Graco PrecisionMix ii Instructions And Parts List
Instructions – Parts List
PRECISIONMIX II
3K System
309107E
For Proportional Mixing of Two and Three Component Coatings
Patent No. 5,368,059
Read warnings and instructions.
See page 2 for the Table of Contents.
Conforms to ANSI/UL
standard 2279
Class 1 Zone 0
AExia II A T4
110474
Certified to CAN/CSA
22.2 No. E79–11
0359
II 2 G
EEXia II A T3
ITS03ATEX21382
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 2001, Graco Inc. is registered to I.S. EN ISO 9001
Table of Contents
Warnings 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using this Manual 2–3. . . . . . . . . . . . . . . . . . . . . . . . .
Related Publications 2–4. . . . . . . . . . . . . . . . . . . . . .
How the PrecisionMix II 3K Works 2–6. . . . . . . . . .
Functional Diagrams 2–7. . . . . . . . . . . . . . . . . . .
Changing the Mixing Order 2–10. . . . . . . . . . . . . . . .
Flow Control Overview 2–12. . . . . . . . . . . . . . . . . . .
Flow Control Features 2–12. . . . . . . . . . . . . . . .
System Requirements 2–12. . . . . . . . . . . . . . . .
General Operation Sequence 2–12. . . . . . . . . .
One Gun Flow Control Using a Flow Meter
in the Mixed Material Line 2–13. . . . . . . . . .
Flow Control Components 2–14. . . . . . . . . . . . .
Flow Control Parameters 2–15. . . . . . . . . . . . . .
Using Recipes/Color Change 2–16. . . . . . . . . . . . . .
No Color Change 2–16. . . . . . . . . . . . . . . . . . . . .
Integrated Color Change 2–16. . . . . . . . . . . . . .
Integrated Color Change with Queue 2–17. . . .
Color Change Sequences 2–18. . . . . . . . . . . . .
Changing from One Color Change
Sequence to Another 2–19. . . . . . . . . . . . . .
Actual Valve Times 2–20. . . . . . . . . . . . . . . . . . .
Installation 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Installation 3–3. . . . . . . . . . . . . . . . . . . . . . . .
Non-intrinsically Safe 3–4. . . . . . . . . . . . . . . . . .
Intrinsically Safe 3–5. . . . . . . . . . . . . . . . . . . . . .
Fluid Supply Requirements 3–6. . . . . . . . . . . . . . . . .
Mounting Components 3–7. . . . . . . . . . . . . . . . . . . .
For Wall Mounting 3–7. . . . . . . . . . . . . . . . . . . . .
Stand Mounting Kit 241501 3–9. . . . . . . . . . . . .
System Installation 3–10. . . . . . . . . . . . . . . . . . . . . . .
Install the Controller and User Interface 3–10.
Power Requirements 3–11. . . . . . . . . . . . . . . . .
Install the Fluid Panel with Fluid Meters 3–12.
Install the Air Control Kit 3–13. . . . . . . . . . . . . .
Install the Operator Station 3–13. . . . . . . . . . . .
Install the Color/Catalyst/Reducer
Change Valves and Solenoids 3–14. . . . . .
Install the Gun Flush Box and
Solenoid Box 3–16. . . . . . . . . . . . . . . . . . . . .
Install the Optional Flow Control 3–20. . . . . . . .
Fluid Connections 3–20. . . . . . . . . . . . . . . . . . . .
Pressure Test and Solvent Flush
the System 3–20. . . . . . . . . . . . . . . . . . . . . .
Digital Outputs 3–21. . . . . . . . . . . . . . . . . . . . . . .
Component Electrical Connections 3–22. . . . . . . . .
Controller Terminal Block 3–29. . . . . . . . . . . . . . . . .
Ground the System 3–30. . . . . . . . . . . . . . . . . . . . . .
Check the Resistance 3–31. . . . . . . . . . . . . . . . . . . .
Power-up Checklist 3–32. . . . . . . . . . . . . . . . . . . . . .
Checking Flow Control I/P Transducers 3–34.
Testing Flow Control External 4–20 mA Input
Signal 3–35. . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Test and Solvent Flush Procedure 3–36.
Test Color Valve Operation 3–36. . . . . . . . . . . .
Pressure Test Component A 3–36. . . . . . . . . . .
Pressure Test Component B and C 3–36. . . . .
Pressure Test the Solvent Lines 3–36. . . . . . . .
Operation 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 4–3. . . . . . . . . . . . . . . . .
Operator Controls and Indicators 4–4. . . . . . . . . . . .
Operator Station 4–4. . . . . . . . . . . . . . . . . . . . . .
User Interface 4–6. . . . . . . . . . . . . . . . . . . . . . . .
Operating Checklist 4–7. . . . . . . . . . . . . . . . . . . . . . .
Mode Switch 4–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purging the Ratio Check Valves 4–8. . . . . . . . . . . . .
Purging the PrecisionMix II 3K System 4–10. . . . . .
Starting Production 4–12. . . . . . . . . . . . . . . . . . . . . . .
Stopping Production 4–14. . . . . . . . . . . . . . . . . . . . . .
Flow Control Operation 4–15. . . . . . . . . . . . . . . . . . .
Flow Control Tips 4–15. . . . . . . . . . . . . . . . . . . . . . . .
Integrated Color Change 4–16. . . . . . . . . . . . . . . . . .
Multiple Gun Flush Box Operation 4–16. . . . . . . . . .
Printer Reports 4–18. . . . . . . . . . . . . . . . . . . . . . . . . .
Run Mode Report 4–18. . . . . . . . . . . . . . . . . . . .
Recipe Report 4–19. . . . . . . . . . . . . . . . . . . . . . .
System Setup (Configuration) Report 4–20. . .
Job Totals Report 4–22. . . . . . . . . . . . . . . . . . . .
Batch Totals Report 4–22. . . . . . . . . . . . . . . . . .
Grand Totals Report 4–23. . . . . . . . . . . . . . . . . .
Alarm Report 4–23. . . . . . . . . . . . . . . . . . . . . . . .
Screen Map 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Run Monitor 6–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Home Screen 6–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Target/Actual 6–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Rate 6–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Potlife Timer 6–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Rate Setpoint 6–5. . . . . . . . . . . . . . . . . . . . . . . .
Enter New Setpoint 6–5. . . . . . . . . . . . . . . . . . . . . . .
Recipe Select 6–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm History 6–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Integrated Color Change with Queue 6–7. . . . . . . .
Modify Queue Screen 6–8. . . . . . . . . . . . . . . . . . . . .
Totalizers 7–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Home Screen 7–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Select Recipe and Totalizer Screen 7–3. . . . . . . . . .
Job Totals 7–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Batch Totals 7–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grand Totals 7–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
Table of Contents
System Configuration 8–1. . . . . . . . . . . . . . . . . . . . . . .
Home Screen 8–3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Password Screen 8–3. . . . . . . . . . . . . . . . . . . . . . . . .
Menu Screen 8–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Language 8–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Station Number 8–5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Units of Measurement 8–6. . . . . . . . . . . . . .
Recipes 8–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Potlife Timer 8–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Rate Limits 8–7. . . . . . . . . . . . . . . . . . . . . . . . . .
Solvent Meter 8–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purge Sequence: Valves 8–8. . . . . . . . . . . . . . . . . . .
Purge Sequence: Purge Alarms 8–9. . . . . . . . . . . .
Mixed Load Volumes 8–10. . . . . . . . . . . . . . . . . . . . .
Guns Setup 8–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mix/Purge 8–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Control 8–11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Integrator Volume 8–12. . . . . . . . . . . . . . . . . . . . . . . .
Integrated Color Change 8–12. . . . . . . . . . . . . . . . . .
Password Selection 8–12. . . . . . . . . . . . . . . . . . . . . .
Time and Date Set 8–13. . . . . . . . . . . . . . . . . . . . . . .
Display Setup 8–14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Print Setup 8–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Flow Switch 8–15. . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Control Setup 8–16. . . . . . . . . . . . . . . . . . . . . . .
Home Screen 8–16. . . . . . . . . . . . . . . . . . . . . . .
Password Screen 8–16. . . . . . . . . . . . . . . . . . . .
Menu Screen 8–16. . . . . . . . . . . . . . . . . . . . . . . .
Flow Control Options 8–17. . . . . . . . . . . . . . . . .
Flow Control Menu 8–17. . . . . . . . . . . . . . . . . . .
Source of Flow Control Data 8–18. . . . . . . . . . .
Flow Control Scaling 8–18. . . . . . . . . . . . . . . . . .
Flow Control Force Output 8–19. . . . . . . . . . . .
Flow Control Delay Time 8–19. . . . . . . . . . . . . .
Flow Control Meter Location 8–20. . . . . . . . . . .
Integrated Color Change Setup 8–21. . . . . . . . . . . .
Home Screen 8–21. . . . . . . . . . . . . . . . . . . . . . .
Password Screen 8–21. . . . . . . . . . . . . . . . . . . .
Menu Screen 8–21. . . . . . . . . . . . . . . . . . . . . . . .
Color Change Mode Screen 8–22. . . . . . . . . . .
Color Change Sequence 8–22. . . . . . . . . . . . . .
Color Change Graph Screen 8–23. . . . . . . . . . .
Purge and Mix Timer Values 8–23. . . . . . . . . . .
A Component Dump Timer Value 8–24. . . . . . .
A Component Solvent Timer Value 8–24. . . . .
B Component Dump Timer Value 8–25. . . . . . .
B Component Solvent Timer Value 8–25. . . . .
C Component Dump Timer Valve 8–26. . . . . . .
C Component Solvent Timer Valve 8–26. . . . .
Gun 1 Trigger Start/Duration Times 8–27. . . . .
Gun 2 Trigger Start/Duration Times 8–27. . . . .
Special 1, 2, 5, and 6
Trigger Start/Duration Times 8–28. . . . . . .
PrecisionMix II 3K Robotic Interface 8–29. . . . . . . .
Pressure Test and Solvent Flush
the System 8–29. . . . . . . . . . . . . . . . . . . . . .
PrecisionMix II 3K Robotic Applications 8–29.
Integrated Color Change 8–30. . . . . . . . . . . . . .
Non-integrated Color Change 8–31. . . . . . . . . .
Digital Inputs 8–32. . . . . . . . . . . . . . . . . . . . . . . .
Recipe Setup 9–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Home Screen 9–3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Password Screen 9–3. . . . . . . . . . . . . . . . . . . . . . . . .
Recipe Selection 9–4. . . . . . . . . . . . . . . . . . . . . . . . . .
Setup Menu with Integrated Color Change On
and Flow Control On 9–5. . . . . . . . . . . . . . . . . . .
Setup Menu with Integrated Color Change
and Flow Control Off 9–5. . . . . . . . . . . . . . . . . . .
Mix Ratio and Tolerance 9–6. . . . . . . . . . . . . . . . . . .
Color Change Sequence 9–7. . . . . . . . . . . . . . . . . . .
Purge Sequence 9–8. . . . . . . . . . . . . . . . . . . . . . . . . .
System Alarms with Flow Control On and
Hand Gun Selected 9–9. . . . . . . . . . . . . . . . . . . .
System Alarms with Flow Control On and
Automatic Gun Selected 9–10. . . . . . . . . . . . . .
System Alarms with Flow Control Off 9–10. . . . . . .
Meter Calibration Tests 9–11. . . . . . . . . . . . . . . . . . .
Component A Flow Meter Calibration 9–12. . . . . . .
Component B Flow Meter Calibration 9–13. . . . . . .
Component C Flow Meter Calibration 9–13. . . . . . .
Solvent Flow Meter Calibration 9–14. . . . . . . . . . . .
Mixed Material Calibration Screen 9–14. . . . . . . . . .
Gun 1 Meter Calibration 9–15. . . . . . . . . . . . . . . . . .
Setup Flow Control 9–16. . . . . . . . . . . . . . . . . . . . . . .
Gain Factor Graphs 9–17. . . . . . . . . . . . . . . . . . . . . .
Flow Meter Calibration Procedure 9–18. . . . . . . . . .
Selection 1, 2, 3, or 4: Calibrating the
Meters Individually 9–18. . . . . . . . . . . . . . . .
Selection 6: Calibrating the Gun 1 Meter 9–20
Selection 5: Mixed Material Calibration 9–21. .
3
Table of Contents
Troubleshooting 10–1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision Number 10–2. . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Reference 10–3. . . . . . . . . . . . . . . .
Alarm Troubleshooting 10–7. . . . . . . . . . . . . . . . . . . .
To Clear the Alarm and
Restart the System 10–7. . . . . . . . . . . . . . .
Ratio Low or Ratio High 10–8. . . . . . . . . . . . . . .
Dose Time A, B, or C 10–9. . . . . . . . . . . . . . . . .
Overdose A, B, or C 10–9. . . . . . . . . . . . . . . . . .
Flow Rate Alarms for a System without
Flow Control 10–10. . . . . . . . . . . . . . . . . . .
Flow Too Low 10–10. . . . . . . . . . . . . . . . . .
Flow Too High 10–10. . . . . . . . . . . . . . . . . .
Flow Rate Alarms for a System with
Flow Control 10–10. . . . . . . . . . . . . . . . . . .
Gun #1 High/Low Flow 10–10. . . . . . . . . .
Gun # 2 High/Low Flow 10–10. . . . . . . . . .
Pot Life Exceeded 10–10. . . . . . . . . . . . . . . . . .
Purge/Load Interlock Not Ready 10–11. . . . . . .
Invalid Recipe 10–11. . . . . . . . . . . . . . . . . . . . . .
I/O Change 10–11. . . . . . . . . . . . . . . . . . . . . . . . .
Purge Not Completed 10–11. . . . . . . . . . . . . . . .
Purge Time Out 10–11. . . . . . . . . . . . . . . . . . . . .
Display Battery Low 10–12. . . . . . . . . . . . . . . .
Control Battery Low 10–12. . . . . . . . . . . . . . . .
Memory Failure 10–12. . . . . . . . . . . . . . . . . . . .
Communications Error 10–12. . . . . . . . . . . . . .
Invalid Guns From Input/Output Alarm 10–12
Air Flow Switch Alarm 10–12. . . . . . . . . . . . . .
Defaults Loaded 10–12. . . . . . . . . . . . . . . . . . .
Software Revision Alarm 10–12. . . . . . . . . . . .
Configuration Module Alarm 10–12. . . . . . . . .
External Alarms 10–12. . . . . . . . . . . . . . . . . . . .
Warnings 10–13. . . . . . . . . . . . . . . . . . . . . . . . . .
Job Total Rollover 10–13. . . . . . . . . . . . . . . . . .
Batch Total Rollover 10–13. . . . . . . . . . . . . . . .
Grand Total Rollover 10–13. . . . . . . . . . . . . . . .
Calibrate A Meter 10–13. . . . . . . . . . . . . . . . . .
Calibrate B Meter 10–13. . . . . . . . . . . . . . . . . .
Calibrate C Meter 10–13. . . . . . . . . . . . . . . . . .
Solenoid Box Troubleshooting 10–14. . . . . . . . . . .
Gun Flush Box Troubleshooting 10–16. . . . . . . . . .
Operator Station
with Color Change Troubleshooting 10–17. . .
Service 11–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the User Interface Battery 11–3. . . . . . .
Replacing the Controller Battery 11–4. . . . . . . . . . .
Replacing Isolation Barrier Fuses 11–5. . . . . . . . . .
Replacing the User Interface 11–5. . . . . . . . . . . . . .
Replacing the Power Supply 11–6. . . . . . . . . . . . . . .
Changing the Power Supply Voltage 11–6. . . . . . . .
Replacing Power Supply Fuses 11–6. . . . . . . . . . . .
Servicing the Operator Station 11–7. . . . . . . . . . . . .
Replacing Control Modules 11–8. . . . . . . . . . . . . . . .
Replacing Control Submodules 11–9. . . . . . . . . . . .
4
Parts 12–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller with User Interface 12–3. . . . . . . . . . . . . .
Part No. 243540 12–3. . . . . . . . . . . . . . . . . . . . .
Part No. 243541 12–3. . . . . . . . . . . . . . . . . . . . .
Controller 12–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part No. 240834 12–4. . . . . . . . . . . . . . . . . . . . .
Flow Control 12–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
One Gun 12–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
One Gun with Flow Meter in
Mixed Material Line 12–6. . . . . . . . . . . . . . .
Communication Ports 12–8. . . . . . . . . . . . . . . . . . . .
Part No. 241379 12–8. . . . . . . . . . . . . . . . . . . . .
Part No. 241378 12–8. . . . . . . . . . . . . . . . . . . . .
Software Utilities Kit 12–8. . . . . . . . . . . . . . . . . . . . . .
Part No. 243546 12–8. . . . . . . . . . . . . . . . . . . . .
Fluid Panel 12–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non-Intrinsically Safe 12–9. . . . . . . . . . . . . . . . .
Intrinsically Safe 12–9. . . . . . . . . . . . . . . . . . . . .
Fluid Panel Module 12–10. . . . . . . . . . . . . . . . . . . .
Part No. 243493 12–10. . . . . . . . . . . . . . . . . . .
Solenoid Module 12–12. . . . . . . . . . . . . . . . . . . . . . .
Part No. 552184 12–12. . . . . . . . . . . . . . . . . . .
Part No. 552186 12–12. . . . . . . . . . . . . . . . . . .
Fluid Meters 12–13. . . . . . . . . . . . . . . . . . . . . . . . . .
Part No. 243512 12–13. . . . . . . . . . . . . . . . . . .
Part No. 243513 12–13. . . . . . . . . . . . . . . . . . .
Part No. 243515 12–14. . . . . . . . . . . . . . . . . . .
Air Supply Station 12–16. . . . . . . . . . . . . . . . . . . . . .
Part No. 570122 12–16. . . . . . . . . . . . . . . . . . .
Operator Station 12–17. . . . . . . . . . . . . . . . . . . . . . .
Part No. 240835 12–17. . . . . . . . . . . . . . . . . . .
Part No. 240877 12–18. . . . . . . . . . . . . . . . . . .
Low Pressure Color Change Module 12–19. . . . .
Part No. 241386 12–19. . . . . . . . . . . . . . . . . . .
Part No. 242025 12–19. . . . . . . . . . . . . . . . . . .
Part No. 241387 12–20. . . . . . . . . . . . . . . . . . .
Part No. 242026 12–20. . . . . . . . . . . . . . . . . . .
High Pressure Color Change Module 12–22. . . . .
Part No. 241499 12–22. . . . . . . . . . . . . . . . . . .
Part No. 241500 12–23. . . . . . . . . . . . . . . . . . .
Part No. 907347 12–25. . . . . . . . . . . . . . . . . . .
Color Change Valve Assemblies 12–26. . . . . . . . .
Low Pressure Color Change Valves 12–26. . .
High Pressure Color Change Valves 12–26. .
Valve Bracket Changing Procedure 12–27. . .
Table of Contents
Gun Flush Box 12–28. . . . . . . . . . . . . . . . . . . . . . . .
Part No. 241389 12–28. . . . . . . . . . . . . . . . . . .
Part No. 241394 12–28. . . . . . . . . . . . . . . . . . .
Gun Flush Solenoid Box 12–29. . . . . . . . . . . . . . . .
Part No. 115125 12–29. . . . . . . . . . . . . . . . . . . .
Gun Holders for Gun Flush Box 12–30. . . . . . . . . .
Cable Chart 12–31. . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote User Interface 12–32. . . . . . . . . . . . . . . . .
Part No. 240874 12–32. . . . . . . . . . . . . . . . . . .
Stand Mount 12–33. . . . . . . . . . . . . . . . . . . . . . . . . .
Part No. 241501 12–33. . . . . . . . . . . . . . . . . . .
Audio/Visual Alarm 12–33. . . . . . . . . . . . . . . . . . . . .
Part No. 241380 12–33. . . . . . . . . . . . . . . . . . .
Accessories 12–34. . . . . . . . . . . . . . . . . . . . . . . . . . .
Part No. 241647 Catalyst Change Kit 12–34.
Part No. 195048 Paint Shield 12–34. . . . . . . .
Part No. 195049 Paint Shield 12–34. . . . . . . .
Part No. 241263 Printer Kit 12–34. . . . . . . . . .
Printer Power Supply 12–34. . . . . . . . . . . . . . .
Part No. 514037 Printer Paper 12–34. . . . . . .
Manual Dump Valve Kits 12–35. . . . . . . . . . . .
2K Fluid Outlet Valves 12–35. . . . . . . . . . . . . .
Part No. 513052 Air Flow Switch 12–35. . . . .
Part No. 241962 Hydro-Softfeel
Material Application Kit 12–35. . . . . . . . . .
Cable Network PC AMR 12–35. . . . . . . . . . . . .
Catalyst Supply Modules 12–35. . . . . . . . . . . .
Utilities Software 13–1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Utilities Overview 13–3. . . . . . . . . . . . . . . . . . . . . . . .
Connection Error 13–3. . . . . . . . . . . . . . . . . . . . . . . .
Mode Switch 13–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Backup PrecisionMix II 13–4. . . . . . . . . . . . . . . . . . .
Restore PrecisionMix II 13–7. . . . . . . . . . . . . . . . . . .
Update the Operating System 13–9. . . . . . . . . . . . .
Update PrecisionMix II Program 13–11. . . . . . . . . .
Connecting Utilities 13–12. . . . . . . . . . . . . . . . . . . .
Update User Interface Program 13–13. . . . . . . . . .
Reset PrecisionMix II Password 13–15. . . . . . . . .
Set PrecisionMix II Date and Time 13–16. . . . . . .
Open Graco Web Site 13–17. . . . . . . . . . . . . . . . . .
Edit Language 13–17. . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 14–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 14–6. . . . . . . . . . . . . . . . . . .
Graco Phone Number 14–6. . . . . . . . . . . . . . . . . . . . . .
5
6
1
Warnings
1–1Warnings
1–2 Warnings
WARNING
FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and
result in fire or explosion and serious injury.
The PrecisionMix Controller must only be installed and serviced by a qualified electrician.
The PrecisionMix Controller is for use only in non-hazardous locations. The maximum applied relay
voltage shall not exceed +24 volts. Do not operate the controller in hazardous locations, as defined
in Article 500 of the National Electrical Code (USA).
Ground the equipment and the object being sprayed. See Ground the System on page 3–30.
Do not install non-intrinsically safe equipment in a hazardous area.
Provide fresh air ventilation to avoid the buildup of flammable vapors from solvent or the fluid being
sprayed.
Extinguish all the open flames or pilot lights in the spray area.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Do not turn on or off any light switch in the spray area while operating or if fumes are present.
Do not smoke in the spray area.
Do not operate a gasoline engine in the spray area.
If there is any static sparking while using the equipment, stop spraying immediately. Identify and
correct the problem.
Keep liquids away from the electrical components.
Disconnect electrical power at the main switch before servicing the equipment.
The battery inside the PrecisionMix Controller may explode if mishandled. Do not recharge or
disassemble the battery. Do not expose the battery to fire or heat. The battery is intended for use
at normal temperatures, where high temperature cycles are not expected to exceed 212 F
(100 C).
TOXIC FLUID HAZARD
Hazardous fluids or toxic fumes can cause serious injury or death if splashed in the eyes or on the
skin, swallowed, or inhaled.
Know the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Wear the appropriate protective clothing, gloves, eyewear, and respirator.
1–3Warnings
WARNING
INJECTION HAZARD
Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause
extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin
can also cause serious injury.
Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medi-
cal attention.
Do not point the spray gun at anyone or at any part of the body.
Do not put hand or fingers over the spray tip.
Do not stop or deflect fluid leaks with your hand, body, glove, or rag.
Follow the Pressure Relief Procedure on page 4–3 whenever you: are instructed to relieve pres-
sure; stop spraying; clean, check, or service the equipment; or install or clean the spray tip.
Tighten all the fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
EQUIPMENT MISUSE HAZARD
INSTRUCTIONS
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result
in serious injury.
This equipment is for professional use only.
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Check the equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated system component. See the
instruction manuals of the individual PrecisionMix components for their maximum working pressures.
Route the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 180F (82C) or below –40F (–40C).
Do not use the hoses to pull the equipment.
Do not move pressurized equipment.
Use fluids or solvents that are compatible with the equipment wetted parts. See the Technical
Data section of all the equipment manuals. Read the fluid and solvent manufacturer’s warnings.
Comply with all applicable local, state and national fire, electrical and other safety regulations.
1–4 Warnings
2
Overview
Overview 2–1
2–2
Overview
Using this Manual
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
Special Note Symbol
This symbol precedes information that should
be taken special note of.
Screen Navigation Symbol
This symbol precedes information that tells you
how to enter information and navigate through
the User Interface screens.
Text that appears in grey on the screens in these
instructions indicates lines that may or may not appear
on your display, depending on previous selections that
have been made.
Text that appears in a grey box indicates a selection
that is being recommended or explained in that section of the instructions.
Manual Overview
The information is organized in the following way:
1. Warnings: Read this section for important safety
information.
2. Overview: This section provides information on
the instruction manuals and on PrecisionMix II 3K
Component ID and function.
3. Installation: This section provides information on
installing a configured PrecisionMix II 3K system.
After installation is complete, a startup checklist is
provided to verify the system is installed correctly
and ready to begin production. Portions of the
checklist will guide you to other procedures, such
as purging the system and configuring the software, to prepare the system for production.
4. Operation: The Pressure Relief Procedure and
miscellaneous operation procedures are in this
section.
5. Screen Map: The screen map shows the general
layout of all the User Interface screens and provides the page number to go to for more detailed
information on each screen.
6. Run Monitor: This section covers the use of the
Run Monitor screens.
7. Totalizer: This section covers the use of the
Totalizer screens.
8. System Configuration: This section covers how
to use the System Configuration screens. These
screens are used to configure how the system will
operate. Integrated color change and flow control
are part of the system configuration.
9. Recipe Setup: This section covers how to use the
Recipe Setup screens to setup recipes.
10. Troubleshooting: This section provides information on troubleshooting alarm conditions and some
system problems.
11. Parts: This section includes parts drawings and
lists for components of the PrecisionMix II 3K
system.
Overview 2–3
Related Publications
Form No. Description
308288 Fluid Manifold Manual
308778 G3000 Meter Manual
309148 Piston Meter Manual
309149 Magnetic Meter Manual
307731 LP Color Change Valve Assy. Manual
307941 LP Color Change Valve Manual
308977 HP Color Change Valve Assy. Manual
Form No. Description
308291 HP Color Change Valve Manual
309227 Gun Flush Box Manual
308818 Printer Manual
308292 Fluid Pressure Regulator
309138 System Electrical Schematic
309158 System Configurator Schematic
309234 Coriolis Meter Manual
2–4
Overview
Overview 2–5
How the PrecisionMix II 3K Works
Usage
The standard Graco PrecisionMix II 3K can blend most
two and three component epoxy or polyurethane
paints. The PrecisionMix is not for use with “quick-setting” paints (those with a pot life of less than 15 minutes). For information on handling quick-setting paints
or abrasive fluids, contact your Graco distributor.
Fluid Supply
The system can be set up to mix components supplied
from pressure tanks or feed pumps. The materials can
be transferred from their original containers or from a
central paint recirculating line.
The standard PrecisionMix II 3K is designed to operate
an air spray or air-assisted system with a capacity of
up to 2000 cc/min.
Adaptive Overrun Correction
The actual volume of fluid dispensed each cycle can
vary slightly from the calculated target. However, the
controller monitors this variance and continuously
makes adjustments to keep the ratio of Component A
to Component B and the ratio of Component C to
Component B within the user specified tolerance.
Other inputs and outputs are provided to control the
purging process, signal an alarm, and interface with
the operator. Refer to Fig. 3.21, page 3–29.
The order in which the three components are mixed
depends on the characteristics of the materials being
used. In the standard configuration, Component A is
mixed with Component C first, then the blend of A and
C is mixed with Component B. The instructions in this
manual correspond with this mixing order.
To convert the PrecisionMix II 3K to a configuration
where Component A is mixed with Component B
before Component C is added, refer to Changing the
Mixing Order, on page 2–10.
The following is a typical ratio cycle:
Figures 2.2, 2.3, and 2.4 show the flow of fluid through
component lines A, B, and C during this cycle.
1. To begin operation, the operator enters the desired
ratio and other parameters through the User
Interface (BB) and turns the operator switch (AA)
to MIX .
Operating Cycle
The 3K fluid manifold consists of four separate fluid
supply lines for Component A, B, C, and the flushing
material. The Component A, B, and C supply lines
have the following parts to individually control the flow
of the three materials. Refer to Fig. 2.2.
Fluid filters (DA, DB, DC)
Check valves (EA, EB, EC)
Flow meters (FA, FB, FC)
Dispense valves (GA, GB, GC)
The dispense valves control the entry of the components into the integrator chambers. The flow meters
monitor the exact fluid volumes being dispensed and
send electrical pulses to the controller. The controller
monitors these pulses and signals the solenoids to turn
the dispense valves on or off accordingly (based on
the target volumes calculated by the controller).
Fig. 2.1
AA BB
2. When the operator triggers the spray gun, the
controller sends a signal to activate the solenoid
valve for the component A dispense valve (GA).
See Fig. 2.2.
3. The component A dispense valve (GA) opens and
Component A begins to flow into the first integrator
chamber (L). When the correct quantity is dispensed (based on the calculated target value), the
component A dispense valve closes. See Fig. 2.2.
2–6
Overview
How the PrecisionMix II 3K Works
Functional Diagram – Component A Dispense
Component A Component BComponent C
A
A
G
A
D
A
E
A
F
A
J
A
K
A
H
C
H
L
C
G
C
K
C
C
D
H
C
E
C
F
C
J
N
B
G
B
B
K
Q
B
B
D
B
E
B
F
B
J
M
Fig. 2.2
KEY for Figs. 2.2, 2.3, and 2.4
Component A
A Supply Line, Component A
DAFluid Filter, Component A ,
100 mesh minimum
EACheck Valve, Component A
FAFlow Meter, Component A
GADispense Valve, Component A
HAPurge Valve (usually air), Component A
JAFluid Shut-off Valve, Component A
KARatio Check Valve, Component A
Component C
C Supply Line, Component C
DCFluid Filter, Component C,
100 mesh minimum
ECCheck Valve, Component C
FCFlow Meter, Component C
GCDispense Valve, Component C
HCPurge Valve (usually solvent),
Component C
JCFluid Shut-off Valve, Component C
KCRatio Check Valve, Component C
P
Component B
B Supply Line, Component B
DBFluid Filter, Component B,
100 mesh minimum
EBCheck Valve, Component B
FBFlow Meter, Component B
GBDispense Valve, Component B
HBPurge Valve (usually solvent),
Component B
JBFluid Shut-off Valve, Component B
KBRatio Check Valve, Component B
Other
L First Integrator
M First Static Mixer
N Second Integrator
P Second Static Mixer
Q Fluid Meter
R Fluid Supply to Gun
R
TI0085B
Overview 2–7
How the PrecisionMix II 3K Works
Functional Diagram – Component B Dispense
Component A Component BComponent C
A
A
G
A
D
A
E
A
F
A
J
A
K
A
H
C
H
L
C
G
C
K
C
C
D
H
C
E
C
F
C
J
N
B
G
B
B
K
Q
B
B
D
B
E
B
F
B
J
M
Fig. 2.3
4. The controller sends a signal to activate the solenoid valve for the component B dispense valve
(GB). See Fig. 2.3.
P
R
TI0087B
5. The component B dispense valve (GB) opens and
Component B flows into the second integrator
chamber (N). The fluid is lined up proportionately
with the previously-dispensed Component A and C
dose. The component B dispense valve closes
when the target volume for Component B is
reached. See Fig. 2.3.
2–8
Overview
How the PrecisionMix II 3K Works
Functional Diagram – Component C Dispense
Component A Component BComponent C
A
A
G
A
D
A
E
A
F
A
J
A
K
A
H
C
H
L
C
G
C
K
C
C
D
H
C
E
C
F
C
J
N
B
G
B
B
K
Q
B
B
D
B
E
B
F
B
J
M
Fig. 2.4
6. The component C dispense valve (GC) opens and
Component C flows into the first integrator chamber. The fluid is lined up proportionately with
Components A and B. The component C dispense
valve closes when the target volume for Component C is reached. See Fig. 2.4.
7. Components A and C flow into a static mixer (M),
where they are mixed. The mixture then flows into
the second integrator chamber (N). See Fig. 2.4.
8. The three components are given a homogeneous
blending as they pass through a second static
mixer tube (P).
P
R
TI0086B
9. The three components continue to be alternately
fed into the integrators as long as the gun is triggered. Output from the mixer tube to the spray gun
may be controlled by a fluid pressure regulator (Q).
After the trigger is released, if the gun is not triggered again within four minutes, the system will go
to an idle mode, which closes off the mix manifold.
When the gun is triggered again, the system will
continue the process where it left off. Operation
can be stopped at any time by energizing the
standby input or shutting off the main power
switch.
Overview 2–9
Changing the Mixing Order
The order in which the three components are mixed
depends on the characteristics of the materials being
used. In the standard configuration, Component A is
mixed with Component C first, then the blend of A and
C is mixed with Component B. The instructions in this
manual correspond with this mixing order.
To convert the PrecisionMix II 3K to a configuration
where Component A is mixed with Component B
before Component C is added, perform the following
steps.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 4–3.
1. Flush the system and relief the pressure.
2. Refer to Fig. 2.5. Unscrew the nut of the Component C tube (T) from the nipple at the dispense
valve (V).
4. Unscrew the nut of the Component B tube (W)
from the nipple at the dispense valve (Y).
5. Remove the screws (S) and take the Component
B meter (Z), bracket, and tube off the fluid panel.
6. Turn the tubes of both meters 180 so the nuts
face in the opposite direction.
7. Reinstall the Component B and C meters, in the
opposite locations.
8. Refer to Fig. 2.6. Disconnect the red air lines (R)
from the elbows at the Component B and C dispense valves and reconnect them to the opposite
dispense valve. Switch the green air lines (G) in
the same way.
9. Refer to Fig. 2.6. Disconnect the red air lines (R)
from the elbows at the Component B and C purge
valves and reconnect them to the opposite purge
valve. Switch the green air lines (G) in the same
way.
10. Using Part No. 196303 Label, relabel dispense
valve B to C and dispense valve C to B.
3. Remove the screws (S) and take the Component
C meter (U), bracket, and tube off the fluid panel.
S
U
V
T
W
Disassembly Reassembly
Fig. 2.5
S
Y
11. Reverse the wires on terminals 4271 and 4291.
Refer to Fig. 3.21, page 3–29.
Z
Z
U
W
Affix Label B Here
Affix Label C Here
2–10
S
S
T
V
Y
TI0223
Overview
Changing the Mixing Order
AB
RGG GGG GRR RRR
Before Changing Component B and C Tubing Connections
CAP BPCP
AB
RGG GGG GRR RRR
After Changing Component B and C Tubing Connections
Fig. 2.6
CAP BP CP
ABCAPBPCP
GGGG G
RGRRR RR
Detail of Solenoid Box
TI0227
Overview 2–11
Flow Control Overview
Flow Control is used to limit the flow of material to the
air spray gun to help avoid sags and runs in the finish
due to coatings being applied too thick or quickly and
to assure adequate coverage. Flow control can be
configured for use with a manual or automatic air spray
gun. Refer to Flow Control Setup, page 8–16.
The flow control module uses flow meters, fluid regulator, current to pressure (I/P) transducer, and the PrecisionMix II 3K controller to adjust and maintain the flow
of material to the air spray gun.
Flow control is an optional feature of the PrecisionMix 3K system. Your system must be
configured with flow control hardware and
software in order to use flow control. Detailed
information on using flow control is in other
sections of this manual.
Flow control is NOT for use with air-assisted or
airless spray guns.
System Requirements
The fluid feed system must have adequate volume and
pressure to supply the air spray gun. The Component
A, B and C fluid supply pressures need to be balanced. The fluid feed hose, gun nozzle and needle
size and travel must be sized and adjusted properly to
keep the flow control operating at its maximum efficiency.
General Operation Sequence
1. When the controller is first turned on, a pre-configured pilot air pressure is applied to the fluid regulator.
2. When the air spray gun is triggered, the controller
waits for the set delay time to elapse before it
starts monitoring the flow and making any necessary adjustments. The delay time is user selectable (typically 1–2 seconds) and helps assure the
fluid is moving at a normal rate before flow rate
adjustments occur.
3. When the fluid moves through the fluid lines, the
flow meter(s) monitors the flow and sends meter
pulses to the controller. These pulses are converted into flow measurements and checked
against the set values in the controller.
Flow Control Features
Ability to control one manual or automatic air
spray gun
Programmable maximum flow setpoint
Programmable lower flow control start value for
manual gun
Delayed activation of flow control after the gun is
triggered
Manual flow rate reset function, which can be
initiated from the in-booth Flow Control Station
An indicator light on the Flow Control Station to
show when the flow rate is resetting for manual gun
operation.
4. If the fluid flow falls outside the set values, the
controller sends a signal to adjust the fluid regulator to correct the flow. The flow is raised or lowered by the pilot air pressure from the current to
pressure (I/P) transducer. The greater the pilot air
pressure to the fluid regulator, the higher the fluid
pressure and the greater the fluid flow.
5. When the air spray gun is turned off, the flow
control holds the pilot air pressure value and does
not attempt to adjust fluid flow until the gun is
triggered again.
6. When the gun is triggered, the process of controlling the fluid flow continues.
2–12
Overview
Flow Control Overview
One Gun Flow Control Using a Flow Meter in the Mixed Material Line
Fig. 2.7 shows a one gun system that is using a flow meter, installed in the mixed material line, to monitor fluid flow
to the gun. Using a flow meter in the mixed material line, rather than monitoring fluid flow with the component A, B,
and C flow meters, provides a faster response to changes in the flow rate setpoint.
PrecisionMix II 3K Controller Panel
User Interface with
Color Change
RS–485
External Analog Setpoint
(use optional)
Current to
Pressure
Transducer
Fig. 2.7
Typical Installation of One Gun Flow Control Using a Flow Meter in the Mixed Material Line
4 to 20 mA Analog In
Flow Control Station
4 to 20 mA Analog Out
Flow Meter Signal
I/P
Fluid Regulator
Flow Meter
(Optional)
Fluid Panel
TI0162
Overview 2–13
Flow Control Overview
Flow Control Components
(Refer to Fig. 2.7)
Flow Meter
Digital pulses are sent by the flow meters to the controller to provide fluid flow rate information.
Fluid Regulator
The flow control regulates the fluid flow to a pre-programmed flow rate by adjusting the fluid regulator. The
fluid regulator uses a pneumatic pilot pressure from a
current to pressure (I/P) transducer to open and close
the regulator needle.
Current to Pressure (I/P) Transducer
An adjustable pneumatic signal is required for the
controller to regulate the fluid flow. The current to
pressure transducer provides this signal. The controller
outputs an analog current signal that varies from 4
milli-amps to 20 milli-amps and the transducer
changes the milli-amp signal to a 1–100 psi (7–700
kPa, 0.1–7 bar) pneumatic signal. The pneumatic
pressure signal is applied to a fluid pressure regulator,
which controls the output fluid pressure to the air spray
gun.
Flow Control Station
The Flow Control Station consists of a Flow Control
Reset/Warning light and Flow Control Reset button,
which are used with manual air spray guns to manually
initiate flow control reset.
Flow Control Reset Button
Pressing the reset button will cause the flow control
system to calibrate the flow rate to the current setpoint.
Flow Control Reset/Warning Light
The controller activates the Reset/Warning light when
the flow control system is resetting flow rate (solid
light) or when a flow control alarm condition occurs
(flashing light––flow rate is outside the set tolerance).
Flow Rate Alarms
Wait for the system to automatically calibrate the flow
rate or manually reset the flow rate by pressing the
reset button.
Flow Control Reset/
Warning Light
PrecisionMix II 3K Controller
The controller can be configured to control and display
the fluid control information, including setpoint, actual
flow, milli-amp output values to the I/P transducer,
system parameter, and I/O conditions. The controller
will indicate when the system is operating within flow
control tolerance and when it is not.
Fig. 2.8
Flow Control
Reset Button
Flow Control Station
9003A
2–14
Overview
Flow Control Overview
Flow Control Parameters (Refer to Fig. 2.9)
The following flow control parameters are entered from
either the User Interface or from digital input:
Setpoint Source – Specifies the source of the
flow limit value as User Interface, network or analog
input (refer to page 8–18).
Analog Scaling – If analog is the source of input,
the scaling for analog input must be set. The setting
is used to calculate the relationship between the
flow rate and a 4–20 mA input signal (refer to page
8–18).
Flow Rate Setpoint – Sets the value for the
desired flow rate. Flow control monitors and calibrates flow rate based on this value and the other
parameters (refer to page 9–9 or 9–16).
Delay Time – Sets the time that flow control waits
after the gun is triggered before starting to monitor
the flow rate. This allows time for the fluid to quickly
reach the setpoint and avoid unnecessary alarms or
corrections (refer to page 8–19).
Flow Control Low Limit – This value is only used
with manual guns and is always entered from the
User Interface (refer to page 9–9). The flow control
stops making adjustment if the flow rate falls below
the difference of setpoint and the “Low Limit”
volume. The warning alarm output will be on when
the actual flow rate falls out of this tolerance for 5
seconds. This helps the system allow for periodic
partial triggering (feathering) of a hand gun without
adjusting the flow rate.
If the setpoint is changed, the low limit will change
accordingly.
Example – If the setpoint is 500 cc/min. and the low
limit is 100 cc/min.:
The flow control will stop making adjustments
when the flow rate falls below 400 cc/min.
Changing the setpoint to 300 cc/min. will
change the low limit value to 200 cc/min.
Alarm
Tolerance
Flow Rate Setpoint
Flow
Delay Time
Fig. 2.9
Low Limit
Gun “feathered”,
No Flow Control
NOTE: Graph shown for hand gun flow control.
Full Flow Control
Time
Alarm
Tolerance
Overview 2–15
Using Recipes/Color Change
There are three modes of operation relating to the
changing of recipes: No Color Change, Integrated
Color Change, and Integrated Color Change with
Queue. Refer to page 8–22. The controller logic
decides whether or not to allow a chosen recipe
change to occur. The criteria for allowing a recipe
change are as follows:
1. The new recipe must contain valid data for the
desired ratio, flow meter K-factors, tolerance, and
pot life times.
2. An active alarm must not exist in the system.
3. An Integrated Color Change can not already be in
progress.
4. The recipe number must not be greater than the
number of recipes configured to run on the system.
5. The input device used to change the recipe value
must be configured as the recipe input device
(User Interface, Network, I/O, or Operator Station).
6. When “No Color Change” is selected, the operator
switch on the Operator Station must be in the
A color change may be performed with the operator
switch in the Mix or Standby position. If the
operator switch is in the Mix position, the system
will be ready for immediate spraying after a color
change. The green light on the Operator Station will
blink while a color change is in operation. The green
light indicates that the system is busy and is not ready
for spraying.
Mix/Load Volumes
If mix/load volumes are configured for the system, the
fill portion of the color change may continue after the
color change has timed out. This feature may be used
in conjunction with a gun flush box to make sure that
the desired volume of material is loaded into the system. The system keeps track of the volume that is
mixed during the fill portion of the color change. If the
mix/load volume is not reached, then the system will
continue to fill until the volume is reached (the operator
switch needs to be in the Mix position for this to
occur automatically). Setting the mix/load volume to
zero will disable the mix/load volume feature.
Standby
position.
No Color Change
The system will boot up for the first time with color
change turned off. In this mode, color changes are
performed manually. The recipe number is changed
through the User Interface, Network, I/O, or Operator
Station. The operator must manually dump and purge
the old material from the system and then load the new
material into the system.
Integrated Color Change
The Integrated Color Change mode of operation
automatically performs the tasks necessary to execute
a color change. This is a time-based mode that is
configurable by the user. Refer to page 8–21. The
timing of the color change is configured in one of four
color change sequences. The color change
sequences contain start times and timer duration for
the devices that are controlled during a color change.
Each recipe is then assigned one of the four color
change sequences for its operation.
Recipe Zero
Recipe zero is considered the “Purge Down” recipe.
The purpose of this recipe is to allow the user to purge
out the material lines and the mixed material lines
without loading a new color. A typical use for recipe
zero is at the end of a shift. The operator performs a
color change to recipe zero and the lines are cleaned
out to prevent hardening of catalyzed material between
shifts. Multiple Purge Downs may also be performed if
the lines are not sufficiently clean. Another Purge
Down is triggered by pressing the Enter key on the
Operator Station or by setting the the color change bit
on the I/O high.
NOTE: Recipe 0 has a unique Purge Sequence 0 to
allow for end of shift or production shutdown. If you are
using a solvent meter, any additional solvent used in
the recipe 0 purge cycle will not be included in the
solvent totals. It is important to configure Purge Sequence 0 to flush all materials clean in one purge
cycle, to maintain accurate solvent use records.
Continued on the next page.
2–16
Overview
Using Recipes/Color Change
Integrated Color Change – continued
The devices that are controlled by the Integrated Color
Change Sequences are as follows.
Purge Valves: The Integrated Color Change
Sequence typically starts by purging out the old mixed
material. The purge can be further defined by setting
the total purge time, the purge time for the first cycle,
the purge time for the last cycle, and the individual
purge times for the three possible purge valves. The
beginning of the purge can be delayed to allow time for
the gun triggers to activate. Refer to page 8–23.
Mix Valves: The sequence fills the hoses with the new
mixed material after the system has finished purging.
The target mix parameters are calculated after the
purge is completed, before the mix begins. The user
defines the mix (fill) time duration for the Color Change
Sequence. Refer to page 8–23.
Dump Valves: The dump valves open immediately
when the Color Change Sequence begins. The user
then configures how long these valves stay open. The
purpose of these valves is to allow the unmixed A, B,
and C component materials to dump from the system
before entering the mix manifold. Refer to page 8–24
and 8–26.
Special Outputs 1, 2, 5, and 6: The special outputs
are optional outputs that the user can configure for
their particular application. Each of these valves can
be turned on and off up to four times during a color
change sequence. Refer to page 8–28.
Specials 1 and 2 are pneumatic outputs, while Specials 5 and 6 are electrical outputs.
Integrated Color Change with Queue
The Integrated Color Change with Queue mode of
operation runs in a similar fashion to the standard
Integrated Color Change mode. The difference
between the two modes is that the Queue parameters
override the normal color change parameters during
the color change. Five data sets can be set up in a
queue and sent to the controller individually. Refer to
page 6–7. A queue data set consists of the following
five parameters.
1. Sequence Number – The number for the color
change sequence that will be used for the new
color.
2. Recipe Number – The recipe number that will be
used for the new color.
3. Color Valve Component A (Resin) – The number
corresponding to the component A color valve
chosen for the new color.
Solvent Valves: The Solvent valves open immediately
when the Color Change Sequence begins. The user
then configures how long these valves stay open. The
purpose of these valves is to push the unmixed A, B,
and C component materials through the dump valves
and clean the hoses for the next material. Refer to
page 8–24 and 8–26.
Gun Triggers 1–2: The gun triggers are electrical
outputs that can be configured to turn on and off up to
two times. These outputs are typically wired to the
spray guns triggers to allow automatic purging and
filling. Refer to page 8–27.
4. Color Valve Component B (Catalyst) – The
number corresponding to the component B color
valve chosen for the new color.
5. Color Valve Component C (Reducer) – The
number corresponding to the component C color
valve chosen for the new color.
A Queue Color Change is triggered by pressing the
Enter key on the Operator Station or by setting the
Color Change Bit on the I/O of the controller. The data
set values on the top of the queue will be used for the
Color Change. When color change is complete, the
top level of the queue is erased and all of the other
data sets move up one level on the queue.
Overview 2–17
Using Recipes/Color Change
Color Change Sequences
There are four color change sequences that can be set
up to control how a color change will operate. These
sequences can be viewed on the User Interface in a
graphical fashion. A typical color change sequence
looks as follows.
Color Change Graph Screen
1. PURGE
MIX**
2. A DUMP
3. A SOLV
4. B DUMP
5. B SOLV
6. C DUMP
7. C SOLV
8. GUN1 TG
9. GUN2 TG
10.SPEC 1
11.SPEC 2
12.SPEC 5
13.SPEC 6
0 Sec 40.0
Color Chg Seq 1. Enter Function (1-13) 01
Sequence 1:
Purge time = 20 Seconds
Mix time = 20 seconds
Component A Dump time = 7 seconds
Component A Solvent time = 5 seconds
Gun 1 time = 40 seconds
Total Sequence Time = 40 seconds
The color change sequence begins by closing all of the
color change valves. Then the dump valve for Component A (resin) will immediately open, as well as the
solvent valve on the color stack. This will allow solvent
to flow into the fluid lines, through the flow meter, and
out through the dump valve.
The color change solvent valve stays open for 5 seconds, then it closes and the new color valve, associated with the new recipe, will open. The dump valve
remains open for two seconds after the new color
valve is opened, to allow the new color to fill the fluid
line and flush out the remaining solvent. The dump
valve is open for a total of 7 seconds.
In parallel with the dumping and filling of the fluid lines,
a purge is occurring through the mix manifold and
mixed material lines. The purge always starts at the
beginning of a color change sequence. The above
sequence triggers Gun 1 for the entire sequence. This
allows the purge to flush solvent through the mix
manifold and mixed material lines and out through the
gun. After 20 seconds, the purge is complete.
The system then begins to mix new material. The
system mixes for 20 seconds until the mix manifold
and the mixed material lines are full of new material.
This sequence is a 40 second long operation.
NOTE: When using automatic spray guns or gun flush
boxes, you must specify trigger times for each gun.
The screen shown above reflects the use of manually
triggered spray guns.
2–18
Overview
Using Recipes/Color Change
Changing from One Color Change
Sequence to Another
It is possible to perform a color change from a recipe
associated with one color change sequence to a recipe
that is associated with another color change sequence.
In this case the system automatically uses the old
sequence for dumping and purging and the new
sequence for loading and mixing. This type of color
change is useful in applications where one material
tends to purge and load more quickly than another.
When switching from one sequence to another, there
are two transition points that determine which
sequence is being used at a given time. The first
transition point occurs when the solvent valve for the
color change stack closes. The second transition point
is when the purge is complete. The table at right lists
the outputs associated with the transition points.
An example of a color change from one sequence to another is as follows.
Transition Point Output
Color Stack Solvent
Component A Closes
Color Stack Solvent
Component B Closes
Color Stack Solvent
Component C Closes
Purge Ends Mix
Dump Valve Component A
Dump Valve Component B
Dump Valve Component C
Gun 1 Trigger
Gun 2 Trigger
Special 1
Special 2
Special 5
Special 6
Sequence 1:
Purge time = 20 Seconds
Mix time = 20 seconds
Component A Dump time = 7 seconds
Component A Solvent time = 5 seconds
Special 1 on time = 0 seconds
Special 1 time = 40 seconds
Total Sequence Time = 40 seconds
Color Change Graph Screen
1. PURGE
MIX**
2. A DUMP
3. A SOLV
4. B DUMP
5. B SOLV
6. C DUMP
7. C SOLV
8. GUN1 TG
9. GUN2 TG
10.SPEC 1
11.SPEC 2
12.SPEC 5
13.SPEC 6
0 Sec 40.0
Color Chg Seq 1. Enter Function (1-13) 01
Sequence 2:
Purge time = 40 Seconds
Mix time = 40 seconds
Component A Dump time = 13 seconds
Component A Solvent time = 10 seconds
Special 2 on time = 0 seconds
Special 2 time = 40 seconds
Total Sequence Time = 80 seconds
Color Change Graph Screen
1. PURGE
MIX**
2. A DUMP
3. A SOLV
4. B DUMP
5. B SOLV
6. C DUMP
7. C SOLV
8. GUN1 TG
9. GUN2 TG
10.SPEC 1
11.SPEC 2
12.SPEC 5
13.SPEC 6
0 Sec 80.0
Color Chg Seq 1. Enter Function (1-13) 01
Overview 2–19
Continued on the next page.
Using Recipes/Color Change
Changing from One Color Change
Sequence to Another – continued
Actual valve times:
Purge time = 20 seconds
Mix time = 40 seconds
Component A Dump time = 8 seconds
Component A Solvent time = 5 seconds
Special 1 on time = 0 seconds
Special 1 time = 20 seconds
Special 2 on time = 20 seconds
Special 2 time = 40 seconds
Total Sequence Time = 60 seconds
Actual Valve Times
1. PURGE
MIX**
2. A DUMP
3. A SOLV
4. B DUMP
5. B SOLV
6. C DUMP
7. C SOLV
8. GUN1 TG
9. GUN2 TG
10.SPEC 1
11.SPEC 2
12.SPEC 5
13.SPEC 6
0 Sec 60.0
Color Chg Seq 1. Enter Function (1-13) 01
2–20
Overview
Loading...