Graco 313885C User Manual
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.
EN
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
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
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
00
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
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
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
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.
EK
PSM★
PS◆
PS★◆
CCM
BCV
FO
ACV
2KS
MA
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
F
12 313885C
6 ft (1.83 m) fluid
hose (supplied)
MB
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
MA
RVA
APV
FI
DVC
AT
DVA
SVA SVB
FI
DVB
SM
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
MB
MS
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
MC
CPV
RVC
1
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
1
3KS fluid inlet. Connect fluid supply line from
2KS fluid manifold outlet here.
2
Connect fluid supply line to gun.
SM
2
TI14382a
FIG. 3. ProMix 2KS and ProMix 3KS Wall Mount Fluid Stations
313885C 15
EasyKey Display and Keyboard
EasyKey Display and Keyboard
LCD Display
F
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 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
F
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.
F
IG. 7. Fluid Plate Programming Screen
313885C 19
Run Mode Screens
1
/
4
3
/
4
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.
1
13
2
3
4
5
6
7
F
IG. 9. Status Screen
Key to F
1
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.
10
1
12
11
9
/
4
8
6
Potlife Timer: shows remaining potlife time in min-
utes. Two times are shown if there are two guns
(manual or semi-automatic mode only).
7
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.
8
Target Flow Rate and Current Flow Rate: in
cc/min.
9
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.
10
Current Date and Time
11
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.
12
Current Flow Control Data: fluid output pressure
and percentage of analog signal range used for driving the fluid regulator V/P.
2
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.
3
Stage 1 Actual Ratio (A:B): in hundredths, calcu-
lated after each dose of A and B.
4
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.
5
Stage 2 Actual Ratio (A+B):C: in hundredths, cal-
culated after each dose of C.
313885C 21
13
Lock Symbol: indicates that Setup screens are
password protected. See page 26.
Run Mode Screens
Manual Override Screen
F
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
F
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
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
3
/
4
IG. 14. Totals Screen
F
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.
F
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
F
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
F
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
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
3
FIG. 20. Setup Screens Map
screen.
This screen appears momentarily
if a password is activated.
1
/
4
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).
F
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
F
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
3
/
6
NOTE: Each screen displays the current screen number
and the total number of screens in the group.
4
/
6
F
IG. 24. System Configuration and Option Screens Map
TI12804a
28 313885C
Setup Mode
Configure Screen 1
F
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
3
/
6
F
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.
4
/
6
F
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
4
/
6
IG. 28. Configure Screen 4
F
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
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