standby mode.

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

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

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.

313885C 77

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. Go to Standby mode (remove Mix input).

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.

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. Go to Standby mode (remove Mix input).

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.

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 (manual or automatic) 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.

78 313885C

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. 74.

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.

System Operation

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 69 for Start Up procedure.

313885C 79

System Operation

Purging Sampling Valves and Tubes

Follow this procedure after meter calibration.

1. Go to Standby mode (remove Mix input).

2. See F

3. Route the sampling tubes into a grounded waste

4. On a single color system, attach a solvent supply

5. On the EasyKey, press the Setup key and

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

IG. 77. Close both fluid shutoff valves and

sampling valves.

container.

line to Flow Meter A inlet.

access the Advanced Setup screens.

tion screen. Press the Down Arrow

key and

select Purge from the menu. Press the Enter key

Dose A, solvent purge valve (B side), component C purge valve, and color change solvent valves (if

used) will open.

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.

IG. 78. 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.

80 313885C

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.

Meter Calibration

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

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

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

6. 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

37) or Recipe Setup Screen 5 (page 42).

• 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.

313885C 81

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.

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 37) or Recipe Setup Screen 5 (page 42).

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

• Follow the Purging Sampling Valves and

Tubes procedure, page 80.

• 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 69.

82 313885C

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. Go to Standby mode (remove Mix input).

4. Select the new recipe. Begin the color change sequence.

5. If a gun flush box is not used, trigger the gun (manual or automatic) into a grounded metal pail until 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 system enters Standby mode (remove Mix input) at the previous color.

Color Change Sequences

FIG. 79 through FIG. 88 illustrate various color change sequences. See Table 12 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.

6. When you are ready to spray, remove the gun from the gun flush box if used, and close its door (manual and semi-automatic systems only).

NOTE: The gun flush box door must be closed for the atomizing air valve to open.

7. Enter Mix mode to start spraying.

Single Color Systems

1. Follow procedure for Purging Fluid Supply System, page 78.

2. Load the new color. See Start Up, page 69.

3. Enter Mix mode to start spraying.

• 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 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.

313885C 83

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.

84 313885C

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 12: 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. 79 IG. 80 IG. 81 IG. 82 IG. 87 IG. 88 IG. 83 IG. 84 IG. 85

0 or 61 X Yes No FIG. 86 0 or 61 0 n/a Yes F 0 or 61 0 n/a No F

IG. 83 IG. 84

313885C 85

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, tha t 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 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 Mixed Fill Time

Valve

Time Sequence

FIG. 79: ProMix 3KS Color Change Chart 1

86 313885C

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 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

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

Valve

Time Sequence

FIG. 80: ProMix 3KS Color Change Chart 2

313885C 87

Color Change

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 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 Mixed Fill Time

Valve

Time Sequence

FIG. 81: ProMix 3KS Color Change Chart 3

88 313885C

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 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

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. 82: ProMix 3KS Color Change Chart 4

313885C 89

Color Change

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 purge and final purge, Purge B (Solvent) only one of the purge valves are used Purge D (3rd/Water) 3rd flush valve is on ly 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 Time 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

FIG. 83: ProMix 3KS Color Change Chart 5

90 313885C

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 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

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

Valve

Time Sequence

Color Change

FIG. 84: ProMix 3KS Color Change Chart 6

313885C 91

Color Change

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. 85: ProMix 3KS Color Change Chart 7

Time Sequence

92 313885C

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

Color Change

Time Sequence

FIG. 86: ProMix 3KS Color Change Chart 8

313885C 93

Color Change

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. 87: ProMix 3KS Color Change Chart 9

94 313885C

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

Color Change

FIG. 88: ProMix 3KS Color Change Chart 10

313885C 95

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:

• Alarm sounds.

• Status bar on the EasyKey Display shows the alarm E-Code with a description (see Table 13).

System Warnings

Table 13 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 13. If you forget which E-Code occurred, use the Alarms Screens (page

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

stamps.

To reset alarms, see Table 14. Many alarms can be

cleared by simply pressing the Alarm Reset

key.

Table 13: System Alarm/Warning Codes

Code Description Details

E-1 Communication Error Alarm Page 97 E-2 Potlife Alarm Page 97 E-3 Ratio High Alarm Page 98 E-4 Ratio Low Alarm Page 99 E-5 Overdose A/B Dose Too Short Alarm Page 100 E-6 Overdose B/A Dose Too Short Alarm Page 100 E-7 Dose Time A Alarm Page 101 E-8 Dose Time B Alarm Page 101 E-9 Mix in Setup Alarm Page 102 E-10 Remote Stop Alarm Page 102 E-11 Purge Volume Alarm Page 102 E-12 CAN Network Communication Error

Alarm E-13 High Flow Alarm Page 104 E-14 Low Flow Alarm Page 104 E-15 System Idle Warning Page 104 E-16 Setup Change Warning Page 104 E-17 Power On Warning Page 104 E-18 Defaults Loaded Warning Page 104 E-19 I/O Alarm Page 105 E-20 Purge Initiate Alarm Page 106 E-21 Material Fill Alarm Page 106 E-22 Tank A Low Alarm Page 106 E-23 Tank B Low Alarm Page 106 E-24 Tank S Low Alarm Page 106 E-25 Auto Dump Complete Alarm Page 107 E-26 Color/Catalyst Purge Alarm Page 107 E-27 Color/Catalyst Fill Alarm Page 107 E-29 Tank C Low Alarm Page 106 E-30 Overdose C Alarm Page 100 E-31 Dose Time C Alarm Page 101

Page 103

96 313885C

Alarm Troubleshooting

Table 14. Alarm Troubleshooting

E-1: COMM_ERROR

Cause Solution

No power to the EasyKey. Connect power to EasyKey.

Alarm Troubleshooting

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

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

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

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

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

A communication cable or connector failed. Replace cable.

E-2: POTLIFE_ALARM

Cause Solution

The potlife time has been exceeded for the mixed material.

NOTICE

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

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

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

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

smaller than 1.6 in. (40 mm).

lint-free cloth.

Press the Alarm Reset alarm. Purge the system with solvent, fresh mixed mate-

rial, or a new color:

• Solvent Purge - See Purging Mixed Material on

page 77. 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 83.

313885C 97

Alarm Troubleshooting

Table 14. 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 10: Mix Manifold Valve Settings,

page 68, for adjustment guidelines.

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

98 313885C

Alarm Troubleshooting

Table 14. 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 10: Mix Manifold Valve Settings,

page 68, for adjustment guidelines.

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

313885C 99

Alarm Troubleshooting

Table 14. 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. 14

Repair the valve (see valve manual 312782).

Totals Screen 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 98-99.

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 68.

100 313885C

Graco 313885C 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

EasyKey Display and Keyboard

EasyKey and 3KS Power Supply Module Connection Ports

Run Mode Screens

Setup Mode

ProMix 3KS Integration Specifics

System Operation

Meter Calibration

Color Change

Alarms and Warnings

Alarm Troubleshooting