Graco Inc. ProMix II Service - Parts
Service - Parts
ProMix™ II
For proportional mixing of plural component coatings. For professional use only.
For use in explosive atmospheres (except the EasyKey™).
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
310653E
ENG
Manual Conventions
Contents
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 2
ProMix™ II Models . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 8
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ProMix™ II Alarms . . . . . . . . . . . . . . . . . . . . . . 10
Fluid Manifold Troubleshooting . . . . . . . . . . . . . 11
Solenoid Troubleshooting . . . . . . . . . . . . . . . . . 12
Operator Station Troubleshooting . . . . . . . . . . . 12
Fluid Panel Control Board Diagnostics . . . . . . . 13
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Before Servicing . . . . . . . . . . . . . . . . . . . . . . . . 14
After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Replacing Air Filter Element . . . . . . . . . . . . . . . 14
EasyKey™ Display . . . . . . . . . . . . . . . . . . . . . . 15
Operator Station . . . . . . . . . . . . . . . . . . . . . . . . 19
Smart Fluid Panel . . . . . . . . . . . . . . . . . . . . . . . 19
Connecting to a PC . . . . . . . . . . . . . . . . . . . . . . . . 25
Connect Cable 118342 . . . . . . . . . . . . . . . . . . . 25
Updating Software . . . . . . . . . . . . . . . . . . . . . . . 26
Software Troubleshooting . . . . . . . . . . . . . . . . . 29
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Pneumatic Diagram . . . . . . . . . . . . . . . . . . . . . . 30
ProMix™ II Electrical Schematic . . . . . . . . . . . . 31
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
ProMix™ II Assembly . . . . . . . . . . . . . . . . . . . . 32
Flow Meter Kits . . . . . . . . . . . . . . . . . . . . . . . . . 34
Operator Station . . . . . . . . . . . . . . . . . . . . . . . . 35
EasyKey™ Display . . . . . . . . . . . . . . . . . . . . . . 36
Smart Fluid Panel . . . . . . . . . . . . . . . . . . . . . . . 38
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 40
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 40
Manual Conventions
WARNING
Hazard Symbol
WARNING: a potentially hazardous situation which, if
not avoided, could result in death or serious injury.
Warnings in the instructions usually include a symbol
indicating the hazard. Read the general Warnings
section for additional safety information.
CAUTION
CAUTION: a potentially hazardous situation which, if
not avoided, may result in property damage or
destruction of equipment.
Note
Additional helpful information.
2 310653E
Manual Conventions
310653E 3
ProMix™ II Models
ProMix™ II Models
WARNING
Do not install equipment approved only for non-hazardous location in a hazardous area. Substitution of
components may impair intrinsic safety. See page 6.
PM
Enter Model number here
ProMix™ II
Unit
PM
A Meter B Meter Color Change
0 None 0 None 0 None, Single Color 0 No
1 G3000 1 G3000 1 2 Color, Low Pressure 1 Ye s
2 G3000HR 2 G3000HR 2 4 Color, Low Pressure
3 Coriolis 3 Coriolis 3 6 Color, Low Pressure
Hazardous Location Approval
Only models with a G3000 (1) or G3000HR (2) for both A and
B meters are approved for installation in a Hazardous Location - Class I, Div I, Group D, T3.
Non-hazardous Location Approval
WARNING
Changing the fluid manifold configuration may change
its pressure rating. Do not exceed the pressure rating
of the lowest rated component. See page 6.
Gun Flush
Box
4 2 Color, High Pressure
5 4 Color, High Pressure
6 6 Color, High Pressure
#53
Conforms to FM std
3600 & 3610 for use in Class I Div 1
Group D T3 Hazardous locations
CAN/CSA 22.2 No.157 & No. 1010.1-92
EEx ib IIA T3
ISSeP 04 ATEX 008
SYST
#53
CAN/CSA
22.2 No.1010.1
Maximum Working Pressure
Maximum working pressure rating is dependent on the A and B meter and color change option selected. The pressure rating is based on the rating of the lowest rated fluid manifold component. Refer to the component pressure
ratings below. Example: Model PM1140 has a maximum working pressure of 3000 psi (21 MPa, 207 bar).
Check the ID plate on your EasyKey™ Display or fluid panel for its maximum working pressure. See F
IG. 1,
page 5.
ProMix™ II Fluid Manifold Components Maximum Working Pressure
Color Change Option 1, 2, or 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 psi (2.1 MPa, 21 bar)
Color Change Option 4, 5, or 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 psi (21 MPa, 207 bar)
Coriolis A and B Meters Option 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2300 psi (16 MPa, 159 bar)
No Meters or G3000 or G3000HR A and B Meters Option 0, 1, or 2 . . . . . . . . . . . . . . 4000 psi (28 MPa, 276 bar)
Flow Meter Fluid Flow Rate Range
G3000 Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75-3000 cc/min. (0.02-0.79 gal./min.)
G3000HR Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38-1500 cc/min. (0.01-0.40 gal./min.)
Coriolis Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-3800 cc/min. (0.005-1.00 gal./min.)
4 310653E
Related Manuals
ProMix™ II ID Plate Locations
ID
IG. 1: EasyKey™ Display and Smart Fluid Panel
F
Related Manuals
Component Manuals in English
Manual Description
310633 ProMix™ II Operation
310653 ProMix™ II Service-Parts
310654 Fluid Mix Manifold
310655 Dispense Valve
308778 G3000, G3000HR Flow Meter
310696 Coriolis Flow Meter
310656 Color Change Kit
307731 Color Change Valve Assembly,
Low Pressure
307941 Color Change Valve, Low Pressure
308291 Color Change Valve Assembly, High
Pressure
308977 Color Change Valve, High Pressure
310695 Gun Flush Box Kit
308818 Printer
310669 ProMix™ II Data Download Kit
310745 Gun Air Shutoff Kit
This manual available in following languages:
Manual Language Manual Language
310653 English 310735 Chinese
310731 French 310736 Japanese
310732 Spanish 310807 Dutch
310733 Italian 310808 Finnish
310734 German 310809 Swedish
310653E 5
Warnings
Warnings
The following warnings include general safety information for this equipment. More specific warnings are included in
the text 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 lights on or off when flammable fumes are present.
• Ground equipment and conductive objects in 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.
INTRINSIC SAFETY
Only models with a G3000 (1) or G3000HR (2) for both A and B meters are approved for installation in a
Hazardous Location - Class I, Div I, Group D, T3. To help prevent fire and explosion:
• Do not install equipment approved only for non-hazardous location in a hazardous area. See the ID
label for the intrinsic safety rating for your model.
• Do not substitute system components as this may impair intrinsic safety.
ELECTRIC SHOCK HAZARD
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.
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 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.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
6 310653E
Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• 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.
• Check equipment daily. Repair or replace worn or damaged parts immediately.
• Do not alter or modify equipment.
• For professional use only.
• Use equipment only for its intended purpose. Call your Graco distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not use hoses to pull equipment.
• Comply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch 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 in this manual. Disconnect power or air supply.
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.
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
310653E 7
Pressure Relief Procedure
Pressure Relief
Procedure
I
WARNING
Follow Pressure Relief Procedure when you stop
spraying, before changing spray tips, and before
cleaning, checking, or servicing equipment. Read
warnings, page 6.
1. Engage the trigger lock.
2. Press Standby key on Operator Station.
Shut
off
3. Shut off air at the spray gun.
8. Engage trigger lock.
9. Press Standby on Operator Station.
10. If you suspect that the spray tip or hose is clogged
or that pressure has not been fully relieved after following the steps above, very slowly loosen tip
guard retaining nut or hose end coupling to relieve
pressure gradually, then loosen completely. Clear
hose or tip obstruction.
WARNING
Pressure upstream of component A and B dispense
valves (A, B) may not be fully relieved.
11. Before servicing or disconnecting flow meters, color
change valves, or other components between the
fluid supply shut off valves (T) and dispense valves
A and B, very slowly loosen swivel fitting (HH) to
relieve pressure gradually.
WARNING
If using an electrostatic gun, shut off electrostatics
before flushing.
4. Relieve fluid and air pressure at component A and
B and solvent feed pumps or pressure pots as
instructed in their separate manuals. Close all fluid
supply shutoff valves.
5. Press Mix on Operator Station.
6. Disengage trigger lock.
7. Hold a metal part of the gun
firmly to a grounded metal
pail. Trigger the gun to relieve
pressure.
T
HH
HH
A
B
T
8 310653E
Shutdown
Shutdown
1. To stop production at any time, press Standby
on the Operator Station.
2.
3.
WARNING
If using an electrostatic gun with a gun flush
box, shut off the electrostatics before placing the
gun in the box.
If you have a gun flush box, place the gun inside
the box when the gun is not in use.
4. If shutdown time WILL exceed the pot life, purge
the ProMix™ II of mixed material. See ProMix™ II
Operation manual.
If shutdown time WILL NOT exceed the pot life,
you do not need to purge the system, but you must
relieve system pressure.
WARNING
Follow Pressure Relief Procedure on page 8 when
you stop spraying, before changing spray tips, and
before cleaning, checking, or servicing equipment.
Read warnings, page 6.
310653E 9
Troubleshooting
Troubleshooting
WARNING
Follow Pressure Relief Procedure, page 8, before
cleaning, checking, or servicing equipment. Read
warnings, page 6.
CAUTION
Do not use the fluid in the line that was dispensed off
ratio as it may not cure properly.
ProMix™ II Alarms
Alarms E-Codes
Description E-Code
Communication Error E1
Purge Error E2
Potlife Exceeded Alarm E3
Ratio Alarm E4
Overdose Alarm E5
Dose Time A Alarm E6
Dose Time B Alarm E7
Autodump Complete Alarm E8
EasyKey in Setup Mode E9
The ProMix™ II has alarms to alert you of a problem
and prevent off-ratio spraying. If an alarm occurs, operation stops and the following occurs:
• A red LED illuminates steadily or flashes on the
Operator Station.
• Operator Station displays an alarm E-Code, E1 to
E9.
• Alarm sounds.
• Status bar on the EasyKey™ Display shows the
alarm E-Code with a description.
Red LED
E-Code
To Clear Alarm and Restart
When an alarm occurs, determine the E-Code
before clearing it. You can use the EasyKey™
Report screen (F
with date and time stamps.
F
IG. 2: Setup Mode - Report Screen
Except for Potlife Exceeded (E3) Alarm and Purge Error
(E2) Alarm, all alarms can be cleared by pressing the
Error Clear
To clear Pot Life Exceeded alarm, the system must be
key on the Operator Station.
IG. 2) to view the last 10 alarms
Operator Station
purged. Press the Purge key on the Operator Station. The system purges until the preset purge time is
complete. Refer to purging procedure in ProMix™ II
Operation manual.
For Additional Information
See ProMix™ II Operation manual for additional alarm
troubleshooting information.
10 310653E
Fluid Manifold Troubleshooting
See FIG. 3. To remove the fluid manifold, see page 23.
See manual 310654 for complete information on the
fluid manifold.
31
A
10
20
Troubleshooting
32
B
B
10
B
K
16
D
D
16
OFF
C
20
16
C
16
OFF
A
A
C
A
D
Component A Side
A Supply Line A connection
A
Fluid Filter A, 100 mesh
C
A
D
Check Valve A
A
Flow Meter A (G3000 shown)
E
A
10
Fluid Shutoff Valve A
A
Dispense Valve A
43
C
16
Air Purge Valve
A
Sampling Valve A
20
A
Air Purge inlet
K
A
Dump Port A (option)
44
A
D
16
ON
B
A
44
B
43
B
43
ON
OFF
A
E
A
K
43
ON
A
A
43
43A OFF
B
44
T
43
B
Component B Side
B Supply Line B connection
B
Fluid Filter B, 100 mesh
C
B
D
Check Valve B
B
Flow Meter B (G3000 shown)
E
B
10
Fluid Shutoff Valve B
B
Dispense Valve B
43
D
16
Solvent Purge Valve
B
Sampling Valve B
20
B
Solvent Purge inlet
K
B
Dump Port B (option)
44
B
D
B
E
Other
31 Integrator
32 Static Mixer
T Mixer Fluid Outlet to gun
B
C
TI7334A
IG. 3. 248251 Fluid Manifold
F
310653E 11
Troubleshooting
Solenoid Troubleshooting
Refer to the Pneumatic Diagram, page 30.
If the dispense or purge valves are not turning on or off correctly, it could be caused by one of the following.
Cause Solution
1. Air regulator pressure set too
high or too low.
2. Air or electrical lines damaged
or connections loose.
3. Solenoid failure
Purge
Solvent
Purge Air
Dispense B
Dispense A
FIG. 4
4. Solenoid, cable, or fluid panel
control board failure.
Check air pressure. 80 psi (550 kPa, 5.5 bar) is commonly used. Do not go
below 75 psi (517 kPa, 5.2 bar) or above 100 psi (0.7 MPa, 7 bar),
Visually inspect air and electrical lines for kinks, damage, or loose connections. Service as needed.
Manually operate the valves by removing the Smart Fluid Panel cover and
pressing and releasing solenoid valve override buttons. F
Use the control board diagnostics to check the signals (page 13). If signals
do not occur correctly, go to Cause 4.
Valves should snap open and shut quickly. If the valves actuate slowly, it
could be caused by:
• Air pressure to the valve actuators is too low. See Cause 1.
• Solenoid is clogged. Make sure air supply has 10 micron filter installed.
• Something is restricting the solenoid or tubing. Check for air output from
air line for corresponding solenoid when valve is actuated. Clear restriction.
• Packings on the mix manifold dispense valves are too tight. Torque
should be 25 in-lbs (2.8 N•m).
• A dispense valve is turned in too far. See ProMix™ II Operation manual
for settings,
• Fluid pressure is high and air pressure is low.
Check voltage level to solenoid by pulling solenoid connector and checking
voltage between pins.
IG. 4.
If voltage is 9-15 VDC, the solenoid is damaged. Replace solenoid or correct
electrical line problem.
If there is no voltage, replace the board.
Operator Station Troubleshooting
Problem Cause Solution
Nothing displayed Power is off Turn on power
Faulty cable Check or replace cable
Circuit board failure Replace circuit board
Error code E1 Faulty fiber optic cable between
EasyKey™ and fluid panel
12 310653E
Check or replace cable
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