Graco 3A0870L User Manual

Repair/Parts

ti15698ati15696a

Pump System Meter System

ProMix

2KE

3A0870L

Plural Component Proportioner

Self-contained, electronic plural component paint proportioner. For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See pages 3 and 4 for model information, including maximum working pressure and approvals.

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

Contents

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

Non-Hazardous Location Models . . . . . . . . . . . . . . 3

Hazardous Location Models . . . . . . . . . . . . . . . . . . 4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Important Two-Component Material Information . 8

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 8

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 8

Keep Components A and B Separate . . . . . . . . . 8

Moisture Sensitivity of Isocyanates . . . . . . . . . . . 8

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 8

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 9

Pump Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Meter Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Pump Systems . . . . . . . . . . . . . . . . . . . . . . . . . 10

Meter Systems . . . . . . . . . . . . . . . . . . . . . . . . . 11

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Maintenance Recommendations . . . . . . . . . . . . . . . 12

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Before Servicing . . . . . . . . . . . . . . . . . . . . . . . . 13

Replace the Air Filter Element . . . . . . . . . . . . . 13

Replace Solenoids . . . . . . . . . . . . . . . . . . . . . . 14

Replace the Power Supply . . . . . . . . . . . . . . . . 15

Replace Alternator Regulator . . . . . . . . . . . . . . 18

Replace Advanced Fluid Control

Module (AFCM) . . . . . . . . . . . . . . . . . . . . . 18

Replace Alarm . . . . . . . . . . . . . . . . . . . . . . . . . 19

Replace Display Module . . . . . . . . . . . . . . . . . . 19

Replace USB Module . . . . . . . . . . . . . . . . . . . . 20

Update Software . . . . . . . . . . . . . . . . . . . . . . . . 20

Pump System Air Controls . . . . . . . . . . . . . . . . 22

Meter System Air Controls . . . . . . . . . . . . . . . . 23

Fluid Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Repair Flow Meters . . . . . . . . . . . . . . . . . . . . . . 27

Repair Mix Manifold . . . . . . . . . . . . . . . . . . . . . 27

Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . 29

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Pump-Based Proportioners, Models

24F088-24F115 . . . . . . . . . . . . . . . . . . . . . 30

Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Air Controls, Pump-Based Models

24F088-24F115 . . . . . . . . . . . . . . . . . . . . . 35

Tubing Chart, Pump-Based Models

24F088-24F115 . . . . . . . . . . . . . . . . . . . . . 36

Meter-Based Proportioners, Models

24F080-24F087 . . . . . . . . . . . . . . . . . . . . . 38

Tubing Chart, Meter-Based Models

24F080-24F087 . . . . . . . . . . . . . . . . . . . . . 41

Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

USB Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Electric Power Assembly . . . . . . . . . . . . . . . . . . 45

Alternator Power Assembly . . . . . . . . . . . . . . . . 46

Alternator Module 255728 . . . . . . . . . . . . . . . . . 47

Sequential Dosing Mix Manifold 262398 . . . . . . 48

Dynamic Dosing Mix Manifold 262399 . . . . . . . 48

1-Color/1 Solvent Valve Stack . . . . . . . . . . . . . . 49

3-Color/1 Solvent Valve Stack . . . . . . . . . . . . . . 49

Pump Stand Kit 24F301

Meter Stand Kit 24G611 . . . . . . . . . . . . . . . 50

Air Flow Switch Kit 15T632 . . . . . . . . . . . . . . . . 50

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 60

2 3A0870L

Related Manuals

#53

Related Manuals

Manual Description

3A0868 ProMix 2KE, Pump-Based, Operation 3A0869 ProMix 2KE, Meter-Based, Operation 313599 Coriolis Meter 308778 G3000 Flow Meter 312781 Fluid Mix Manifold 312782 Dosing Valve 312784 Gun Flush Box Kit 15V826 312792 Merkur Displacement Pump 312793 Merkur Bellows Displacement Pump 312796 NXT Air Motor

Manual Description

406714 Rebuild Kit for High Pressure

406823 Dispense Valve Seat Kits 3A1244 Graco Control Architecture

3A1323 16G353 Alternator Conversion Kit 3A1324 16G351 Electric Power Conversion Kit 3A1325 ProMix 2KE Stand Kits 3A1332 24H255 3-Color Valve Stack Kit 3A1333 24H253 USB Module Kit 313542 Beacon Tower

Non-Hazardous Location Models

Approved for Non-Hazardous Location

Maximum Working Pressure

Part No. Series Description

Pump Systems 24F088 A 3:1, Merkur, A and B 300 (2.1, 21) 24F089 A 23:1, Merkur, A and B 2300 (15.8, 158) 24F090 A 30:1, Merkur, A and B 3000 (20.7, 207) 24F091 A 45:1, Merkur, A and B 4500 (31.0, 310) 24F092 A 3:1, Merkur A, Merkur Bellows B 300 (2.1, 21) 24F093 A 23:1, Merkur A, Merkur Bellows B 2300 (15.8, 158) 24F094 A 35:1, Merkur A, Merkur Bellows B 3500 (24.1, 241) 24F095 A 3:1, Merkur, A and B 300 (2.1, 21) 24F096 A 23:1, Merkur, A and B 2300 (15.8, 158) 24F097 A 30:1, Merkur, A and B 3000 (20.7, 207) 24F098 A 45:1, Merkur, A and B 4500 (31.0, 310) 24F099 A 3:1, Merkur A, Merkur Bellows B 300 (2.1, 21) 24F100 A 23:1, Merkur A, Merkur Bellows B 2300 (15.8, 158) 24F101 A 35:1, Merkur A, Merkur Bellows B 3500 (24.1, 241) Meter Systems 24F080 A G3000, 1 color/1 catalyst 3000 (27.58, 275.8) 24F081 A G3000, 3 colors/1 catalyst 3000 (27.58, 275.8) 24F082 A G3000, 1 color/1 catalyst 3000 (27.58, 275.8) 24F083 A G3000, 3 colors/1 catalyst 3000 (27.58, 275.8)

psi (MPa, bar)

Dispense Valve

Module Programming

USB Module Approvals*

✔ ✔ ✔ ✔ ✔ ✔ ✔ ✔

✔ ✔

* ProMix 2KE non-hazardous location equipment manufactured in the United States, with serial number beginning

with A or 01, has FM and CE approvals. Equipment manufactured in Belgium, with serial number beginning with M or 38, has CE approval.

3A0870L 3

Hazardous Location Models

#53

0359

Ex ia px IIA T3 Ta = 0°C to 54°C FM10 ATEX 0025 X

II 2 G

Intrinsically safe and purged equipment for Class I, Division 1, Group D, T3 Ta = 0°C to 54°C

See Special Conditions for Safe Use in Warnings, page 5.

Hazardous Location Models

ProMix 2KE systems are not approved for use in hazardous locations unless the base model, all accessories, all kits, and all wiring meet local, state, and national codes.

Approved for Hazardous Location

Class 1, Div 1, Group D (North America); Class 1, Zones 1 and 2 (Europe)

Maximum Working Pressure

Part No. Series Description

psi (MPa, bar)

Pump Systems

24F102 A 3:1, Merkur, A and B 300 (2.1, 21)

24F103 A 23:1, Merkur, A and B 2300 (15.8, 158)

24F104 A 30:1, Merkur, A and B 3000 (20.7, 207)

24F105 A 45:1, Merkur, A and B 4500 (31.0, 310)

24F106 A 3:1, Merkur A, Merkur Bellows B 300 (2.1, 21)

24F107 A 23:1, Merkur A, Merkur Bellows B 2300 (15.8, 158)

24F108 A 35:1, Merkur A, Merkur Bellows B 3500 (24.1, 241)

24F109 A 3:1, Merkur, A and B 300 (2.1, 21)

24F110 A 23:1, Merkur, A and B 2300 (15.8, 158)

24F111 A 30:1, Merkur, A and B 3000 (20.7, 207)

24F112 A 45:1, Merkur, A and B 4500 (31.0, 310)

24F113 A 3:1, Merkur A, Merkur Bellows B 300 (2.1, 21)

24F114 A 23:1, Merkur A, Merkur Bellows B 2300 (15.8, 158)

24F115 A 35:1, Merkur A, Merkur Bellows B 3500 (24.1, 241)

Meter Systems

24F084 A G3000, 1 color/1 catalyst 3000 (27.58, 275.8)

24F085 A G3000, 3 colors/1 catalyst 3000 (27.58, 275.8)

24F086 A G3000, 1 color/1 catalyst 3000 (27.58, 275.8)

24F087 A G3000, 3 colors/1 catalyst 3000 (27.58, 275.8)

USB Module Approvals*

✔

* ProMix 2KE hazardous location equipment manufactured in the United States, with serial number beginning with

A or 01, has ATEX, FM, and CE approvals, as noted. Equipment manufactured in Belgium, with serial number beginning with M or 38, has ATEX and CE approvals, as noted.

4 3A0870L

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

FIRE AND EXPLOSION HAZARD

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

• Use equipment only in well ventilated area.

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

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

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

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

• Use only grounded hoses.

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

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

• Keep a working fire extinguisher in the work area.

SPECIAL CONDITIONS FOR SAFE USE

• To prevent the risk of electrostatic sparking, the equipment’s non-metallic parts should be cleaned only with a damp cloth.

• Pump Systems: The aluminum adapter plate may spark upon impact or contact with moving parts, which may cause fire or explosion. Take precautions to avoid such impact or contact.

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.

3A0870L 5

Warnings

WARNING

INTRINSIC SAFETY

Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe equipment will create a hazardous condition and can cause fire, explosion, or electric shock. Follow local regulations and the following safety requirements.

• Only models with model numbers 24F084-24F087 and 24F102-24F115, utilizing the air-driven alternator, are approved for installation in a Hazardous (explosive atmosphere) Location. See Hazardous Location Models, page 4.

• Be sure your installation complies with national, state, and local codes for the installation of electrical apparatus in a Class I, Group D, Division 1 (North America) or Class I, Zones 1 and 2 (Europe) Hazardous Location, including all of the local safety fire codes, NFPA 33, NEC 500 and 516, and OSHA 1910.107.

• To help prevent fire and explosion:

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

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

• Equipment that comes in contact with the intrinsically safe terminals must be rated for Intrinsic Safety. This includes DC voltage meters, ohmmeters, cables, and connections. Remove the unit from the hazardous area when troubleshooting.

• The equipment is intrinsically safe when no external electrical components are connected to it.

• Do not connect, download, or remove USB device unless unit is removed from the hazardous (explosive atmosphere) location.

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.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• 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 the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

6 3A0870L

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 from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and

follow the Pressure Relief Procedure when equipment is not in use.

• 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.

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.

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 MSDSs to know the specific hazards of the fluids you are using.

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

• Always wear chemically impermeable gloves when spraying, dispensing, 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, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

3A0870L 7

Important Two-Component Material Information

Isocyanate Conditions

Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates.

Read material manufacturer’s warnings and material MSDS to know specific hazards and precautions related to isocyanates.

Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not available, a supplied-air respirator is required for everyone in the work area.

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

Material Self-ignition

Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS.

Moisture Sensitivity of Isocyanates

Isocyanates (ISO) are catalysts used in two component coatings. ISO will react with moisture (such as humidity) to form small, hard, abrasive crystals, which become suspended in the fluid. Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts.

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

To prevent exposing ISO to moisture:

• Always use a sealed container with a desiccant

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

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

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

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

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

Changing Materials

Keep Components A and B Separate

Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (resin) and component B (isocyanate) parts.

8 3A0870L

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

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

Pressure Relief Procedure

Meter Systems

To reduce the risk of skin injection, relieve pressure when you stop spraying, before changing spray tips, and before cleaning, checking, or servicing equipment.

NOTE: The following procedure relieves all fluid and air pressure in the ProMix 2KE system.

Pump Systems

1. Press on Run Mix Spray (Screen 2) or

from any screen to put the system in Standby.

2. Follow procedure for Purging Fluid Supply Sys- tem, page 10, if desired or necessary.

3. Shut off air supply to A and B pumps and solvent supply pumps.

4. With the gun triggered, push the manual override on the A and B dose and solvent valve solenoids to relieve pressure. See FIG. 1, page 12. Verify that fluid pressure is reduced to 0.

1. Press on Run Mix Spray (Screen 2) or

from any screen to put the system in Standby.

2. Shut off the A1 (A2 and A3, if using multiple colors) and B fluid supply pumps/pressure pots.

3. Remove the Control Box cover.

4. With the gun triggered, push the manual override on the A1 (A2, A3), and B dose valve solenoids to relieve pressure. See FIG. 1, page 12.

5. Follow Purging procedure, page 11.

6. Shut off the fluid supply to solvent valves A and B.

7. With the gun triggered, push the manual override on the A and B solvent valve solenoids to relieve solvent pressure. See FIG. 1. Verify that solvent pressure is reduced to 0.

8. Reinstall the Control Box cover.

5. Reinstall the Control Box cover.

3A0870L 9

Purging

Pump Systems

There are 2 pump purging procedures in this manual:

• Purging Mixed Material

• Purging Fluid Supply System

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

Purging Mixed Material

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

• end of potlife

• breaks in spraying that exceed the potlife

• overnight shutdown

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

1. Press on Run Mix Spray (Screen 2) or

from any screen to put the system in Standby.

2. Trigger the gun to relieve pressure.

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

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

7. If the system is not completely clean, repeat step 6.

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

8. Trigger the gun to relieve pressure. Engage trigger lock.

9. If spray tip was removed, reinstall it.

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

NOTE: If your system uses 2 guns, you must trigger both guns simultaneously during a purge to purge both guns and lines. Verify that clean solvent flows from each gun. If not, repeat purge or clear clog/blockage in system.

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

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

5. 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.

6. If using a gun flush box, place the gun into the box

and close the lid. Press on Run Mix Spray

(Screen 2). The purge sequence automatically starts.

10 3A0870L

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

1. Press on Run Mix Spray (Screen 2) or

from any screen to put the system in Standby.

2. Trigger the gun to relieve pressure.

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

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

5. Disconnect the component A and B fluid supplies at the pump inlets, and connect solvent supply lines.

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

Purging

1. Press on Run Mix Spray (Screen 2) or

from any screen to put the system in Standby.

2. Trigger the gun to relieve pressure.

7. Remove the Control Box cover to access the solenoid valves. See FIG. 1, page 12.

8. Purge as follows:

• Purge component A side. See FIG. 1, page 12.

Press the manual override on the Dose Valve A solenoid valve and trigger the gun into a grounded metal pail.

Purge component B side. Press the manual override on the Dose Valve B solenoid valve and trigger the gun into a grounded metal pail until clean solvent flows from the gun.

Repeat to thoroughly clean the mix manifold.

9. Reinstall the Control Box cover.

10. Shut off the solvent fluid supply.

11. Disconnect the solvent supply lines and reconnect the component A and B fluid supplies.

NOTE: The system remains full of solvent.

Meter Systems

Purge the system:

• at the end of potlife

• breaks in spraying that exceed the potlife

• overnight shutdown or end of shift

• the first time material is loaded into equipment

• servicing

• shutting down equipment for an extended period of time

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

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

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

7. Press on Run Mix Spray (Screen 2). The

purge sequence automatically starts.

If the gun flush box is not used, trigger the gun into a grounded metal pail until the system returns to Standby mode.

8. If the system is not completely clean, repeat step 6.

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

9. Trigger the gun to relieve pressure. Engage trigger lock.

10. If spray tip was removed, reinstall it.

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

NOTE: The system remains full of solvent.

NOTE: If your system uses 2 guns, you must trigger

both guns simultaneously during a purge to purge both guns and lines. Verify that clean solvent flows from each gun. If not, repeat purge or clear clog/blockage in system.

3A0870L 11

Purging

Solvent Valve A Solenoid

Manual Overrides

Dose Valve A1 Solenoid

Solvent Valve B Solenoid

Dose Valve B Solenoid

Dose Valve A2 Solenoid Location

Dose Valve A3 Solenoid Location

ti15730a

Gun Flush Box Solenoid Location

FIG. 1. Solenoid Valves in Control Box

Shutdown

1. Follow Purging procedure for your system, page 10

or 11.

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

3. Non-IS Systems: Shut off ProMix 2KE power (0 position). NOTE: Meter-based systems will restart in Recipe 0.

Maintenance Recommendations

The following table shows starting maintenance recommendations. Maintenance needs will vary based on individual applications and material differences.

Recommended Maintenance

Component

Solvent Valves 1,000,000 cycles

Fluid Filter daily

Air Filter monthly

Pumps 250,000 cycles

Dose Valves 1,000,000 cycles

Meters 5,000 gallons

Frequency

12 3A0870L

Service

Pump System

Meter System

209

206

209

206a, 209a

ti15708a

ti16437a

ti12691a

Service

Before Servicing

• To avoid electric shock, turn off power before servicing.

• Servicing the Control Box exposes you to high voltage. Shut off power at main circuit breaker before opening enclosure.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

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

• Read Warnings, pages 5- 8.

1. Follow Pressure Relief Procedure, page 9, if ser-

vice time may exceed pot life time, before servicing fluid components, and before transporting equipment to a service area.

2. Close air shutoff valves.

4. Remove and replace element (206a, 209a).

5. Screw filter bowl (B) on securely. Install cover (A).

3. Non-IS Systems: Shut off power (0 position).

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

Replace the Air Filter Element

Removing a pressurized air filter bowl could cause serious injury. Depressurize air line before servicing.

Pump systems have two air filters: the 5 micron air manifold filter (209) and the 40 micron pump air filter (206). Meter systems have only the 5 micron filter (209). Check filters daily and replace element(s) as needed. Order 15D909 (5 micron) or 15D890 (40 micron).

1. Close main air shutoff valve on air supply line and on system. Depressurize air line.

2. Remove the filter cover (A).

3. Unscrew the filter bowl (B).

FIG. 2. Replace Air Filter Element(s)

3A0870L 13

Service

ti16646a

320

306

320

305

ti16450a

Replace Solenoids

The system has a minimum of 4 solenoids. If you have a 3-color system or a gun flush box, you have additional (optional) solenoids for each.

To replace a single solenoid:

1. Follow Before Servicing, page 13. Disconnect

main power.

2. Open Control Box.

3. Disconnect 2 solenoid wires (N) from harness (320). See FIG. 3.

4. Unscrew 2 screws (P) and remove solenoid (306).

5. Install new solenoid (306).

6. Connect 2 wires (N) to harness (320). Solenoid wires are polarized (red+, black-). Refer to System Electrical Schematics, pages 54-57.

To replace the solenoid module:

1. Follow Before Servicing, page 13. Disconnect

main power.

2. Open Control Box.

3. Disconnect all solenoid wires (N) from harnesses (320).

NOTE: If you have an intrinsically safe model, you will need to remove the alternator air regulator from the solenoid module. See page 18 for removal instructions.

4. Remove two screws (305).

5. Remove and replace solenoid module.

6. Connect all wires (N) to harnesses (320). Solenoid wires are polarized (red+, black-). Refer to System Electrical Schematics, pages 54-57.

7. Replace Control Box cover.

FIG. 3. Replace a Single Solenoid

FIG. 4. Replace Solenoid Module

14 3A0870L

Service

Line

Neutral

Ground

411

404

403

ti16391a

Connect cable (401a) here.

ti16602a

LINE POWER

FILTER

POWER SUPPLY

TERMINAL

BLOCK

SWITCH ROCKER

L N GRND

L GRND N

L N

Replace the Power Supply

All electrical wiring must be completed by a qualified electrician and comply with all local codes and regulations.

Wall Power Supply and Filter

1. Follow Before Servicing, page 13. Disconnect

main power.

2. Open Control Box.

3. Disconnect the three input wires from the line filter (403).

10. Connect the power supply wire harness (411/PS) to the switch (402), as shown. See also Electrical Schematic. Connect the PS ground wire to the ground terminal (T) of the advanced fluid control module.

11. See FIG. 5. Connect wire harness (411) to the line filter (403) and terminal block (404) as shown. See also Electrical Schematic.

12. Connect CAN cable (401a) to the advanced fluid control module.

FIG. 5. Terminal Block Electrical Connections

4. See FIG. 8. Disconnect the power supply CAN cable (401a) from the advanced fluid control module (302).

5. Disconnect line filter wires and power supply wires from the power switch (402).

6. Disconnect the power supply ground wire, PS(GND), from the advanced fluid control module ground terminal (T).

7. Remove four screws (405) and remove power supply (401). If replacing filter, remove two screws (407) and the filter (403).

8. Install the new power supply (401) and line filter

9. See FIG. 8. Connect wire harness (410/LF) to the

(403), using supplied screws (405, 407), as shown.

line filter (403) and to the power switch (402), as shown. See also Electrical schematic.

FIG. 6. Reconnect CAN cable.

FIG. 7. Electrical Schematic

3A0870L 15

Service

405

401

407

ti16454a

401a

302

1: PS(N)

1A: LF(N)

2: PS(L)

1A: LF(N)

403

402

LF(L)

LF(N)

PS(L)

PS(N)

PS(GND)

406

FIG. 8. Replace Wall Power Supply

16 3A0870L

Service

501

Supply line disconnect

Exhaust air line disconnect

509

Cable connectors

Air regulator line

501h

501d

ti16456a

ti16455a

Alternator Power Supply and Turbine

1. Follow Before Servicing, page 13. Disconnect main air.

2. Open Control Box.

3. See FIG. 9. Disconnect output power cable connections from alternator module (501). Disconnect ground lead (G) from control box ground terminal (T).

4. Disconnect the power supply cables from the Advanced Fluid Control Module, the USB Module, and the Display Module.

5. Disconnect air regulator line and exhaust air line from alternator module.

6. Remove four screws (509) from mounting to remove alternator from control box.

7. Remove seven screws (501h) to separate alternator housings.

8. Replace turbine (501d) if necessary. Lightly lubricate turbine o-ring to ease alternator housing reassembly.

9. Follow steps in reverse order to reassemble alternator regulator assembly and to reconnect power

FIG. 9. Remove Alternator Module (and Turbine)

3A0870L 17

Service

ti16456a

506

505

Solenoid Module

Air regulator line

303

302

ti16452a

Replace Alternator Regulator

1. Follow Before Servicing, page 13. Disconnect

main air.

2. Open Control Box.

3. Disconnect supply air line from regulator assembly (505).

4. Loosen air regulator swivel fittings (506) and remove from solenoid module.

5. Repair or replace alternator regulator parts as necessary. See Alternator Power Assembly, page 46, for repair parts. Replace air regulator swivel fitting (506).

6. Reconnect air line. Set regulator air pressure to 18 psi (0.12 MPa, 1.2 bar).

NOTICE

To avoid damage to the alternator, do not set the regulator air pressure higher than 18 psi (0.12 MPa, 1.2 bar).

7. Close Control Box and restore power.

Replace Advanced Fluid Control Module (AFCM)

1. Follow Before Servicing, page 13. Disconnect

main power.

2. Open Control Box.

3. Remove all cables from AFCM (302). Take note of cable locations.

4. Disconnect ground wire from ground screw (GS).

5. Loosen four mounting screws (303).

6. Slide AFCM up and out of keyhole slots.

7. Follow steps in reverse order to install a new AFCM. See electrical schematic for cable connection information.

8. Follow instructions in Manual 3A1244 to update the software on the new AFCM.

9. Close Control Box and restore power.

FIG. 10. Replace Alternator Regulator

18 3A0870L

FIG. 11. Replace AFCM

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