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Graco 312779E User's Manual

1. COM LE COM con TEL joa COM ieri COM ma SOL 14523 6 STD COLOR BOARD 2 COLORS 13 THRU 30 _ E COM p Jj nie 1210 T COM CLR 23 1240 icm em Fe jas COM 1200 COM M ia NA gt MC COM MDC Tu n COM 412V0C ag COM Tu COM lans NU UO 129 Schematic Diagrams EasyKey Electrical Schematic 312779E QqvaHgwingssvfd Svfu H gt _ ld Quvog AvTusid Spry Syry SI S GA CL 2 ungaw u3MOd 8 08 DMY 91 DN AN9 99 DMY 9L IHA NUD dd MO 17 NI JOVLIOA 104110 024 DMY 81 938 81 DMY 81 2 18 Qe 81 519 6r ZH DMY 18 038 DMV 3LIHWYDV 18 N3385 Quvo8 AV 14510 Wavv 130 Meter Performance Data G3000 Meter Performance Data G3000 and B Disd 00 enssaJd pue psepuels uedo suin Sz Bumes 929UP8J9 O ONLY esiodnuoo 7 39 SOSIA pinjJ 15891 06 1 62 1 86 1 22 1 9
2. 1441 US 20 to 50 C aZ Minneapolis MN APPROVED install per 289833 9 2G C Ex ia Um 250 V EMOSATEXO072 0359 13582 ProMix 2KS PART NO SERIES NO MFG YR N N x o lt Certificate is listed here System Configuration and Part Numbers System Configuration and Part Numbers Wall Mount Fluid Station Configurator Key The configured part number for your equipment is printed on the equipment identification labels See 1 for location of the identification labels The part number includes one digit from each of the following six categories depending on the configuration of your system Automatic Control and Display A and B Meter Color Valves Catalyst Valves Flow System Control D EasyKey with LCD Display 0 No Meters Label Location on Fluid Station 12423 Maximum Fluid Working Pressure is listed here 1 8 in Coriolis and 2 5 Electronic Proportioner 0074 Ex ia T3 C 0359 AIR WPR MPa bar MAX FLUI bar MAX TEMP 50 C 122 F equipment for Class Div 1 Group D T3 0 No Valves G3000 A and B single color G3000HR A and B 1 Two Valves low pressure 2 Four Valves low pressure 53000 and 1 8 in Coriolis B 1 8 in Coriolis A and G3000HR B 3 Seven Valves low pressure 4 Twelve Va
3. 81 Advanced Setup Screen 1 7 Run Flow Control Calibration page 74 73 Integrated Flow Control Flow Control Calibration Flow Control Calibration is an automatic routine that establishes a pressure vs flow profile between low and high operating points See FIG 86 The profile may be unique to each recipe or may be globally copied to all recipes NOTE Calibration cannot be done in recipe O or 61 1 Load a color 2 Goto Advanced Setup Screen 5 see FIG 82 Select the flow rate range that best covers the larg est flow target for your application for example 0 1200 Flou Rate Range Tolerance Alarm Time Advanced Calibration 82 Advanced Setup Screen 5 Automatic Mode with Flow Control Only 74 3 Go to Advanced Setup Screen 1 see Fic 83 Turn Manual Override On qut Flow Control Override Manual Override 1 Potlite Volume Catalyst Purge sec Color Catalust Fill 4 Fidvanced Calibration Fic 83 Advanced Setup Screen 1 4 Goto the Manual Override Screen see FIG 84 Set Manual Override to Mix and set Flow Ctrl Cali bration to Start Manual Override Active Recipe Recipe Manual Override Flow Rate Range Flow Set Point Flow Ctrl Calibration Start Global FC Data Sim Fic 84 Manual Override Screen 312779E Integrated Flow Control 5 Return to the Status Sc
4. k F actor 0 119 cc pulse Recipe 312779E 8 Dispense component or into beaker 9 10 11 a To avoid splashing slowly open sampling valves b For more accurate calibration adjust the valve to dispense at a flow rate similar to your produc tion spray flow rate c Dispense a minimum of 250 cc make sure enough material is dispensed to accurately read the volume with your beaker The A and B vol umes do not have to be equal or at any particu lar ratio d Close sampling valve tightly The volume that the ProMix measured displays on the EasyKey Compare the amounts on the EasyKey to the amount in the beakers NOTE For maximum accuracy use a gravimetric mass method to determine the actual volumes dis pensed If the screen and actual volumes are different enter the actual dispensed volume in cc for A B or Sol vent Volume field and press the Enter ii key If the value was substantially different repeat the calibration process NOTE If the screen and actual volume is the same or if for any reason you want to cancel the calibra tion procedure scroll to Abort on the Calibration Screen menu and press the Enter key 312779E 12 13 14 15 Meter Calibration After the volume for A B or Solvent is entered the ProMix 2KS controller calculates the new flow meter K factor and shows it on the Calibration Screen NOTE K factor values on t
5. 1 100 w mb E HH T V P Voltage Air Pressure Valve T118958a Fic 74 ProMix 2KS Flow Control Schematic Diagram 24H989 Module 312779 69 Integrated Flow Control Flow Control Operating Process Example Operating Ranges Flow Control operating ranges correlate the desired flow rate to the incoming flow set point signal see below The operating ranges are 0 300 cc min 0 600 cc min 0 1200 cc min 0 10096 96 open in manual override mode In this example the range is set to 0 300 cc min and the target flow rate is 150 cc min Step 1 Flow Set Point Input Signal Discrete Input A discrete signal is 0 10Vdc which corresponds linearly to the set operating range For example if the set range is 0 300 cc min and the desired flow rate is 150 cc min the ProMix 2KS receives a flow rate setpoint bVdc sig nal from the PLC or robot Network Communication Input A network communication signal is either the desired flow rate 150 cc min in this example or the 96 open 70 Step 2 Pressure Loop NOTE The gun must be triggered during the pressure loop See FIG 75 for module 249849 and FIG 76 for module 24H989 The ProMix 2KS drives the system to the nec essary pressure to meet the desired flow rate 150 cc min The pressure sensor in the module verifies the actual pressure and returns the reading back to the Pro Mix 2KS Step 3 Flow Loop NOTE The gun must be triggered during
6. 1 DISPLAY 2 INTEGRATION 3 BOARD 1 DIGITAL OUTPUT COMMON POWER 4 2 PURGE RECIPE CHG ACTIVE OUTPUT 5 3 MIX ACTIVE OUTPUT 6 MIX READY OUTPUT 7 6 FLOW CAL ACTIVE 7 FLOW RATE ALARM OUTPUT FLOW CONTROL CAL BLK aL 8 DIGITAL OUTPUT COMMON POWER 11 2 GUN TRIGGER WHT 2 1 DIGITAL OUTPUT COMMON POWER 12 3 DIGITAL IN COMMON RED 3 2 SPECIAL OUTPUT 1 4 REMOTE STOP GRN 4 3 SPECIAL OUTPUT 42 13 4 SPECIAL OUTPUT 43 5 ALARM RESET BRN 5 15 6 _ ALARM OUTPUT BLU eos 5 DIGITAL OUTPUT COMMON POWER 16 7 DIGITAL OUTPUT COMMON ORG 7 17 8 LIFE YEL 8 18 9 FLOW RATE ANALOG IN PUR 9 10 FLOW RATE ANALOG COMMON GRAY 1 110 HARNESSES 24 YEL GRAY TERMINAL 65485 INTEGRATION A WHT BLU BLOCKS 65485 INTEGRATION BLU WHT RS485 INTEGRATION GROUND SHIELD 85485 NETWORK A WHT ORG RS485 NETWORK B ORG WHT 65485 NETWORK GROUND SHIELD FILL ACTIVE A Uw gt CABLE 7 FOIN BLK J8 L FO OUT BLU S ee WEB SERVER MODULE 128 312779E System Electrical Schematic Schematic Diagrams NOTE The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS system Some compo nents shown are not included w
7. NOTE If a Dose Time alarm E 7 E 8 occurs clear the alarm 3 Doacomplete system purge following the instruc tions under Purging Using Recipe 0 page 96 4 Shut off the fluid supply to the solvent purge valve SPV and the air supply to the air purge valve 106 5 With the gun triggered push the manual override on the A and B purge valve solenoids to relieve air and solvent pressure See FiG 104 Verify that solvent pressure is reduced to O NOTE If a Purge Volume alarm E 11 occurs clear the alarm 91 System Operation Systems with Color Change and without Dump Valves NOTE This procedure relieves pressure through the sampling valve 1 Complete all steps under Single Color Systems page 91 2 Close the A side shutoff valve SVA Fic 106 Open the A side sampling valve RVA 3 Direct the A side sampling tube into a waste con tainer 4 See 105 Open the color change module Using the solenoid identification labels as a guide press and hold the override button on each color solenoid until flow from the sampling valve stops 5 Press and hold the solvent solenoid override until clean solvent comes from the sampling valve then release 6 Shutoff the solvent supply to the color change stack solvent valve 7 Press and hold the solvent solenoid override until solvent flow from the sampling valve stops 8 Open the A side shutoff valve SVA FiG 106 Close the A si
8. RED 4 BLACK a 3 0 DOSE B 2 BLACK a RED IDOSEA 1 516 cen 2 ___ AIRFLOW SWITCH 1 3 1 6 J AIR FLOW SWITCH 2 5 SiG FO OUT 5 COM e SOLVENT FLOW SWITCH BLU _ GFB 1 PRESSURE SWITCH FOIN J 9 H Z Le 5 1 GEB 2 PRESSURE SWITCH BLK 1 c C e 312779E CLR8 CLR 7 CLR6 CLR5 CLR 4 CLR 3 CLR 2 CLR 1 SOL CLR CLR 21 CLR 20 CLR 19 CLR 18 CLR 17 CLR 16 CLR 15 CLR 14 CLR 13 Jn 12VDC i 12VDC quu EOM cm LE 12VDC com ae 12VDC COM 12VDC COM TMANIFOLD Havoc peu nA Tum T m E HAC 5s 23120 gt gt gt J2 1 SIG RED 2 COM BLK J4 1 PRESSURE 2 COM RED 3 WHT PRESSURE BLK SHIELD BARE Lt ILI 14523 COLOR BOARD 1 COLORS 1THRU 12 CATALYST Aeg ipu d aaa COM CLR 10 ge aoe AMC Fe jan
9. press to enter exit Setup mode Enter if cursor is in menu box press Enter key to view menu Press Enter to save a value either keyed in from the numerical keypad or selected from a menu Up Arrow move to previous field or menu item or to previous screen within a group Down Arrow move to next field or menu item or to next screen within a group Left Arrow move to previous screen group Right Arrow move to next screen group Alarm Heset resets alarms 312779E EasyKey Display and Keyboard AC Power Fiber Optic Strain Audible Alarm Switch Relief Port Main Power Ground Screw I S Power Graco Web Discrete Cable Interface Connector Ports 12638 12657 8 EasyKey Connections and AC Power Switch AC Power Switch Graco Web Interface Port Turns system AC power on or off Used to communicate with the ProMix from a PC to Upgrade software I S Power gt View software version T gt Download Power circuit to Fluid Station Job and alarm logs e Material usage report z Setup values can also upload Potlife Exceeded Audible Alarm Clear job alarm and material usage reports Alerts the user when a Potlife Exceeded alarm occurs Upload a custom language to view on Screen Restore factory defaults Clear by pressing the Alarm Reset 5 Restore setup password See manual 313386 for more information NOTE
10. e in multiple color systems to purge out material lines without loading a new color e atthe end of a shift to prevent hardening of cata lyzed material NOTE Each screen displays the current screen number and the total number of screens in the group The total number of screens in a group and the fields displayed on each screen may vary depending on selections made in the System Configuration Screens and Option Screens Recipe 0 Screen 1 hecipe Air Solvent 5 First Purge Source Chop Type Final Purge Source Air Chop Tine 2 0 sec Solvent Chop Time 2 0 sec Calibration 57 Recipe 0 Screen 1 olent First Purge Source Select Air Solvent or 3rd Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 33 Chop Type Select Air Solven or Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 33 This refers to the process of mix ing air and solvent or air and 3rd flush fluid together during the flush cycle to help clean the lines and reduce solvent usage 312779E Setup Mode Final Purge Source Select Air Solvent or Ord Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 33 Air Chop Time Enter the air chop time 0 0 to 99 9 seconds Solvent Chop Time 3rd Flush Valve Chop Time Enter the solv
11. Slow actuation of component A or B valves See E 3 RATIO HIGH ALARM and E 4 RATIO LOW ALARM pages 117 118 Running a high mix ratio and a high flow rate It may be necessary to restrict the flow rate through the component B dose valve by adjusting its hex nut E See page 88 312779E 119 Alarm Troubleshooting Table 17 Alarm Troubleshooting E 7 DOSE TIME A ALARM and E 8 DOSE TIME B ALARM E 7 gun trigger input is active AFS or Integration and no A meter pulses are detected during the dose time selected E 8 gun trigger input is active AFS or Integration and no B meter pulses are detected during the dose time selected System is in Mix mode gun is only partially triggered Fully trigger the gun allowing air but no fluid to pass through gun Fluid flow rate is too low Increase flow rate Dose time setting is too short for the current flow rate Increase the dose time setting Flow meter or cable failed or flow meter clogged To check meter sensor operation remove meter cap to expose sensor Pass a ferrous metal tool in front of the 12792 If there is a meter or cable failure you will see a large dif ference between the amount of fluid dispensed and the flow meter volume displayed by the EasyKey Clean or repair meter as necessary Also see meter manual 308778 Follow Meter Calibration procedure page 100 Slow actuation of component A or B valves See E 3 RATIO HIGH AL
12. air spray and high pres e Has user selectable ratio assurance and can main sure 3000 psi 21 MPa 210 bar systems with up tain up to 1 accuracy depending on materials to 30 color change valves and up to 4 catalyst and operating conditions change valves e Models are available to operate air spray or air assisted systems with a capacity of up to 3800 NOTE Optional accessories are available for in cc min field installation to achieve 30 colors Component Identification and Definition SeeTable 1 and FIG for the wall mount system components and FIG 5 for the RoboMix system components Table 1 Component Descriptions EasyKey EK Used to set up display operate and monitor the system The EasyKey accepts 85 250 VAC 50 60 Hz line power and converts that power to acceptable low voltage and optical signals used by other system components Wall Mount Fluid Includes air control solenoids flow switches and mountings for the fluid flow meters and Station ST used on the fluid manifold assembly Its control board manages all proportioning functions ADxxxx and AExxxx Models only RoboMix Fluid Includes air control solenoids flow switches fluid flow meters and the fluid manifold Station RS used assembly to control and monitor fluid dispensing Its control board manages all propor on RDxxxx and tioning functions RExxxx Models only Fluid Manifold FM Pneumatically Operated Dose Valves for component A and B Purge
13. mation loops e The pressure loop monitors fluid pressure with the pressure sensor in the module This allows the sys tem to react very quickly to set point changes The gun must be triggered during the pressure loop e The flow loop monitors fluid flow through flow meter pulses ensuring accuracy The gun must be triggered during the flow loop The Flow Control System creates a data table that tar gets a desired flow rate based on the fluid pressure It then monitors the flow loop to maintain the flow rate 312779E Integrated Flow Control Flow Input Feedback from Meters A and B Air operated Fluid Regulator Mixed Material Line 17 Fluid Pressure Sensor Meter B VS Fluid Control RSs 5 NS RSs Board ERE mm al NOY eter A Analog Signal to V P Air Signal to Regulator Air Line V P Voltage Air A Pressure Valve 4 4 lt lt 4 lt Pressure Input Feedback from Fluid Pressure Sensor 117118 Fic 73 2KS Flow Control Schematic Diagram 249849 Module Air operated Remote Flow Input Feedback from Mixed Material Line FMG Regulator Meters A and B Z Fluid VI i Control Board Fluid Pressure Sensor Meter A Air Signal to Regulator Pressure Input Feedback from Fluid Pressure Sensor Analog Signal to V P
14. values on this screen are cc independent of the units set in Configure Screen 1 e The controller will use the active recipe K factors for meter calibration The active recipe must be recipe 1 to recipe 60 Recipes 0 and 61 do not have K factor values 1 Before calibrating meter A or B prime the system with material For a color catalyst change system make sure the color catalyst valve is open 2 Shut off all spray or dispense devices connected to the ProMix 3 Close both fluid shutoff valves and sampling valves Wall Mount Fluid Station only 100 4 Place the beakers minimum size 250 cc in hold ers Put the sampling tubes into the beakers Wall Mount Fluid Station only NOTE If tubes need replacing use 5 32 in or 4mm OD tubing 5 Onthe EasyKey press the Setup 55 setup screens 6 Select Recipe amp Advanced Setup and press the Enter key to select ProMix 2ES EK 2 04 0089 BC 0 00 L1 0 00 FP 0 00 000 AK zK Manual C2 0 00 KP Vb f 0000 0000 192 166 175 1 MAL 0 04 8 5504 set Up Home Recipe amp Advanced Setup System Configuration 7 Press the Right Arrow m key to select the Cali bration Screen Press the Enter key to select either Dose Valve A or B Press the Down Arrow 7 key and select Start from the menu Start only one at a time Meter Actual Volume Meter Calibration Measured volume Gee
15. 11 Moisture Sensitivity of Isocyanates 11 Changing Materials 11 Glossary of Terms 12 uu TI 14 WGA 9 oath Sort ca dx 14 Component Identification and Definition 14 Wall Mount System Components 16 System Components 18 EasyKey Display and Keyboard 20 PT 20 KODA an 20 AC Power Switch 21 VO uc mor ur E 21 Potlife Exceeded Audible Alarm 21 Graco Web Interface Port 21 Ethernet Connection 21 Run Mode 5 lt 22 Splash sine iu eoe Rt 22 Status Screen 24 Manual Override Screen 25 Totals Sereen dro tb Reis 26 Reset Total Screen 26 Reset Solvent Screen 26 Alarms Screen 27 Level Control Screen 27 Setup Mode veEvI RE RIS 28 Password Screen 29 Set Up Home Screen 29 System Configuration Screens 31 Option Screens eade bs eR RISE 36 Advanced Setup Screens 3
16. 20 21 22 23 24 25 26 27 28 29 30 31 32 Recipe Bits 0 1 0 1 0 1 1 0 0 1 1 1 1 1 0 0 0 0 0 0 0 0 1 0 0 0 0 0 543 2 00 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 1 0 0 0 0 1 312779E 66 Integrated Flow Control Flow Control Description Flow control is an optional feature which incorporates an intrinsically safe regulator control module with the Pro Mix 2KS automatic system Flow control precisely regu lates the flow of material to a manual or automatic air spray gun to help ensure adequate coverage and avoid sags or runs in the finish coat NOTE Flow control cannot be selected with dynamic dosing It is not for use with air assisted or airless spray guns Flow control uses the existing flow meters in a wall mounted fluid station or a RoboMix fluid station There is no flow meter in the mixed material line Flow Control Components 249849 Flow Control Module See FiG 71 The 249849 Flow Control Module includes an air operated fluid pressure regulator fluid pressure sensor voltage to air pressure valve and circuit board See manual 3A2097 The function of this unit is to receive the flow analog signal and drive manage the desired flow rate
17. 24H989 Flow Control Module See FiG 72 The 24H989 Flow Control Module is for use with a user supplied remotely mounted air operated fluid pressure regulator The module includes a remote fluid pressure sensor and connecting cable voltage to air pressure valve and circuit board See manual 3A2097 The function of this unit is to receive the flow analog signal and drive manage the desired flow rate NOTE For best results place the supplied pressure sensor as close to the remote fluid regulator as possible 312779E Integrated Flow Control Fluid Pressure Gauge Port Air operated Fluid Regulator Fluid Pressure Sensor 1 8 npt f Fluid Inlet 7a dii Power and Signal Cable Input 1 8 npt f Fluid Outlet Air Inlet Fitting 1 4 in 6 mm OD Tube Circuit Board V P Voltage Air Pressure Valve TI17116a Fic 71 Cutaway of 249849 Flow Control Module Remote Fluid Pressure Sensor Air Outlet Fitting 1 4 in 6 mm OD Tube Air Pressure Gauge not included Power and Signal 5 Cable Input ircuit Board hidden V P Voltage Air Air Inlet Fitting Pressure Valve 1 4 in 6 mm OD Tube 118956 Fic 72 Cutaway of 24H989 Flow Control Module 67 Integrated Flow Control Fluid and Air Pressure Requirements The fluid input pressure to the fluid regulator must be high enough to provide a 15 20 psi 0 1 0 14 MPa 1 0 1 4 bar pressure differential across the regulator at
18. Color Purge Time 0 gt 1 Color Fill Time 1 gt 2 First Purge Time 2 gt 3 Chop Time air solvent or air 3rd flush 3 gt 4 Final Purge Time 4 gt 5 Mixed Fill Time 5 gt 6 Notes Load tables from new recipe Purge from old recipe Fill from new recipe Fic 112 Color Change Chart 4 106 312779E Color Change ProMix 2KS Recipe Change Chart 5 B1 to B2 same A with Dump Valves Valve Time Sequence A Dump B Color Change Solvent po on Catalyst Change Solvent Color Change A Catalyst Change B Catalyst Purge Time 0 gt 1 Catalyst Fill Time 1 gt 2 CC Purge Fill Timers are independent of Mixed Material Purge Timers This line defines when the Mixed Fill Time Air Chop Time begins The longer of the two timers Solvent Chop Time defines when the Mixed Fill Time First Purge one of these 3rd Flush Chop Time begins N Air Purge Solvent Purge 3rd Flush Valve Dispense A Dispense B Gun Trigger s by Operator MO First Purge Time 0 gt 1 Chop Time air solvent or air 3rd flush 1 gt 2 Final Purge Time M2 gt M3 Mixed Fill Time 3 gt 4 Notes Load tables from new recipe Purge from old recipe Fill from new recipe Fic 113 Color Change Chart 5 ProMix 2KS Recipe Change Chart 6 A1 to A2 B1 to B2 with Dump Valves 2 GFBs Time Sequence Dump A pO Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Color Purge Tim
19. Final one of these 3rd Flush Valve Dispense A Gun Trigger s by Operator Lu 0 1 2 3 4 Color Purge Time 0 gt 1 First Purge Time 1 22 Chop Time air solvent or air 3rd flush 2 23 Final Purge Time 3 24 Notes All timing from Recipe 0 Fic 120 Color Change Chart 12 110 312779E ProMix 2KS Recipe Change Chart 18 Recipe 0 OR 61 to Recipe X without Dump Valves Valve Time Sequence Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B A A A NS NE Color Fill Time 0 gt 1 Mixed Fill Time 1 gt 2 Notes Load tables from new recipe Purge from old recipe Fill from new recipe Fic 121 Color Change Chart 13 ProMix 2KS Recipe Change Chart 14 A1 to A2 B1 to B2 with All Valve Time Sequence ee Color Change Solvent Color Change s _ 1111 P4 P1 P3 Color Purge Ti CC Timers are independent of Mixed Material Purge Timers This Color Fill Time 1 gt 2 line defines when the Mixed Fill Time defines when the Mixed Fill Time en Air Chop Time Solvent Chop Time First Purge one of these 3rd Flush Chop Time Air Purge NI ard Flush Valve Dispense A Dispense B Gun Trigger s by Operator SEEN a MO First Purge Time 0 gt 1 Chop Time air solvent or air 3rd flush 1 gt 2 Final Purge T
20. Fluid outlet size static 1 4 npt f External Power Supply Requirements 85 250 Vac 50 60 Hz 2 amps maximum draw 15 amp maximum circuit breaker required 8 to 14 AWG power supply wire gauge Operating temperature 41 122 F 5 50 C Environmental Conditions Rating indoor use pollution degree 2 installation category 11 Noise Level Sound pressure below 70 dBA Sound power below 85 dBA Wetted 303 304 SST Tungsten carbide with nickel binder perfluoroelastomer PTFE Dependent on programmed K factor and application The maximum allowable flow meter pulse frequency is 425 Hz pulses sec For more detailed information on viscosities flow rates or mixing ratios consult your Graco dis tributor See individual component manuals for additional technical data 312779E 133 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warra
21. It is available as a catalyst change valve stack for either low or high pressure with up to 4 catalyst change valves Each stack includes one additional valve for solvent to clean the fluid line between catalyst changes Includes an air operated fluid pressure regulator fluid pressure sensor voltage to air pressure transducer and circuit board The function of this unit is to receive the flow ana log signal and drive manage the desired flow rate Used to communicate between the EasyKey and Wall Mount Fluid Station or RoboMix Used to provide power to the Wall Mount Fluid Station or RoboMix Assembly FC 312779E 15 Overview Wall Mount System Components EK ACV CCM See the ProMix 2KS Repair Parts manual for optional cable lengths T112553a Fic 3 Wall Mount System shown with G3000 Meters Color Catalyst Change Accessory Solvent Meter and Flow Control 16 312779E DVA Fl DVB MA AT APV RVA SVA SM SVB Fic 4 Wall Mount Fluid Station Key MA Component A Meter DVA Component A Dose Valve RVA Component A Sampling Valve SVA Component A Shutoff Valve MB Component B Meter DVB Component B Dose Valve RVB Component B Sampling Valve SVB Component B Shutoff Valve MS Solvent Meter accessory SPV Solvent Purge Valve APV Air Purge Valve SM Static Mixer Fl Fluid Integrator AT Purge Valve Air Supply Tube 312779E SPV MB RVB Overview T112556b 17 Overview
22. RoboMix System Components EK ACV Air Controls Purge Air RoboMix A Control Air FC See the ProMix 2KS Repair Parts manual for optional cable lengths TI12552a Fic 5 RoboMix System shown with Color Catalyst Change and Flow Control 18 312779E Overview Air Logic In Cable Path B Supply 1 4 npt A Supply 1 4 npt Ground Screw Air Purge m Solvent Supply 1 4 A Dump Out B Dump Out Cover is removed for clarity MB DVB Ge A n 7 a 27 Y E E 7 77 a 4 71125790 DVA Fic 6 Details of RoboMix Fluid Station 312779 19 EasyKey Display Keyboard EasyKey Display and Keyboard LCD Display ZEN pd Navigation Keys Fic 7 EasyKey Display and Keypad Display Shows graphical and text information related to setup and spray operations Back light will turn off after 10 minutes without any key press Press any key to turn back on Keypad Used to input numerical data enter setup screens scroll through screens and select setup values In addition to the numbered keys on the EasyKey key pad which are used to enter values in setup there are keys to navigate within a screen and between screens and to save entered values See Table 2 20 Table 2 Keypad TI11630A Alarm Reset Key me ee Keypad Functions see FIG 7
23. Screen Timeout Configure Month 1 Dau Flush Volume Check Year Flush and Fill Input Time K Factor Input Date Format Min Material Fill Volume ec Configure Options ProMix 2 5 Warning Switching to Global Source Run Automatic rat Global source recipe for Dump Valve A Flush and Fill Input Dump Valve B On 3rd Flush Valve Cro This will overwrite recipe data Are you sure Configure Dose Size Bo t E ternal Color Change Minimum Valve B A Open 4 Ruta Dump Dose Time Alarm sec Flou Rate Monitor B Solvent Push Enable Solvent 4 Number of Guns Gun Flush Box 4 Configure Options Set Up Home ProM XS 0 Flaw Control nO t Recipe amp Advanced Setup Seda uus 5 Sustem Configuration Solvent Monitor Web Browser 192 158 178 5 or EK 204 008 BC LXX CI LXX FP 2 04 0089 2K Manual 2 4 XP VES D MC 1042 0198 Configure 192 168 178 1 00204AA3804F Communications Flow Control Discrete Froportioning Gun 1 Trigger Control Network ID Configure Fic 27 System Configuration and Option Screens Map 312779E Setup Mode T112804a NOTE Each screen displays the current screen number and the total number of screens in the group 31 Setup Mode Configure Screen 1 Language English Enter Password J Display Units cc Liter Buzzer All Alarms No Screen Timeout Fic 28 Configure Sc
24. b Trigger the gun man ual or automatic into a grounded metal pail Goto Mix mode d Ifthe flow meters over run because air in the system an alarm will occur and operation stops Press the Alarm Reset 5 key to clear alarm e Goto Mix mode 11 Adjust the flow rate The fluid flow rate shown on the EasyKey Status screen is for either component A or B depending on which dose valve is open The fluid supply lines on the screen highlight to show which dose valve is open 10 20 2010 Pol 4 1 450cc min 4 430cc min 4 Fic 102 Status Screen Flow Rate Display 90 Watch the fluid flow rate displayed on the Status screen while the gun is fully open Verify that the flow rate of components A and B are within 10 of each other If the fluid flow rate is too low increase air pres sure to component A and B fluid supplies or increase the regulated fluid pressure If the fluid flow rate is too high reduce the air pressure close the fluid manifold dose valves fur ther or adjust the fluid pressure regulator NOTE Pressure adjustments of each component will vary with fluid viscosity Start with the same fluid pres sure for component A and B then adjust as needed NOTE Do not use the first 4 5 oz 120 150 cc of mate rial as it may not be thoroughly mixed due to alarms while priming the system 12 Turn on atomizing air to the gun Check the spray pattern as instru
25. on color change board do not Verify that color change board switches are set correctly match hardware configuration See installation manual Fuse F1 F2 or both are blown Verify condition of fuses and replace if necessary See Repair Parts manual 126 312779E Schematic Diagrams Schematic Diagrams System Pneumatic Schematic COLOR COLOR CHANGE VALVE CONTROL STACKS AIR EXHAUST MUFFLER re e COLOR 1 l COLOR2 E 12 VDC gt 4 COLOR3 ssp i COLOR4 4 WAY SOLENOID S COLORS pL COLOR6 COLOR7 B COLOR8 COLOR SOLVENT T BER x qose 8 COLOR9 4 WAY SOLENOID Z COLOR 10 2 3 mi COLOR 11 2 COLOR 12 12 VDC a lt CATALYST 1 5 CATALYST 2 gt CATALYST 3 4 WAY SOLENOID XT 3 8 AIR FILTER y CATALYST SOLVENT MANUAL DRAIN i 5 MICRON WALL MOUNT ONLY 4 IE COLOR 13 COLOR 14 gt COLOR 15 COLOR 16 COLOR 17 S 7 COLOR 18 COLOR 19 4 WAY SOLENOID 2 COLOR 21 m AIR EXHAUST MUFFLER COLOR 22 COLOR 23 12VDC COLOR 24 5 E 7 DUMP A COLOR 25 3 WAY SOLENOID yy OPTIONAL COLOR 26 OK jd COLOR 27 lt COLOR 28 AIR INPUT COLOR 29 12VDC COLOR 30 pae 3 WAY SOLENOID o lt E OPTIONAL 9 c iis Tim 36 SERIES SOLENOID VAL
26. t Fic 33 Configure Screen 4 dynamic dosing setup mode enabled Dose Time Alarm Enter the dose time 1 to 99 seconds This is the amount of time allowed for a dose to occur before a dose time alarm occurs Number of Guns This field only appears if Run Mode is set to Manual or Semi Automatic in Configure Screen 3 page 33 Enter the number of spray guns 1 or 2 NOTE Only 1 gun is used in automatic mode Gun Flush Box manual or semi automatic mode This field only appears if Run Mode is set to Manual or Semi Automatic in Configure Screen 3 page 33 Enter the number of gun flush boxes Off 1 or 2 34 Configure Screen 5 on 5 192 158 178 5 Flow Control special Uutputs solvent Monitor Browser t Fic 34 Configure Screen 5 Configure Flow Control This field only appears if Run Mode is set to Automatic in Configure Screen 3 page 33 Select On or Off If set to On Advanced Setup Screen 5 page 41 is added Special Outputs Select special outputs 0 4 Each output has two differ ent start times and durations Solvent Monitor Select solvent monitor Off Flow Switch or Meter Web Browser IP The default web browser IP address prefix is 192 168 178 Assign a unique number for each EasyKey in your system 1 99 and enter it here 312779E Configure Screen 6 Communications Flow Control liscrete Proportioning Gun 1 Trigger Control Ne
27. B pressure be 5 15 higher than the component pressure NOTE When using dynamic dosing it is very important to maintain a constant well regulated fluid supply To obtain proper pressure control and minimize pump pul sation install a fluid regulator on the A and B supply lines upstream of the meters In systems with color change install the regulator downstream of the color catalyst valve stack To Static Proportioned Material Mixer Component pulsed Component pulsed injection Fic 92 Schematic Diagram of Dynamic Dosing Operation 312779E 85 System Operation Select a Component B Restrictor Size Install the 150955 Injection Kit in the fluid manifold as explained in the ProMix 2KS Installation manual Use the charts provided in that manual to select an appropri ate restrictor size based on the desired flow and mix ratio Turn On Dynamic Dosing 1 On the EasyKey press the Setup 55 the Set Up Home screen Select System Configu ration to access the configuration screens FIG 93 set Up Home PraMi 2ES EK 2 04 0089 BC 1 1 LAK FP 04 009 AK AP 0 1042 0198 192 165 15 1 MAL 0 048 5504 Recipe amp Advanced Setup sustem Configuration Fic 93 Set Up Home Screen 2 Navigate to System Configure Screen 4 Select DD option from the Dose Size drop down menu FIG 94 Dose Size Dose ime Hlarm Confi
28. Copy 30 0 21 2 1 25 0 17 1 7 20 0 14 1 4 O 15 0 10 1 0 JA 10 07 0 7 o 3 5 035 0 35 0 0 50 100 150 200 250 300 350 Flow cc min 86 Typical Flow Calibration 0 300 cc min range 312779 75 Integrated Flow Control Global FC Data Copy oet Global FC Data Copy to Start on the Manual Over ride Screen see 87 Global copy provides a start ing point for all recipes enabling Continuous Learning see page 76 to take over Global copy works very well with multiple colors when the viscosities are similar It may only require a calibra tion and global copy each time a regulator is serviced or If restriction downstream of the regulator is changed Manual Override Active Recipe 5 New Recipe Manual Override SG Flow Rate Range cc min 4 Flow set Point Flow Ctrl Calibration cc min Global FC Data Fic 87 Manual Override Screen Continuous Learning The flow profile will automatically adjust as necessary to drive to the required flow set point reflecting changes in material viscosity or system dynamics such as restric tions downstream from the regulator When changing recipes the profile is saved to the cur rent active recipe A Job Complete input will also save the profile to the active recipe 76 Setting Ki and Kp FIG 89
29. Cross contamination can result in cured material in fluid lines which could cause serious injury or dam age equipment To prevent cross contamination of the equipment s wetted parts never interchange component A isocyanate and component B resin parts 312779E 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 vis cosity If used this partially cured ISO will reduce perfor mance and the life of all wetted parts NOTE The amount of film formation and rate of crystal lization varies depending on the blend of ISO the humidity and the temperature To prevent exposing ISO to moisture e Always use a sealed container with a desiccant dryer in the vent or a nitrogen atmosphere Never store ISO in an open container e Use moisture proof hoses specifically designed for ISO such as those supplied with your system e Never use reclaimed solvents which may contain moisture Always keep solvent containers closed when not in use e Never use solvent on one side if it has been con taminated from the other side e Always lubricate threaded parts with ISO pump oil or grease when reassembling Changing Materials e When changing materials flush the equipment
30. High the Mix Start input keep it High and monitor the Mix Active output to ensure the ProMix 2KS followed through on the request Stop Mixing To stop mixing to perform a purge or color change remove the Mix Start input the status bar on the EasyKey will show STANDBY Monitor the Mix Ready output to ensure the Active output goes Low Color Change To perform a color change ensure there are no alarms except the Potlife Alarm If alarms are present the Alarm Reset input should be sent momentarily to clear the alarm 5 100 msec NOTE Alarm Reset will not reset a Potlife alarm Only dispensing the Potlife Volume or a complete Purge Color Change will reset a Potlife alarm The Alarm Reset Input will silence the audible alarm Turn the Color Change Start input on momentarily gt 100 msec while the proper sequence of recipe bits are set NOTE The Recipe Bits must be presented at least 100 msec before the Color Change Start input is turned on and remain until a new recipe is required 312779E System Operation During the short On state the recipe will be read from this binary sequence and the status bar of the EasyKey will display COLOR CHANGE XX The Purge CC Active output will be High for the duration of the color change purge process During the Mixed Mate rial Load portion at the end of the Color Change sequence the Fill Active output will be on indicating that portion of the color change These will n
31. If using the Graco Gateway in your system dis connect its cable from the EasyKey before updating the ProMix 2KS software Ethernet Connection You can access data on an office or industrial network through the internet with the proper configuration See manual 313386 for more information 312779E 21 Run Mode Screens Run Mode Screens NOTE See Fic 11 for of the Run screens Detailed screen descriptions follow Splash Screen At power up the Graco logo and software revision will display for approximately 5 seconds followed by the Status Screen see page 24 GRACO Control 2 00 0013 Fasukey 2 0 013 9 Splash Screen The Splash screen will also momentarily display Estab lishing Communication If this display remains for more than one minute check that the fluid station circuit board is powered up LED is on and that the fiber optic cable is properly connected see Installation manual NOTE If the software version of the fluid plate does not match the version of the EasyKey the EasyKey will update the fluid plate and the fluid plate programming screen will appear until the update is completed Programming Fluid Plate Code 10 Fluid Plate Programming Screen 22 312779E Job Complete Are uou sure want to reset job totals Enter job number or press enter to accept default Fic 11 Run Screens 312779E 10 20 2010 7 51 1zps
32. Special 3 output is on monitor only Special 4 1 indicates the Special 4 output is on monitor E o 91 00 0 0 1 0 0 0 0 0 0 0 0 0 0 NotUsed 2 12 Alarm General 1 indicates a General Alarm is in process If Mix Active is still High then a Warning only See the Modbus charts in the Graco Gateway manual 312785 for details on type 43 0 0 11 0 0 0 0 0 0 0 0 0 0 0 0 00 Alarm Potlife 1 indicates a Potlife Alarm is in process NOTE Shaded cells relate to the flow charts on pages 55 59 312779 61 2KS Integration Specifics Table 7 ProMix 2KS Active Alarms Modbus Register 40010 No Active Alarms pomenem Rane 62 312779E 2KS Integration Specifics ProMix 2KS EasyKey PLC Output Digital Input Sourcing Input Common ProMix 2KS EasyKey PLC Input Digital Output Sinking Output Common ProMix 2KS EasyKey PLC Input Digital Output Sourcing Output Common mius Common 70 Automation 24 Vdc Sourcing Input Diagram 312779E 63 ProMix 2 5 Integration Specifics Table 8 Discrete Terminal Connections Terminal Terminal Location Details also see pages 60 and 61 Digital Inputs 42 Remote Board Set Bit to Initiate Mix Mode maintain 2 Remote Board Purge Set Bit to 1 to initiate Purge Sequence maintained m 42
33. Valves for solvent and air purge Sampling Valves for calibrating the flow meters and performing ratio checks Wall Mount Panel only Shutoff Valves for component A and B to close their fluid passages to the mix mani fold to allow for accurate calibration and ratio checks Wall Mount Panel only Mix Manifold which includes the fluid integrator and static mixer Fluid Integrator is the chamber where component A and B align at the selected ratio and begin to mix gt Static Mixer has 24 elements to uniformly blend the materials downstream of the fluid integrator 14 312779E Flow Meters MB MS Color Change Valves ACV and Color Change Module CCM Catalyst Change Valves BCV Dual Fiber Optic Cable FO Fluid Station Power Supply Cable PS Flow Control Regulator Overview Table 1 Component Descriptions The following optional flow meters are available from Graco e 3000 is a general purpose gear meter typically used in flow ranges of 75 3800 cc min 0 02 1 0 gal min pressures up to 4000 psi 28 MPa 276 bar and viscosi ties of 20 3000 centipoise The K factor is approximately 0 119 cc pulse G3000HR is a high resolution version of the G3000 meter It is typically used in flow ranges of 38 1900 cc min 0 01 0 5 gal min pressures up to 4000 psi 28 MPa 276 bar and viscosities of 20 3000 centipoise The K factor is approximately 0 061 cc pulse G250 is a general purpose gear met
34. comparison There is too much restriction in the system Check that the system is fully loaded with material Check that the supply pump s cycle rate is set prop erly Check that the spray tip nozzle is properly sized for the flow and application and that it is not clogged Check that the fluid regulator is set properly If the alarm occurs during start up after purging the flow Restrict gun needle travel to slow down the initial fluid rate was probably too high delivery rate until fluid hoses are loaded with material If the alarm occurred after you were spraying for some Adjust component A and B fluid supply regulator pres time the pressures from the fluid supplies could be sures until they are about equal f the pressures are unbalanced already about equal verify that component A B dose valves are operating properly Slow actuation of the component A or B valves This can Manually operate the Dispense A and B solenoid valves be caused by as instructed in the ProMix 2KS Repair Parts manual to check operation e Air pressure to the valve actuators is too low e Increase air pressure Air pressure must be 75 120 psi 0 52 0 84 MPa 5 2 8 4 bar 120 psi is recom mended e Something is restricting the solenoid or tubing and There may be dirt or moisture in the air supply Filter interrupting valve actuation air appropriately e A dose valve is turned in too far e Refer Table 13 Mix Manifold Val
35. if the Autokey is changed or an invalid configuration file is sent to the EasyKey Init Error Occurs if the recipe data codes specifying the type of machine they were made on are not what is expected For example a 3KS machine receives a con figuration file originally made on a 2KS machine Config Error Occurs if a configuration file sent to the EasyKey specifies a different hardware setup than what exists For example the configuration file specifies 2 color change boards but only 1 is present Range Error Occurs if a valve used in a recipe is not present in the current hardware setup For example a recipe calls for valve 30 but the system has only 12 valves LC Error Level Control Error Occurs if level control data is received by the EasyKey and the current Autokey setting 2K or 3K has changed since the level control data was originally initialized LC Range Error Level Control Range Error Occurs if level control data includes a valve range exceeding the capability of the machine Flush the system or perform a color change If possible identify the origin of the reboot or power cycle Reinstall the Autokey or verify that the Autokey is set properly Verify that the source data is from a valid recipe 1 60 Verify that the Autokey is set properly or that the configu ration file is valid Verify that the configuration file is valid Verify that the configuration file specifications and the hardware co
36. made in Option screens 1 and 2 Setup Mode 12806 43 Setup Mode NOTE Each screen displays the current screen number and the total number of screens in the group The total number of screens in a group and the fields displayed on each screen may vary depending on selections made in the System Configuration Screens and Option Screens Recipe Setup Screen 1 hecipe Ratio Tolerance Color Valve Catalyst Valve MESE Calibration Fic 50 Recipe Setup Screen 1 Ratio Enter the mix ratio of component A over component B 0 0 1 to 50 1 Ratio Tolerance Enter the ratio tolerance 1 to 99 This refers to the percent of acceptable variance that the system will allow before a ratio alarm occurs Component A Color Valve if present This field only appears if the system includes a color change module Enter the color valve number 1 to 30 Component B Catalyst Valve if present This field only appears if the system includes a color change module Enter the catalyst valve number 1 to 4 44 Recipe Setup Screen 2 Recipe Minimum Flush Volume z cc Potlife Time minutes Color Catalust Purge 1 Color Catalust Fill SEC Calibration 51 Recipe Setup Screen 2 Minimum Flush Volume This field only appears if Flush Volume Check is set to On in Option Screen 1 on page 36 Enter the mini mum flush volume 0 to 999 cc Entering 0 disables
37. shows the definition and relationship between Ki and Kp e default value for Ki is 40 e The default value for Kp is 400 For most applications Ki and Kp do not need to change Do not change these vallues unless you are sure it is required Before adjusting these values ensure that the input fluid pressure to the regulator is pulsation free and the outlet pressure is higher than 12 psi 08 MPa 0 84 bar for each flow rate set point Applications with viscosities less than 20 cps or greater than 300 cps may require that the Ki and Kp be adjusted Do this by making small variable changes to the values in Advanced Setup Screen 5 See Fic 88 Flou Rate Range Tolerance Alarm Time Advanced Calibration 88 Advanced Setup Screen 5 Automatic Mode with Flow Control Only 312779E Integrated Flow Control Pressure Flow Control Mode This mode may be used with a ProMix 2KS connected both to a robot with flow control and to a manual gun When the Flow Control Override is set to Pressure the Because there are two flow paths the meters cannot be system will only drive to the pressure associated with used to close the flow loop Therefore the robot can run the flow rate request of the saved calibration table It will a calibration by itself When calibration is complete set not close the loop with the flow meters to Pressure The robot will run in open loop mode and the manual gun can sp
38. the highest flow setting For example if the maximum flow rate set point is 280 cc min and 35 psi outlet pres sure is required to achieve that flow the input pressure must be 50 55 psi Required air pressure to the flow control module is 70 100 psi 0 35 0 7 MPa 3 5 7 0 bar NOTE e For flow control modules 249849 and 24H989 used with a 1 1 fluid regulator the fluid outlet pressure from the regulator must be between 12 75 psi 08 0 5 MPa 0 84 5 2 bar for all flow set points Flow rate set points with pressures outside this range are not achievable There must be at least 12 psi 08 MPa 0 84 bar fluid pressure at the lowest flow rate e fflow control module 24H989 is used with a fluid regulator at a ratio greater than 1 1 the relationship of air pressure to fluid outlet pressure is very impor tant The lowest recommended air pressure from the V P is 10 12 psi 07 08 MPa 0 70 0 84 bar Back pressure will be required to ensure minimal fluid pressure at the lowest flow rate setpoint The turn down ratio of the typical fluid regulator is approximately 3 1 or 4 1 depending on material type and viscosity For example if the lowest flow rate required is 100 cc min the top flow rate achievable may be 300 400 cc min NOTE The top flow rate is not the maximum flow rate range selected 68 Flow Control Operation See FIG 73 for module 249849 and FIG 74 for module 24 989 The Flow Control System includes two infor
39. through Dis crete for integrated flow control applications to ensure fast coordination with the flow control process Applications without flow control can use Gun Trigger input through Network Communications or Discrete I O NOTE The Gun Trigger input has the same effect as the air flow switch used on manual ProMix 2KS sys tems 81 System Operation Alarm Monitoring Reset Discrete Anytime an alarm occurs the Alarm Reset input will reset the alarms and allow for processing of the next step by automation except for the following condi tions e Potlife Alarms cannot be reset by the Alarm Reset input or through the EasyKey Alarm Reset 5 key Only Purge Color Change or spraying the Potlife volume will reset a Potlife alarm See Alarm Potlife output information on page 54 e When Flow Control is turned on see Configure Screen 5 on page 34 the Flow Rate Alarm output will be High when the instantaneous flow rate is above or below the Flow Rate tolerance setting High Flow or Low Flow will be the condition indi cating in the status bar of the EasyKey This output will be High along with the Mix Active output The PLC should monitor the amount of time this condi tion exists and take action at a predetermined time With Flow Control there will be times for example during flow rate changes where the general alarm as described here will be High typically momen tarily The PLC must read this Alar
40. time but low enough to avoid splashing or an injection injury Generally a setting of 100 psi 0 7 MPa 7 bar is sufficient If using a gun flush box place the gun into the box and close the lid Go to Purge mode The purge sequence automatically starts If the gun flush box is not used trig ger the gun manual Or automatic into a grounded metal pail until the P y purge sequence is complete L2 o When done purging the EasyKey automatically switches to Standby mode If the system is not completely clean repeat step 3 NOTE If necessary adjust purge sequence so only one cycle is required s Trigger the gun to relieve pressure Engage trigger lock 5 If spray tip was removed reinstall it breaks in spraying that exceed the potlife overnight shutdown before servicing the fluid manifold assembly hose or gun 6 Adjust the solvent supply regulator back to its nor Solvent purges the component B catalyst right side of the mix manifold and the inner tube of the integrator Air purges the component A resin left side and the outer tube of the integrator 1 Goto Standby mode remove Mix input Trigger the gun to relieve pressure If you are using a high pressure gun engage the trig ger lock Remove spray tip and clean tip separately If using an electrostatic gun shut off the electrostatics before flushing the gun 312779E mal operating pressure 95 Syst
41. 13 1 bar Check the identification label on the EasyKey or fluid station for the system maximum working pressure See FiG 1 ProMix Fluid Components Maximum Working Pressure Base System no meters option 0 no color catalyst change option 0 and no flow control option Meter Option 1 and 2 G3000 G3000HHR Meter Option 3 4 5 6 and 7 one or two Coriolis Meters Color Change Option 1 2 3 and 4 and Catalyst Change Option 1 and 2 low pressure valves Flow Control Option Y Yes Flow Meter Fluid Flow Rate Range Coriolis Meter 53000 Solvent Meter accessory Standard Features EasyKey with LCD Fiber Optic and Power Cables 50 ft 15 25 m Wall Mount Fluid Station 50 cc Integrator and Static Mixer Discrete I O Board A Side Dump Valve if color valve s selected B Side Dump Valve if catalyst valve s selected Flow Control with 15 ft 4 57 m Cable if selected Basic Web Interface 312779E 4000 psi 27 58 MPa 275 8 bar 4000 psi 27 58 MPa 275 8 bar 2300 psi 15 86 MPa 158 6 bar 300 psi 2 07 MPa 20 6 bar 190 psi 1 31 MPa 13 1 bar 75 3800 cc min 0 02 1 0 gal min 38 1900 cc min 0 01 0 50 gal min 20 3800 cc min 0 005 1 00 gal min 38 1900 cc min 0 01 0 50 gal min System Configuration and Part Numbers RoboMix Fluid Station Configurator Key The configured part number for your equipment is printed on the equipment identification labels See Fic 2 for location o
42. 6 1 96 1 61 LZE 1 91 bob Ve EOL 1 6 1 8 1 4 1 9 1 9 be EZ v 0001 0091 osoq 2206 0002 2504 2201 2262 00 lt 2 000 00S 008 UILU 99 009 S MOJ Ul9 s S 3 LON uiu 22 131 312779E Meter Performance Data G3000 A Coriolis Meter Performance Data G3000 on A Coriolis on B 6154 00 pue psepuels uedo suin Sz 929U8J9 O esiodnuoo 7 39 SOSIA PINIA 15891 0 1 62 1 82 1 96 1 96 1 56 1 66 1 06 1 61 1 81 VV EOL 1 6 1 8 1 9 1 9 v m 2206 00S 2201 0001 0091 0002 00 lt 2 2206 000 005 008 UILU 99 009 S MOJ Ul9 s S 3 LON uiu 22 312779 132 Technical Data Technical Data Maximum fluid working pressure Base system 4000 psi 27 58 MPa 275 8 bar Low pressure color change 300 psi 2 07 MPa 20 6 bar Coriolis meter 2300 psi 15 86 MPa 158 6 bar RoboMix system 190 psi 1 31 MPa 13 1 bar Flow control 190 psi 1 31 MPa 13 1 bar Max
43. 8 Recipe Setup Screens 43 0 Screens 47 Calibration Screen 49 ProMix 2KS Integration Specifics 51 Discrete vs Network Communications 51 Discrete TOS ponte octies eon ined qox E ea 51 Automation Flow Charts 55 2 Integrated Flow Control 67 Flow Control Description 67 Flow Control Components 67 Fluid and Air Pressure Requirements 68 Flow Control 68 Flow Control Operating Process Example 70 Flow Control 72 Flow Control 72 Flow Control Calibration 74 Pressure Flow Control Mode 77 Flow Control Troubleshooting 78 System Operation 80 Operation Modes 80 Sequential Dosing 80 Dynamic DOSING 80 Recipe Color 80 Solvent PUslt 2 aie ot eae were ER 80 Typical PLC Interaction with ProMix 2KS 81 General Operating Cycle Sequential Dosing 83 General Operating Cycle Dynamic Dosing 85 Mix Manifold Valve Settings 88 Slat DD ora ech eee H
44. 85 52 Gun Trigger When High this input signals the ProMix 2KS that the gun is actually triggered It should be sent every time the gun is triggered This input provides tim ing for alarm functions and also drives the flow control functions Without it no flow control functions will start Job Complete This is a momentary input 100 msec minimum When recognized by the ProMix 2KS the Job totals are cleared and a time date stamp is added for retrieval Remote Stop Use this input when external equipment is used to stop the system Clear any alarms before using this input For more information about when this input is needed contact your Graco distributor Alarm Reset This is a momentary input 100 msec minimum When recognized by the ProMix 2KS it clears any active alarms and allows the automation to take the next step Common This is not an input but the ProMix 2KS expects to have the COM side of the 24 Vdc supply con nected as shown in Table 8 This ensures proper opera tion of each input and output Terminal Strip Detail RS485 Integration A RS485 Integration 85485 Integration Ground RS485 Network A RS485 Network B RS485 Network Ground Flow Control Calibrate Gun Trigger Digital Common INPUTS Remote Stop Alarm Reset General Alarm Digital Common OUTPUTS Potlife Alarm Flow Rate Analog In Flow Rate Analog Common BE O O O O O O O O O O O O O O O O 12958
45. ARM and E 4 RATIO LOW ALARM pages 117 118 The supply pump is not turned on Turn on the supply pump System is in Mix mode with O volume entered for Min Verify condition of fuse and replace if necessary See Material Fill Volume see Option Screen 1 page 36 Hepair Parts manual and Fuse F1 is blown 120 312779E Alarm Troubleshooting Table 17 Alarm Troubleshooting E 9 MIX IN SETUP ALARM Cause Attempt to operate system while in Setup mode System must be in Standby to change current recipe and cannot be operated E 10 REMOTE STOP ALARM Cause Automation has requested that the system abort all oper Abort operations Troubleshoot automation system ations E 11 PURGE VOLUME ALARM __ _ CH ProMix 2 5 solvent flow switch is not activated while Verify that the gun is not shut off and that the solvent flow purging switch is activated while purge is taking place Minimum flush volume is not achieved Increase solvent supply or decrease minimum volume setting No meter pulses during Color Catalyst Dump Color change solvent supply not set up or functional Check Color Change setup 312779E 121 Alarm Troubleshooting Table 17 Alarm Troubleshooting 12 CAN COMM ERROR ALARM Cause e Verify that all cables are connected securely and that the Color Change power LED turns on If the power LED does not turn on the problem is probably caused by a bad connection The nut on the connec Com
46. Cal Active Flow Input 2 2 volts LIE t Input OSsolvent Push Advanced Setup Screen 8 Special Un Purge Length n Fill Advanced Calibration 46 Advanced Setup Screen 6 This screen shows the status of recipe analog inputs and digital outputs If box is shaded the input recipe is active Advanced Setup Screen 7 O O Purge O Recipe Change 0 Obun Trigger O Purge Active OF ill Active Active IB Ready OGeneral Alarm LIPatliFe Alarm OF low Alarra 4 t 1Job Complete ORemote Stop LIReset Alarm Advanced Calibration 47 Advanced Setup Screen 7 This screen shows the status of digital inputs and digital outputs If box is shaded the input is active If not input is off See pages 52 54 for details on the inputs and out puts 42 Advanced Calibration 48 Advanced Setup Screen 8 This screen appears only if Flush and Fill Input is set to Global in Option Screen 1 page 36 and Special Out puts is set to 1 2 3 or 4 in Configure Screen 5 page 34 The I O board has four programmable outputs 312779E Recipe Setup Screens NOTE See Fic 49 for a map of the Recipe screens Detailed screen descriptions follow Flow Control Override Dt uu Manual Override 1 Gun 1 Potlife Volume 35 cc Color Catalyst Purge sec Color Catalyst Fill SEC Advanced Calibration Recipe 0 Screens Recipe First Purge Source Chop Type Fi
47. Change Chart 9 ProMix 2KS Recipe Change Chart 10 Recipe X 0 OR 61 to Recipe 0 with Dump Valves EN 1 2 Color Catalyst Purge Time 1 gt 2 Color Catalyst Purge Timers are independent of Mixed Material Purge Air Chop Time Timers Solvent Chop Time First Purge one of these 3rd Flush Chop Time Air Purge olvent Purge Final Purge one of these 3rd Flush Purge Dispense A Gun Trigger s by Operator First Purge Time 0 gt 1 Chop Time air solvent or air 3rd flush M1 gt M2 Final Purge Time M2 gt M3 Notes All timing from Recipe 0 118 Color Change Chart 10 312779E 109 Color Change ProMix 2KS Recipe Change Chart 11 Recipe 0 OR 61 to Recipe X with Dump Valves Valve Time Sequence oo Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B B A A Gun Trigger s by Operator e 0 1 2 3 Color Fill Time 0 gt 1 Catalyst Fill Time 1 22 Mixed Fill Time 2 53 Notes Load tables from new recipe Purge from old recipe Fill from new recipe Fic 119 Color Change Chart 11 ProMix 2KS Recipe Change Chart 12 Recipe X 0 OR 61 to Recipe 0 without Dump Valves Valve Time Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Air Chop Time Solvent Chop Time First Purge one of these 3rd Flush Chop Time Bow Solvent Purge gt
48. DED WARNING Cause The factory defaults have been installed on the system action required See Event Log available through advanced web interface 312779E 123 Alarm Troubleshooting Table 17 Alarm Troubleshooting 19 ALARM The and Purge digital inputs are on at the same time Ensure that only one input is on at a time At least 1 sec delay is required when switching from Mix to Purge or vice versa NOTE The I O alarm incorporates several sub alarms relating to internal data issues as detailed below These alarms are only seen in the Alarm log or through BWI or AWI and may not apply to all software versions FP Reboot Fluid Plate Reboot Occurs if the system detects a fluid plate control board reboot or power cycle not triggered from the EasyKey The system reverts to Recipe 61 and mixed material may be the lines Autokey Lost Occurs if the Autokey is lost or changed after having been detected A short term loss of the Autokey will not be registered Some system functions may become unavailable For example an automatic system will not respond to PLC or robot control Illegal Source Occurs if a recipe outside of the range 1 60 is detected as the source data for global recipe data copies This is possible if an invalid configuration file is sent to the EasyKey 2K 3K Error Occurs if the recipe data is incompatible with the current Autokey setting 2 or This is possi ble
49. Fic 63 EasyKey Terminal Strips 312779E ProMix 2KS Integration Specifics Digital Output Common Power Special Output 4 Special Output 33 Special Output 2 Special Output 1 Digital Output Common Power Digital Output Common Power Flow Rate Alarm Output Flow Control Calibrate Active 2 Fill Active Mix Ready Output lt Mix Active Output C CA DIGITAL V lt AJ N Purge Recipe Change Active Output RN1RN2 OU O Digital Output Common Power C Recipe Change Input Recipe Bit 5 Input C o 5 Recipe Bit 4 Input Recipe Bit 3 Input Recipe Bit 2 Input U4 US q Recipe Bit 1 Input A NO 2 Recipe Bit Input AJ cO Digital Input Common AJ Co Mix Input Purge Input Job Complete Input Spare Digital Input Common External Color Change Ready FiG 64 255766 Discrete Board 312779E 53 ProMix 2KS Integration Specifics Digital Outputs See Automation Flow Charts pages 55 59 Purge CC Active This output will remain High during the manual Purge or Color Change purge sequence See the Color Change Charts FIG 109 FiG 126 for fur ther information Fill Active This output will remain High while the Pro Mix 2KS is in the Mixed Material Fill at the end of a typi cal color change sequence Mix Active This output will remain High while the Pro Mix 2KS is in Mix mode There may be alarm outputs
50. IPMENT MISUSE HAZARD Misuse can cause death or serious injury e Do not operate the unit when fatigued or under the influence of drugs or alcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information about your material request MSDS forms from distributor or retailer Check equipment daily Repair or replace worn or damaged parts immediately with genuine manu facturer s replacement parts only Do not alter or modify equipment Use equipment only for its intended purpose Call your distributor for information Houte hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed e Read MSDS s to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines e Always wear chemically impermeable gloves when spraying or cleaning equipment PERSO
51. ITI N Dose Time A Alarm Page 120 Dose Time B Alarm Page 120 m Co 9 Setup Alarm Page 121 E E 10 21 Remote Stop Alarm Page 121 Purge Volume Alarm Page 121 CAN Network Communication Error Page 122 Alarm 13 High Flow Alarm Page 122 Material Fill Alarm Page 125 E 23 Tank B Low Alarm Page 125 Tank S Low Alarm Page 125 Auto Dump Complete Alarm Page 126 Color Catalyst Purge Alarm Page 126 Color Catalyst Fill Alarm Page 126 E 11 E E E 15 16 12 18 19 0 2 2 2 24 25 26 27 115 Alarm Troubleshooting Alarm Troubleshooting Table 17 Alarm Troubleshooting E 1 COMM ERROR No power the EasyKey Connect power to EasyKey No power to Fluid Station The intrinsically safe power Verify that the cable is correctly connected See Installa cable between the EasyKey and Fluid Station is not con tion manual nected No power to Fluid Station The fluid control board fuse is Verify condition of fuse and replace if necessary See blown Repair Parts manual The fiber optic cable between the EasyKey and Fluid Verify that the cable is correctly connected See Installa Station is not connected tion manual The fiber optic cable is cut or bent Verify that the cable has not been cut or bent at a radius smaller than 1 6 in 40 mm Dirty fiber optic cable ends Disconnect fiber optic cable ends and clean with a
52. KS Recipe Change Chart 16 External Color Change Option Time Sequence Air Chop Time Solvent Chop Time 3rd Flush Chop Time Load tables from new recipe 312779E ProMix 2KS Recipe Change Chart 17 Recipe 0 OR 61 to Recipe X with Dump Valves and 3rd Flush Valve Valve Time Sequence i Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Mixed Fill Time does not begin until the Exiting Fill Time and Color Catalyst Fill Time is complete Exiting Fill Dispense B Gun Trigger s by Operator Exiting Fill Time 0 22 Color Fill Time 0 gt 1 Catalyst Fill Time 1 22 Mixed Fill Time 2 53 Notes Load tables from new recipe Mixed Material Purge Timers from old recipe CC Purge Fill Timers and Mixed Fill Time from new recipe Exiting Fill Source and Length are Programmable Fic 125 Color Change Chart 17 ProMix 2KS Recipe Change Chart 18 Recipe 0 OR 61 to Recipe X without Dump Valves and 3rd Flush Valve Time Sequence Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B olvent Purge 3rd Flush Purge Exiting Fill Dispense A A A A Gun Trigger s by Operator 0 1 2 3 Exiting Fill Time 0 gt 1 Color Fill Time 1 22 Mixed Fill Time 2 53 Notes Load tables from new recipe Mixed Material Purge Timers from old recipe CC Purge Fill Timers and Mixed Fill Time from new recipe Exiting Fill Sour
53. M3 Final Purge Time M3 gt M4 Mixed Fill Time M4 gt M5 Notes Load tables from new recipe Purge from old recipe Fill from new recipe Applies to ALL charts when 3rd Flush Valve is ON 110 Color Change Chart 2 312779E 105 Color Change ProMix 2KS Recipe Change Chart 3 A1 to A2 same B with Dump Valves Time Sequence Dump Dump B DumpA 7 Color Change Solvent Catalyst Change Solvent Color Change A P4 Catalyst Change B PO P3 Color Purge Time P0 gt P1 Color Fill Time P1 gt P2 CC Timers are independent of Mixed Material Purge Timers This line defines when the Mixed Fill Time Air Chop Time begins The longer of the two timers Solvent Chop Time defines when the Mixed Fill Time First Purge one of these 3rd Flush Chop Time begins N Air Purge Ne Solvent Purge NI 3rd Flush Valve Dispense A Dispense B Gun Trigger s by Operator 0 First Purge Time 0 gt 1 Chop Time air solvent or air 3rd flush 1 gt 2 Final Purge Time M2 gt M3 Mixed Fill Time M3 gt M4 Notes Load tables from new recipe Purge from old recipe Fill from new recipe 111 Color Change Chart 3 ProMix 2KS Recipe Change Chart 4 A1 A2 same B without Dump Valves Dump A Color Change Solvent Color Change Catalyst Change B Air Chop Time Solvent Chop Time 3rd Flush Chop Time 3rd Flush Valve Dispense A Gun Trigger s by Operator
54. NAL 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 e Protective eyewear e Clothing and respirator as recommended by the fluid and solvent manufacturer e Gloves e Hearing protection 10 312779E Important Two Component Material Information Important Two Component Material Information Isocyanate Conditions Spraying or dispensing materials containing isocya nates creates potentially harmful mists vapors and atomized particulates Head material manufacturer s warnings and mate rial MSDS to know specific hazards and precautions related to isocyanates Prevent inhalation of isocyanate mists vapors and atomized particulates by providing sufficient ventila tion 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 Keep Components A and B Separate
55. Operation System Operation Operation Modes gt System mixes and dispenses material apply Mix input Standby Stops the system remove Mix input 21 Purge Purges the system using air and solvent apply Purge input Sequential Dosing Components A and B dispense sequentially in the nec essary volumes to attain the mix ratio Dynamic Dosing In typical operation ratios 1 1 and above component A dispenses constantly Component B dispenses intermit tently in the necessary volume to attain the mix ratio Recipe Color Change The process when the system automatically flushes out the old color and loads a new color See pages 102 113 Solvent Push The Solvent Push feature enables the user to save some mixed material by pushing it out to the gun with solvent The feature requires an accessory solvent meter See page 99 for complete information 80 312779E Typical PLC Interaction with ProMix 2KS This section describes a typical interaction when a local PLC is directly connected to the Discrete connec tions of the ProMix 2KS See ProMix 2KS Integration Specifics on page 51 for a detailed explanation of inputs and outputs NOTE Communications fields of Configure Screen 6 must be set to DISCRETE see page 35 Start Mixing To start the mix process the PLC will monitor and ensure the Mix Ready output is High This provides assurance it is ready to mix PLC will drive
56. Operation G 7 GRACO ProMix 2KS 312779E Plural Component Proportioner EN Automatic system for proportional mixing of plural component coatings with Wall Mount Fluid Station or RoboMix Fluid Station For professional use only Approved for use in explosive atmospheres except the EasyKey See pages 4 7 for model information including maxi Important Safety Instructions mum working pressure Equipment approval labels Read all warnings and instructions in this on page 3 Some components shown are not included manual Save these instructions with all systems Automatic System with RoboMix Fluid Station Automatic System with Wall Mount Fluid Station S o TI12552a AS osa C US C C 0359 APPROVED DIE PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 3 Equipment Approvals 3 System Configuration and Part Numbers 4 Wall Mount Fluid Station Configurator Key 4 Standard Features 5 Fluid Station Configurator 6 Standard Features 7 ACCOeSSOTIGS vod ERE 8 Warnings tees pees eee SE 9 Important Two Component Material Information 11 Isocyanate Conditions 11 Material Self ignition 11 Keep Components and B Separate
57. Recipe O Recipe O Recipe O Recipe Advanced Calibration Fic 39 Advanced Setup Screens 38 Color Catalyst Purge Color Catalyst Fill Advanced Calibration screens 1 and 2 Screen 5 appears if Flow Control is set to On in Configure screen 5 oet Up Home ProMix Recipe amp Advanced Setup System Configuration EK 2 04 009 LXX C1 LXX 2 04 008 AK 2K Manual C2 AP 5 0 7 1042 0195 132 168 178 1 2 Meter A Meter Calibration Measured Actual Volume Occ jcc K Factar 0 119 cc pulse Calioration Recipe Tolerance Dolor Valve Catalyst Valve Calibration O Mix OPurge Active O Purge LIFil Active ORecipe Change O Active OGun Trigger Ready OJob Complete Alarm ORemote Stop LIPatlife Alarm OReset Rlarm OFlow Rlarm 4 Advanced Calibration t d On Purge Length Un Fill Length i 2 3 HU 01 01 Lo C 0 Lol o Lo Lo T112805a 312779E NOTE Each screen displays the current screen number and the total number of screens in the group The total number of screens in a group and the fields displayed on each screen may vary depending on selections made in the System Configuration Screens and Option Screens Advanced Setup Screen 1 Flow Control Override Manual Override Gun 1 Potlite Volume Color Catalyst Pur
58. Remote Board Job Complete Set Bit to 1 to initiate Job Complete Input momentary J2 Remote Board External CC Ready Set Bit to 1 to initiate External Color Change maintained J2 Remote Board Spare 42 Remote Board Digital Input Common J3 Remote Board Digital Input Common 1 2 3 4 9 6 2 until changing again J3 Remote I O Board Recipe Bit 0 Set Binary Bits for Recipe to Change To hold J3 Remote I O Board Recipe Bit 1 Set Binary Bits for Recipe to Change To hold until changing again J3 Remote I O Board Recipe Bit 2 Set Binary Bits for Recipe to Change To hold until changing again J3 Remote I O Board Recipe Bit Set Binary Bits for Recipe to Change To hold until changing again J3 Remote I O Board Recipe Bit 4 Set Binary Bits for Recipe to Change To hold until changing again J3 Remote I O Board Recipe Bit 5 Set Binary Bits for Recipe to Change To hold until changing again J3 Remote I O Board Color Change Set Bit to 1 to initiate Color Change momentary 1 10 Pin Terminal Block Flow Control Calibrate Set Bit to 1 to initiate Flow Control Calibrate momentary 10 Pin Terminal Block Gun Trigger Set Bit to 1 to indicate Gun is Triggered fluid flow expected 2 T 10 Pin Terminal Block Digital Input Common 4 10 Pin Terminal Block Remote Stop Set Bit to 1 to initiate a Remote Stop momentary 5 10 Pin Terminal Bloc
59. TNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant heret
60. The Alarm Level values may be adjusted using the advanced web interface 312779E Run Mode Screens See 22 If the tank volume reaches the low level threshold the EasyKey screen will display the Tank Level Low alarm and prompt the user to do one of the following 1 Refill tank volume to clear the alarm 2 Resume mixing by selecting Spray 25 Remain der If this selection is chosen a second alarm will occur after 25 of the remaining volume is mixed Hefill tank volume to clear the alarm Warning Tank Level Low Alarm Color 1 Liters Alarm Level Liters Current Volume 1 Refill Tank Volume 2 eprau of Remainder Selection ir Fic 22 Tank Level Low Screen Tank A Shown 27 Setup Mode Setup Mode P he S 2 k d NOTE See FIG 23 for a map of the Setup screens Ld Detailed screen descriptions follow Press the Setup key to enter Setup mode Enter Password This screen appears only if a password is activated Set Up Home ProMi 2KS To access Advanced Setup Screens 204009 BC LXX 111500 ira IP 192 168 178 1 MAC 204 Screens page 31 Press the Setup key to exit Setup mode and return to the Status Screen Setup Locked This screen appears momentarily if a password is activated UM 450 4 112803 Fic 23 Setup Screens Map 312779 28 Password Screen If a password has be
61. This screen appears only if K factor Input is set to ipe in Option Screen 1 page 36 K factor A Meter Enter the k factor cc pulse for flow meter A This is the amount of material that passes through the flow meter per pulse electrical pulse signal K factor B Meter Enter the k factor cc pulse for flow meter B K factor Solvent Meter This field only appears if Solvent Monitor is set to Meter in Configure Screen 5 page 34 Enter the k factor cc pulse for the solvent flow meter 46 Recipe Setup Screen 6 Recipe cc min cemin Flow Rate Monitor Low Flow Limit High Flow Limit SEES Calibration Fic 55 Recipe Setup Screen 6 This screen appears only if Flow Rate Monitor is set to in Option Screen 2 on page 37 Flow Rate Monitor Select the desired flow rate monitoring Off Warning or Alarm Low Flow Limit Enter the low flow rate limit 1 to 3999 cc min High Flow Limit Enter the high flow rate limit 1 to 3999 cc min Recipe Setup Screen 7 Recipe Special Fic 56 Recipe Screen 7 This screen appears only if Flush and Fill Input is set to Recipe in Option Screen 1 page 36 and Special Out puts is set to 1 2 3 or 4 in Configure Screen 5 page 34 The I O board has four programmable outputs 312779E Recipe 0 Screens NOTE See FIG 49 on page 43 for a map of the Recipe 0 screens Detailed screen descriptions follow Hecipe 0 is typically used
62. V Solvent Purge Valve SVA Component A Shutoff Valve APV Air Purge Valve MB Component B Meter SM Static Mixer DVB Component B Dose Valve Fl Fluid Integrator RVB Component B Sampling Valve Air Purge Valve Air Supply Tube Fic 91 Wall Mount Fluid Station Sequential Dosing 84 312779E System Operation General Operating Cycle Dynamic Dosing Overview Dynamic Dosing provides on demand proportioning eliminating the need for an integrator and therefore min imizing undesired material contact This feature is espe cially useful with shear sensitive and waterborne materials A restrictor injects component B into a continuous stream of component A The software controls the dura tion and frequency of each injection See FIG 92 for a schematic diagram of the process Component A continuous flow Dynamic Dosing System Parameters The following parameters affect dynamic dosing perfor mance e Component A Flow Ensure that the supply pump is sized to provide sufficient and uninterrupted flow Note that component A provides majority of system flow at higher mix ratios Component B Flow Ensure that the supply pump is sized to provide sufficient and uninterrupted flow Component A Pressure Ensure precise pressure regulation It is recommended that the component A pressure be 5 15 lower than the component B pressure e Component B Pressure Ensure precise pressure regulation It is recommended that the component
63. VES A CANNE 3 WAY SOLENOID 4 OPTIONAL 6 12 VDC DN lt 3 WAY SOLENOID OPTIONAL Lal MANFOID 20007 312779E 127 Schematic Diagrams System Electrical Schematic NOTE The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS system Some compo nents shown are not included with all systems Non Hazardous Area NON HAZARDOUS AREA a M C r P a P OPERATOR INTERFACE UNE FILTER DC OK 1 L1 85 250 424 VDC POWER 2 H N ND E SUPPLY COMMON L ROCKER SWITCH POWER HARNESS HARNESS 12VDC S RED BARRIER 3 p BOARD I CABLE 60STD es ERES E 100 OPTION 52 25 52 daret eg 6g ves dp ye 400 DISPLAY MEMBRANE 1 BOARD SWITCH 5 WITH 4 1 MIX INPUT 5 2 PURGE INPUT 6 3 JOB COMPLETE INPUT EIS cra 5 POWER DIST 6 DIGITAL INPUT COMMON 10 TERMINAL 1 11 BLOCKS 2 4 5 6 7 8 DIGITAL INPUT COMMON RECIPE BIT 0 INPUT RECIPE BIT 1 INPUT RECIPE BIT 2 INPUT RECIPE BIT 3 INPUT RECIPE BIT 4 INPUT RECIPE BIT 5 INPUT RECIPE CHANGE INPUT
64. abel RoboMix Fluid Station Systems 6 312779E System Configuration and Part Numbers Hazardous Location Approval Models using G250 or G250HR for both A and B meters are approved for installation in a Hazardous Location Class Div 1 Group D or Zone Group T3 Maximum Working Pressure Maximum working pressure rating for RoboMix Systems is 190 psi 1 31 MPa 13 1 bar Check the identification label on the EasyKey or RoboMix fluid station for the system maximum working pressure See Fic 2 ProMix RoboMix Systems Maximum Working Pressure RoboMix Fluid Station Options all 190 psi 1 31 MPa 13 1 bar Flow Meter Fluid Flow Rate Range G250 Meter 75 3800 cc min 0 02 1 0 gal min G250HR Meter 38 1900 cc min 0 01 0 50 gal min Standard Features EasyKey with LCD RS 485 Network Cable 50 ft 15 25 m Fiber Optic and Power Cables 50 ft 15 25 m Remote Fluid Station 25 cc Integrator Discrete I O Board A Side Dump Valve if color valve s selected B Side Dump Valve if catalyst valve s selected Flow Control with 15 ft 4 57 m Cable if selected Basic Web Interface 312779E 7 Accessories Accessories 15V964 Gateway Profibus Communication Kit 5 m 15G614 Flow Control Extension Cable 40 ft 12 2 m 8 312779E Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion point symbol alerts you
65. ange hold the proper mix ratio and obtain properly mixed material If pressures are not balanced B Pressure Too High or B Pressure Too Low it may not be possible to hold the desired mix ratio The system will generate an off ratio alarm and stop operation NOTE In multi flow rate systems it is recommended that you set up the system to run properly at the highest flow rate to ensure adequate fluid supply across the flow rate range In dynamic dosing component A dose valve is con stantly on Component B dose valve will cycle on and off one cycle every 0 5 1 0 seconds indicates proper balance Monitor system performance by watching the EasyKey display for warning messages which provide information on system performance and adjust pressures accord ingly See Table 12 on page 88 11 9 2009 15 45 4 d 3 100 F psi 5 3 e 383 4 B Pressure Too Lou Fic 96 B Pressure Too Low displayed on EasyKey 312779E System Operation 2597 B Pressure N Too Low B Pressure Too High B Pressure A Pressure Fic 97 A B Control Range with Properly Sized Restrictor ae o RO Xo B Pressure Too Low B Pressure Too High B Pressure A Pressure NOTE If the restrictor is too small it may be necessary to supply more differential pressure than is available in your system Fic 98 A B Control Range with Too Large a Restricto
66. anuals Equipment Approvals Equipment approvals appear on the following labels which are attached to the Fluid Station and EasyKey See FIG 1 on page 4 and FIG 2 on page 6 for label loca tions EasyKey and Fluid Station Label ATEX Certificate is listed here Intrinsically Safe IS System Install per IS Control Drawing No 289833 EasyKey Interface IS Associated Apparatus for use in non hazardous location with IS Connection to Smart Fluid Plate IS Apparatus for use in Class Division 1 Group D T3 Hazardous Locations Read Instruction Manual Warning Substitution of components may impair intrinsic safety PART NO SERIES US FMO8ATEX0074 APPROVED Intrinsically safe equipment for Class Div 1 Group D T3 C 20 to 50 0359 Ex ia T3 MAX AIR WPR MES SERIAL bar MAX FLUID WPR MFG YR GRACO INC MPa bar PSI lt gt 50 122 inneapolis GRACO 55440 U S A Fluid Station Label ProMix 2KS SERIES SERIAL MFG YR FLUID PANEL PART NO MAX AIR WPR Hane ed safe pacha bar oorr Class l M p D T3 We GRACO INC 0073 1441 289033 C G 0359 Ex ia IIA T3 eraco 55440 U S A Artwork No 293538 13581 ATEX Certificate is listed here EasyKey Label POWER REQUIREMENTS VOLTS AMPS 2 AMPS MAX GRACO INC for Glass hid PD 50 60 Hz
67. appear if Manual Override is set to On in Advanced Setup Screen 1 page 39 It shows the active recipe new go to recipe and manual override mode lf Flow Control is set to On in Configure Screen 5 on page 34 this screen will also display Flow Rate Range Flow Set Point Flow Control Calibration Start Abort and Global Flow Control Data Copy Start Abort Manual Override Menu This field allows you to set the operating mode from the EasyKey Press the Enter key to view the menu then select the desired operating mode Standby Mix Purge or Recipe Change See Fic 14 Manual Override Active Recipe Recipe Manual Override Flow Rate Range Flow Set Point Flaw Ctrl Calibration Global FC Data Copy LRecire Change Fic 14 Manual Override Menu 312779E Run Mode Screens Flow Rate Range This screen displays the flow rate range selected on Advanced Setup Screen 5 see page 41 Flow Set Point The Flow Set Point is user settable If Flow Control Override is set to or Pressure in Advanced Setup Screen 1 on page 39 the Flow Set Point will dis play as cc min Enter the desired flow set point within the range If Flow Control Override is set to Open the Flow Set Point will display as Open This percentage relates to the flow control V P ratio which translates to a fluid flow rate Set the initial percentage at 35 a
68. appears if Exiting Fill Source is set to Air Solvent or 3rd Valve Enter the time sec onds 48 Recipe 0 Screen 4 Recipe Special Un Purge Length Un Fill 60 Recipe 0 Screen 4 This screen appears only if Flush and Fill Input is set to Recipe in Option Screen 1 page 36 and Special Out puts is set to 1 2 3 or 4 in Configure Screen 5 page 34 The board has four programmable outputs 312779E Calibration Screen Meter A Meter Calibration Measured Actual volume volume K Factor 0 119 cc pulse Recipe 110 0 FiG 61 Calibration Screen Use this screen to calibrate a meter Set to Meter Meter or Solvent Meter available if Solvent Moni tor in Configure Screen 5 page 34 is set to Meter e Start start calibration Abort stop calibration e Purge purge sampling valves after calibration See Meter Calibration page 100 for when and how to calibrate meter 312779E Setup Mode 49 Setup Mode 50 312779E ProMix 2KS Integration Specifics ProMix 2KS Integration Specifics Discrete vs Network Communications The ProMix 2KS Automatic system does not use a Booth Control Instead it uses Discrete or Network Communications to drive the system Each method can be used exclusively or both at the same time In Automatic mode the following fields can be set to Discrete or Network see Configu
69. ating meters Do not open sampling RVB see valves unless fluid shutoff valves are closed FIG 91 88 312779E Start Up 1 Go through the Pre Operation Checklist Table 14 Table 14 Pre Operation Checklist Checklist System grounded Verify all grounding connections were made See the Installation manual All connections tight and correct Verify all electrical fluid air and system connec tions are tight and installed according to the Installation manual Check air purge valve tubing Check the air purge valve supply tube daily for any visible solvent accumulation Notify your supervisor if solvent is present Fluid supply containers filled Check component A and B and solvent supply containers Mix manifold valves set Check that mix manifold valves are set correctly Start with the settings recommended in Mix Mani fold Valve Settings page 88 then adjust as Fluid supply valves open and pressure set Component A and B fluid supply pressures should be equal unless one component is more viscous and requires a higher pressure setting Solenoid pressure set 75 100 psi inlet air supply 0 5 0 7 MPa 5 2 7 bar 2 Turn the AC Power Switch ON 0 OFF ON 112656 Fic 100 Power Switch 312779E 8 Open the fluid supply valves to the 9 Adjust the air pressure Most appli System Operation Graco logo software revision and Establishing Communication w
70. bably too high delivery rate until fluid hoses are loaded with material If the alarm occurred after you were spraying for some Adjust component A and B fluid supply regulator pres time the pressures from the fluid supplies could be sures until they are about equal f the pressures are unbalanced already about equal verify that component A and B dose valves are operating properly Slow actuation of the component A or B valves This can Manually operate the Dispense A and B solenoid valves be caused by as instructed in the ProMix 2KS Repair Parts manual to check operation e Air pressure to the valve actuators is too low e Increase air pressure Air pressure must be 75 120 psi 0 52 0 84 MPa 5 2 8 4 bar 120 psi is recom mended e Something is restricting the solenoid or tubing and There may be dirt or moisture in the air supply Filter interrupting valve actuation air appropriately e A dose valve is turned in too far e Refer to Table 13 Mix Manifold Valve Settings page 89 for adjustment guidelines e Fluid pressure is high and air pressure is low e Adjust air and fluid pressure See recommended air pressure above 312779E 117 Alarm Troubleshooting Table 17 Alarm Troubleshooting E 4 RATIO LOW ALARM Sequential Dosing System The mix ratio is lower than the set tolerance on the previous dose cycle Dynamic Dosing System The mix ratio is lower than the set tolerance for an A to B component volume
71. ce and Length are Programmable Fic 126 Color Change Chart 18 312779E Color Change 113 Color Change 114 312779E Alarms and Warnings NOTE Do not use the fluid in the line that was dis pensed off ratio as it may not cure properly System Alarms System alarms alert you of a problem and help prevent off ratio spraying If an alarm occurs operation stops and the following occurs Buzzer sounds for E 2 only see page 32 to set for all alarms e Status bar on the EasyKey shows the alarm E Code with a description see Table 16 System Warnings Table 16 lists the System Warning Codes Warnings do not stop operation or sound an alarm They are saved in the date time stamped log which can be viewed on a PC using the ProMix 2KS Web Interface see manual 313386 To Reset Alarm and Restart NOTE When an alarm occurs be sure to determine the E Code before resetting it See Table 16 If you forget which E Code occurred use the Alarms Screen page 27 to view the last 10 alarms with date and time stamps To reset alarms see Table 17 Many alarms can be cleared by simply pressing the Alarm Reset 5 312779E Alarms and Warnings Table 16 System Alarm Warning Codes Communication Error Alarm Page 116 Potlife Alarm Page 116 Ratio High Alarm Page 117 Ratio Low Alarm Page 118 Alarm 4 E 5 Overdose A B Dose Too Short Page 119 Alarm E 6 Overdose B A Dose Too Short Page 119
72. cted in your spray gun manual NOTE Do not allow a fluid supply tank to run empty It is possible for air flow in the supply line to turn gear meters in the same manner as fluid This can lead to the proportioning of fluid and air that meets the ratio and tol erance settings of the equipment This can further result in spraying uncatalyzed or poorly catalyzed material 312779E Shutdown Overnight Shutdown 1 Leave the power on 2 Run Recipe 0 to purge solvent through meters and gun Service Shutdown 1 Follow Pressure Relief Procedure on page 91 2 Close main air shutoff valve on air supply line and on ProMix 2KS Shut off ProMix 2KS power 0 position Fic 103 4 fservicing EasyKey also shut off power at main cir cuit breaker 0 OFF 12657 Fic 103 Power Switch 312779E System Operation Pressure Relief Procedure NOTE The following procedures relieve all fluid and air pressure in the ProMix 2KS system Use the procedure appropriate for your system configuration Relieve pressure when you stop spraying before changing spray tips and before cleaning checking or servicing equipment Single Color Systems 1 While in Mix mode gun triggered shut off the A and B fluid supply pumps pressure pots Close all fluid shutoff valves at the pump outlets 2 With the gun triggered push the manual override on the A and B dose valve solenoids to relieve pres sure See FIG 104
73. d 3rd flush fluid together during the flush cycle to help clean the lines and reduce solvent usage Final Purge Source Select Air Solvent or 3rd Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 33 Air Chop Time Enter the air chop time 0 0 to 99 9 seconds Solvent Chop Time 3rd Flush Valve Chop Time Enter the solvent or 3rd flush valve chop time 0 0 to 99 9 seconds 312779E Setup Mode Recipe Setup Screen 4 Recipe First Purge Time Total Chop Time Final Purge Time Fill Time SEL SEC SEC SEC 4 SEES Calibration 53 Recipe Setup Screen 4 This screen appears only if Flush and Fill Input is set to Recipe in Option Screen 1 page 36 If Number of Guns is set to 2 in Configure Screen 4 page 33 a Gun 2 column will appear in this screen First Purge Time Enter the first purge time 0 to 999 seconds Total Chop Time Enter the total chop time 0 to 999 seconds Final Purge Time Enter the final purge time 0 to 999 seconds Mixed Material Fill Time Enter the mixed material fill time 0 to 999 seconds It refers to the amount of time that is required to load mixed material from the dose valves to the applica tor gun 45 Setup Mode Recipe Setup Screen 5 Recipe K Factar H Meter B Meter cc pulse 0 119 0 119 Solvent Meter 0 119 Calibration 54 Recipe Setup Screen 5
74. d mixer volume 75 cc Spray Gun Volume 20 cc Hose Volume x Feet of Hose 75 20 PLV Color Catalyst Purge This field only appears if the system includes a color change module and Flush and Fill Input is set to Global in Option Screen 1 page 36 Enter the purge time 0 to 99 seconds It refers to the amount of time required to flush the lines from the color or catalyst mod ule to the dose valve or dump valve Color Catalyst Fill This field only appears if the system includes a color change module and Flush and Fill Input is set to Global in Option Screen 1 page 36 Enter the fill time O to 99 seconds It refers to the time required to fill the lines from the color or catalyst module to the dose valve or dump valve 39 Setup Mode Advanced Setup Screen 2 2 0 sec 2 0 sec First Purge Source Type Final Purge Source Air Chop Time solvent Chop Time Advanced 42 Advanced Setup Screen 2 This screen appears only if Flush and Fill Input is set to Global in Option Screen 1 page 36 First Purge Source Select Air Solvent or 3rd Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 33 Chop Type Select Air Solvent or Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 33 This refers to the process of mix ing air and solvent or air and 3rd flush fl
75. d on maximum desired flow rates Flow Rate Analog Signal the type of communication signal that can be used on the ProControl module Flow Rate Tolerance the settable percent of accept able variance that the system will allow before a flow rate warning occurs Flow Set Point a predefined flow rate target Flush Volume Check system monitors flush volume E 11 Alarm occurs if minimum volume is not achieved Minimum flush volume is user settable 0 999 cc Grand Total a non resettable value that shows the total amount of material dispensed through the system Gun Trigger Input Signal used to manage ratio assurance dose times and flow control processes Intrinsically Safe IS refers to the ability to locate cer tain components in a hazardous location Idle if the gun is not triggered for 2 minutes the system enters Idle mode Trigger the gun to resume operation 312779E Job Total a resettable value that shows the amount of material dispensed through the system for one job A job is complete when a color change or complete system flush occurs K factor a value that refers to the amount of material that passes through a meter The assigned value refers to an amount of material per pulse Ki refers to the degree fluid flow over shoots its set point Kp refers to the speed in which the fluid flow reaches its set point Manual Mode when the proportioning or flow control system is controlling the in
76. de sampling valve RVA 92 Systems with Color Catalyst Change and Dump Valves NOTE This procedure relieves pressure through the dump valves 1 Complete all steps under Single Color Systems page 91 2 Shut off all color and catalyst supplies to the valve stacks 3 Press and hold the dump valve A solenoid override FiG 104 4 105 Open the color change module Using the solenoid identification labels as a guide press and hold the override button on each color solenoid until flow from dump valve A stops 5 Press and hold the dump valve B solenoid override FiG 104 6 See 105 Using the solenoid identification labels as a guide press and hold the override but ton on each catalyst solenoid until flow from dump valve B stops 7 Press and hold the dump valve A solenoid override FiG 104 8 Press and hold the A side color solvent solenoid override until clean solvent comes from the dump valve then release 9 Press and hold the dump valve B solenoid override FiG 104 10 Press and hold the B side catalyst solvent solenoid override until clean solvent comes from the dump valve then release 11 Shutoff the solvent supply to the color catalyst change stack solvent valves 12 Press and hold the A and B solvent solenoid over rides and dump valve overrides until solvent flow from the dump valves stops 312779E System Operation RoboMix Fluid Station Dose Valve B Overrid
77. ds 50 of the potlife volume the system will go into Standby mode 6 Perform a manual purge or recipe change to purge the remaining mixed material This will clear the sys tem out of Solvent Push allowing you to resume Mix mode NOTE Once the system senses that solvent exceeds 50 of potlife volume attempts to re enter Solvent Push will cause an Overdose A B Alarm E 5 E 6 DVB is closed TI12556b SS SPV is open 99 Meter Calibration Meter Calibration To avoid splashing fluid in the eyes wear eye protec tion The fluid shutoff valves and ratio check valves are retained by mechanical stops that prevent accidental removal of the valve stem while the manifold is pres surized If you cannot turn the valve stems manually relieve the system pressure then disassemble and clean the valve to remove the resistance Calibrate the meter e The first time the system is operated e Whenever new materials are used in the system especially if the materials have viscosities that differ significantly e Atleast once per month as part of regular mainte nance e Whenever a flow meter is serviced or replaced NOTE e K factors on the Calibration Screen are updated automatically after the calibration pro cedure is completed e K factor values on the screen are viewable only If needed you can manually edit the K factors in Advanced Setup Screen 4 see page 41 or Recipe Setup Screen 5 page 46 e
78. e 89 5 Lia et 91 Pressure Relief Procedure 91 PUOI PETS 95 Solvent Push Feature 99 Meter Calibration 100 ColorChange t b inua 102 Color Change Procedures 102 Color Change Sequences 102 Alarms and Warnings 115 System Alarms E 115 System Warnings 115 Alarm Troubleshooting 116 Schematic Diagrams 127 System Pneumatic Schematic 127 System Electrical Schematic 128 EasyKey Electrical Schematic 130 Meter Performance Data G3000 on A and B 131 Meter Performance Data G3000 on A Coriolis on B 132 Technical Data I be I Xe S 133 Graco Standard Warranty 134 Graco Information 134 312779E Related Manuals Component Manuals in English Description 312778 ProMix 2KS Automatic System Installation 312780 ProMix 2KS Automatic System Repair Parts 312784 312786 Dump Valve and Third Purge Valve Kits 312785 Network Communication Kits 308778 G3000 G3000HR G250 G250HR Flow Meter 313386 Basic Web Interface Advanced Web Interface 406800 15V825 Discrete I O Board Kit 312784 312786 312785 312779E Helated M
79. e 0 gt 1 Color Fill Time P1 gt P2 Catalyst Purge Time P2 gt P3 Catalyst Fill Time P3 gt P4 Purge Fill Timers are independent of System Purge Timers This line defines when the System Fill Time Air Chop Time begins The longer of the two timers Solvent Chop Time defines when the System Fill Time First Purge one of these 3rd Flush Chop Time begins Air Purge Solvent Purge Final Purge one of these 3rd Flush Valve ome Dispense Gun Flush Box Output 1 aided MO M1 M2 M3 MA First Purg Chop Time air solvent or air 3rd flush 1 gt 2 Final Purge Time M2 gt M3 Mixed Fill Time M3 gt M4 Notes Load tables from new recipe Purge from old recipe Fill from new recipe 114 Color Change Chart 6 312779E 107 Color Change ProMix 2KS Recipe Change Chart 7 A1 to A2 B1 to B2 with Dump Valves 1 GFB Time Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Color Purge Time 0 gt 1 Color Fill Time 1 gt 2 Catalyst Purge Time P2 gt P3 Catalyst Fill Time P3 gt P4 CC Purge Fill Timers are independent of Mixed Material Purge Timers This line defines when the Mixed Fill Time Air Chop Time begins The longer of the two timers Solvent Chop Time defines when the Mixed Fill Time First Purge one of these 3rd Flush Chop Time beg
80. e 36 K factor A Meter Enter the k factor cc pulse for flow meter A This is the amount of material that passes through the flow meter per pulse electrical pulse signal K factor B Meter Enter the k factor cc pulse for flow meter B K factor Solvent Meter This field only appears if Solvent Monitor in Configure Screen 5 page 34 is set to Meter Enter the k factor cc pulse for the solvent flow meter 312779E Setup Mode Advanced Setup Screen 5 Flou Rate Range Tolerance Alarm Time Advanced Calibration 45 Advanced Setup Screen 5 Automatic Mode with Flow Control Only This screen appears only if Flow Control is set to On in Configure Screen 5 page 34 Flow Rate Range Enter the flow rate range 0 300 0 600 or 0 1200 This determines the flow control PID loop resolution Flow Rate Tolerance Enter the flow rate tolerance 1 to 99 This is the per centage of variance that the system will allow before a flow rate warning alarm occurs Flow Rate Ki Enter the flow rate Ki flow control PID loop integral value This refers to the degree that fluid flow over shoots its set point Flow Rate Kp Enter the flow rate Kp flow control PID loop gain value This refers to the speed at which the fluid flow reaches its set point Flow Rate Alarm Time Enter the flow rate alarm time 1 to 99 seconds 41 Setup Mode Advanced Setup Screen 6 Calibrate OFC
81. e Button Dose Valve A Override Button 2655 Wall Mount Fluid Station 1 E Raver 1 1T CAN Fiber Optic IEEE ooooonjooooooooon OOOO0O Valve Overrides Dose A EE X m n 78 Dump Valve Dump Valve B Optional Solenoid 1 Locations d Jm m GFB2 uos HAI Jose Valve ard Purge Valve Solenoid Solenoid Dose Valve B Purge Valve A Purge Valve B Solenoid Solenoid Solenoid TI12652b FiG 104 Fluid Solenoids 312779E 93 System Operation n CL S 0 5 A 2 A J FILS t J o E AY Solenoid 2 Sol
82. e Idle mode and resume mixing mate rial where it left off Purge Start This is a maintained input When recog nized by the ProMix 2KS the Purge Sequence will start using the Purge Time from the active recipe This will also include the Solvent Fill Time Proper monitoring of the Purge Color Change Output is required to ensure this function has begun Once this output is removed the system will immediately go to Standby mode Color Change Start This is a momentary input 100 msec minimum When recognized by the ProMix 2 5 the Color Change sequence will begin starting at the Color Catalyst Dump NOTE If the new recipe has the same color as the active recipe then the Color Catalyst Dump and Color Catalyst Fill times are skipped and the Color Change Sequence starts with the Purge Also the rec ipe bit configuration for the Color Change must be loaded at least 100 msec before the Color Change Start input is turned on The recipe bit configuration must remain on while the Color Change Start input is removed Graco recommends the recipe bits stay active and do not change until a new color is required The PLC should monitor the Purge Color Change Output as well as the Fill Active Output to ensure the process hap pens as required A complete color change without errors resulting in a Mix Ready Output state is a com pleted color change NOTE This also applies if using the Modbus Registers see the Modbus Map table in manual 3127
83. e Mix input Trigger the gun to relieve pressure If you are using a high pressure gun engage the trig ger lock Remove spray tip and clean tip separately If using an electrostatic gun shut off the electrostatics before flushing the gun 2 Attach solvent supply lines as follows e Single color single catalyst systems discon nect the component A and B fluid supplies at the flow meter inlets and connect regulated sol vent supply lines e Multiple color single catalyst systems dis connect only the component B fluid supply at the flow meter inlet and connect a regulated sol vent supply line e Multiple color multiple catalyst systems connect the solvent supply lines to the desig nated solvent valve on the color and catalyst valve stacks Do not connect a solvent supply to either flow meter 312779E 3 Adjust the solvent fluid supply pressure Use the lowest possible pressure to avoid splashing 4 Remove the Fluid Station cover to access the sole noid valves See FIG 104 on page 93 5 Purge as follows e Single color single catalyst systems Purge component A side Press the manual override on the Dose Valve A solenoid valve and trigger the gun into a grounded metal pail Purge component B side Press the manual override on the Dose Valve B solenoid valve and trigger the gun into a grounded metal pail until clean solvent flows from the gun Repeat to thoroughly clean the fluid integrator e M
84. e is nec essary to properly drive the inputs and monitor the out puts See Advanced Setup Screen 7 page 42 This screen shows the actual status of all inputs and outputs It is important to ensure that each input from local automa tion PLC is received by the EasyKey and to verify that the ProMix 2KS is sending outputs to the automation The following paragraphs describe each discrete function in detail Terminal Strips see 63 Barrier Board Discrete I O Board see FIG 64 TI12496a 51 2 5 Integration Specifics Digital Inputs See Automation Flow Charts pages 55 59 Mix Start This is a maintained input When High the ProMix 2KS will attempt to enter Mix mode This Mix Start input should not be attempted unless the Mix Ready output is recognized This ensures that there are no alarms and that the Mix Start input is appro priate This input stays High at all times when mixing on demand is required When Low the intent is to stop mix ing material and perform a purge or recipe change Do not toggle this input to set the unit to Standby mode during short work stoppages The ProMix 2KS will auto matically go into Idle mode after 2 minutes of inactivity When a Gun Trigger input is seen the ProMix 2KS will automatically leav
85. eady bit 2 1 ProMix 2KS Color Change Process Check Alarm Condition is Alarm General bit 1 NO Complete YES Process Alarm See Alarm Processing page 59 Fic 68 Color Change Mode Process Flow Chart 58 312779E Alarm Processing See 69 Table 5 Table 6 and Table 7 NO Determine the exact alarm from Table 7 on page 62 and solve what caused the alarm as required the alarm Reset Alarm 1 e Is Mix Ready bit 1 69 Alarm Processing Flow Chart 312779E ProMix 2KS Integration Specifics Alarm Processing An Alarm Condition has been found previously Alarm General 1 Check if Potlife Alarm is Alarm Potlife bit 2 1 YES Two options e Purge or Color Change to remove mixed material in the line e Place in Mix mode and spray the Potlife Volume set in the ProMix 2KS NOTE The Reset key only silences the alarm To clear the alarm you must use one of these two options YES Go to next process as desired 59 2 5 Integration Specifics Table 5 ProMix 2KS Digital Inputs Modbus Register 40040 Digital Input Binary 08 000000 X X X X X X Binary bits for viewing discrete inputs only 8 Color Change Set bit to 1 to initiate Color Change momentary CC 7 Mx Set bit initiate Mx mode maintain bit
86. ed power source All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations 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 e Only models with G3000 2250 G3000HH G250HH or intrinsically safe Coriolis meter are approved for installation in a Hazardous Location Class Div 1 Group D or Zone Group T3 Do not install equipment approved only for a non hazardous location in a hazardous area See the ID label for the intrinsic safety rating of your model Do not substitute or modify system components as this may impair intrinsic safety 312779E 9 Warnings 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 e Tighten all fluid connections before operating the equipment Do not point gun at anyone or at any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment EQU
87. ed purge media usually solvent The selected purge valve opens dur ing the Final Purge Time and closes when the time expires Fill Step M3 M4 This sequence fills the line from the dose valves to the gun and is also referred to as the mixed material fill The system begins mixing components A and B until the Fill Time expires Purge Active Step M0 M3 The system turns on the Purge Recipe Change Purge Active output during steps MO M3 Fill Active Step M3 M4 The system turns on the Recipe Change Fill Active out put during step M3 M4 103 Color Change Table 15 Color Change Chart Reference Number of Catalyst Dump 3rd Purge Gun Flush Change Valves Valve Boxes es Color Change Starting Recipe owa EE NN NE EE NM WE Ending Recipe Refer to Fig FiG 110 FiG 109 FiG 112 FiG 111 FiG 113 FiG 123 FiG 115 FiG 117 FiG 114 FiG 116 FiG 118 118 FiG 120 FiG 118 120 FIG 119 119 FiG 121 119 FiG 121 118 FiG 118 FiG 120 118 120 118 FiG 125 FiG 125 FiG 126 FiG 125 FiG 126 Yes Yes Yes Yes 0 1 or2 0 1 or2 0 1 or2 Z OJO D o Y lt lt 0 Yes 0 1 or2 0 1 or2 0 1 or2 0 1 or2 0 1 or2 0 1 or2 0 1 o
88. em Operation Purging Using Recipe 0 Hecipe 0 is typically used multiple color systems to purge out material lines without loading a new color e atthe end of a shift to prevent hardening of cata lyzed material To setup Recipe 0 go to Advanced Setup Select the Recipe tab and change the Recipe to 0 The Recipe 0 Setup Screen appears Set the chop times from 0 999 seconds in increments of 1 second 1 Goto Standby mode remove Mix input Trigger the gun to relieve pressure If you are using a high pressure gun engage the trig ger lock Remove spray tip and clean tip separately 2 If using a gun flush box place the gun into the box and close the lid 3 Select Recipe 0 and press Enter 4 Ifa gun flush box is not used trigger the gun manual Or automatic into a 4 grounded metal until the purge T sequence is com plete 5 The color change LED blinks while Recipe 0 runs and turns solid after purge sequence is complete 6 Ifthe system is not completely clean you repeat Recipe 0 by pressing Enter 96 Purging Fluid Supply System Follow this procedure before 1 the first time material is loaded into equipment servicing shutting down equipment for an extended period of time putting equipment into storage Some steps are not necessary for initial flush ing as no material has been loaded into the system yet Go to Standby mode remov
89. en activated see Configure Screen 1 page 32 the Password screen will appear You must enter the password to access the Set Up Home Screen Entering the wrong password returns the display to the Status Screen NOTE If you forget the password you can reset the password to 0 using the ProMix Web Interface see manual 313386 Enter Password Fic 24 Password Screen NOTE If a password is activated Setup Locked dis plays momentarily after exiting Setup mode and return ing to the Status Screen A lock 5 symbol appears on the Status Screen setup Locked 25 Setup Locked Screen 312779E Setup Mode Set Up Home Screen Set Up Home Promis 2KS Recipe amp Advanced Setup System Configuration EK 2 04 009 BC 1 8 L1 1 3 FP 04 009 AK AP 0 1042 0198 192 166 176 1 MAL 00204AR 3204F Fic 26 Set Up Home Screen This screen displays when you enter Setup mode From it you can go to Recipe and Advanced Setup Screens pages 38 46 or System Configuration Screens pages 31 37 Press the Enter Hi key to go to the selected screen set The screen also displays software versions and internet addresses of various components The values shown in FiG 26 are only examples and may vary on your screen See Table 3 for further information 29 Setup Mode Table 3 Component Software Versions Display may vary from examples Component shown Descripti
90. enoid Identification af 5 B Identification Label ip 8 8 Label ec te 2 E 0 i dB 91 AB 9 on 2 112826 Solvent Solenoid Overrides FiG 105 Color Change Solenoids Key DVA FI DVB MA Component A Meter MB DVA Component A Dose Valve RVA Component A MS Sampling Valve MA SVA Component A m Shutoff Valve MB Component B Meter ais DVB Component B Dose Valve J r RVB Component B ji Sampling Valve SVB Component B Shutoff Valve I MS Solvent Meter AT accessory x SPV Solvent Purge Valve 2 Air Purge Valve TI2556b SM Static Mixer Fl Fluid Integrator AT Air Purge Valve Air RVA APV SVA SVB SPV Fic 106 Wall Mount Fluid Station 94 Supply Tube 312779E Purging Head Warnings page 9 Follow the Grounding instructions in your system Installation manual To avoid splashing fluid in the eyes wear eye protec tion There 4 purging procedures in this manual Purging Mixed Material below Purging Using Recipe 0 page 96 Purging Fluid Supply System page 96 Purging Sampling Valves and Tubes page 98 Use the criteria listed in 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 System Operation Set the solvent supply pressure regulator at a pres sure high enough to completely purge the system in a reasonable amount of
91. ent of acceptable variance that the system will allow before a ratio alarm OCCUIS Sequential Color Change the process when a color change is initiated and the system automatically flushes the old color and loads a new color Sequential Dosing Components A and B dispense sequentially in the necessary volumes to attain the mix ratio Solvent 3rd Purge Valve Chop Time duration of each activation of the solvent or 3rd purge valve during a chop sequence User settable from 0 0 99 9 seconds Solvent Fill the time required to fill the mixed material line with solvent Solvent Push enables the user to save some mixed material by pushing it out to the gun with solvent Hequires an accessory solvent meter Standby refers to the status of the system Third Purge Valve refers to the use of three purge valves used to flush some waterborne materials The valves are used to flush with water air and solvent V P refers to the voltage to air pressure device in the flow control module 13 Overview Overview Usage The Graco ProMix 2KS is an electronic two component paint proportioner It can blend most two component solvent and waterborne epoxy polyurethane and acid catalyzed paints It is not for use with quick setting paints those with a potlife of less than 15 minutes e proportion at ratios from 0 1 1 to 50 1 in 0 1 e Color change options are available for low pressure increments 300 psi 2 1 MPa 21 bar
92. ent or 3rd flush valve chop time 0 0 to 99 9 seconds Recipe 0 Screen 2 Recipe Color Catalust Purge 5 First Purge Time Total Chop Time Final Purge Time SEES Calibration 58 Recipe 0 Screen 2 lf Number of Guns is set to 2 in Configure Screen 4 page 33 a Gun 2 column will appear in this screen Color Catalyst Purge Time This field only appears if the system includes a color change module Enter the purge time 0 to 999 sec onds First Purge Time Enter the first purge time 0 to 999 seconds Total Chop Time Enter the total chop time 0 to 999 seconds Final Purge Time Enter the final purge time 0 to 999 seconds 47 Setup Mode Recipe 0 Screen 3 lsec hecipe Minimum Flush Valume Exiting Fill Source Exiting Fill Time MESE Calibration 59 Recipe 0 Screen 3 This screen only appears if Solvent Monitor is set to Meter in Configure Screen 5 page 34 and Flush Vol ume Check is set to in Option Screen 1 page 36 or 3rd Flush Valve is set to On in Configure Screen 3 on page 33 Minimum Flush Volume This field only appears if Flush Volume Check is set to On in Option Screen 1 on page 36 Enter the mini mum flush volume 0 to 999 cc Exiting Fill Source This field only appears if 3rd Flush Valve is set to On in Configure Screen 3 on page 33 Select Off Air Solvent or 3rd Valve Exiting Fill Time This field only
93. er used in RoboMix systems It is typically used in flow ranges of 75 3800 cc min 0 02 1 0 gal min pressures up to 300 psi 2 1 MPa 21 bar and viscosities of 20 3000 centipoise The K factor is approximately 0 119 cc pulse G250HR is high resolution version of the G250 meter used in RoboMix systems It is typically used in flow ranges of 38 1900 cc min 0 01 0 5 gal min pressures up to 300 psi 2 1 MPa 21 bar and viscosities of 20 3000 centipoise The K factor is approximately 0 061 cc pulse 3000 is a gear meter used for solvents in flow ranges of 38 1900 cc min 0 01 0 50 gal min pressures up to 3000 psi 21 MPa 210 bar and viscosities of 20 50 centi poise The K factor is approximately 0 021 cc pulse Required to use the Solvent Push feature Coriolis is a specialty meter capable of a wide range of flow rates and viscosities This meter is available with 1 8 in or 3 8 in diameter fluid passages For detailed information on the Coriolis meter see manual 313599 The K factor is user settable at lower flow rates use a lower K factor 1 8 in fluid passages set K factor to 020 or 061 3 8 in fluid passages set K factor to 061 or 0 119 An optional component It is available as a color change valve stack for either low or high pressure with up to 30 color change valves Each stack includes one additional valve for solvent to clean the fluid line between color changes An optional component
94. f the identification labels The part number includes one digit from each of the following six categories depending on the configuration of your system RoboMix and Display A and B Meter Color Valves Catalyst Valves Flow System Control D EasyKey with LCD Display 0 No Meters 0 No Valves 0 No Valves 1 G250 A and B single color single catalyst 2 G250HR A and B 1 Two Valves 1 Two Valves p low pressure low pressure 2 Four Valves 2 Four Valves low pressure low pressure 3 Seven Valves low pressure 4 Twelve Valves low pressure 2KS Intrinsically Safe IS System Install Electronic Proportioner per IS Control Drawing No 289833 EasyKey Interface IS Associated Apparatus for use in non hazardous fu location with IS Connection to Smart Label Location on FMOBATEX0074 APPROVED Fluid Plate IS Label Location EE DT Intrinsically safe Apparatus for use in RoboMix Fluid Station Div 1 Group D T3 Class Division 1 Group D T3 on EasyKey C Ta 20 to 50 C Hazardous Locations 25120 9892 Read Instruction Manual AIR WPR Warning Substitution of components Maximum Fluid 7 7 100 may impair intrinsic safety Working Pressure PART NO SERIES SERIAL s Here T Configured Part Number We GRACO INC MPa bar PSI P O Box 1441 MAX TEMP 50 122 7 Minneapolis 2 Identification L
95. ge SEC Color Catalyst Fill Advanced Calibration 40 Advanced Setup Screen 1 1 CC Flow Control Override This field only appears if Flow Control is set to On in Configure Screen 5 on page 34 and Manual Override is set to On see below The selections made will affect the display in Manual Override Screen on page 25 Choose the desired selection as defined below Description Off Normal Normal operation Open Flow control regulator is opened to a GE 1 nd Pressure Flow control is opened to a o OS Flow Control Override Manual Override 1 Potlite Volume Color Catalyst Purge Color Catalyst Fill Fic 41 Flow Control Override Menu 312779E Setup Mode Manual Override This field only appears if Run Mode is set to Automatic or Semi automatic in Configure Screen 3 page 33 Set to On to override all outside control If selected the Manual Override Screen page 25 will be added and the Flow Control Override field appears see above Gun 1 Gun2 Potlife Volume Enter the potlife volume 1 to 1999 cc for each gun This is the amount of material required to move through the mix manifold hose and applicator gun before the potlife timer is reset Use the following information to determine approximate pot life volume PLV in cc Hose ID inches Volume cc foot 3 16 5 43 1 4 9 648 3 8 21 71 Integrator manifold an
96. ge and Color Cata lyst Fill are added to Advanced Setup Screen 1 page 39 Advanced Setup Screen 2 and 3 are added See pages 40 42 If set to Recipe Color Catalyst Purge and Color Cata lyst Fill are added to Recipe Setup Screen 2 page 44 Recipe Setup Screen 3 4 and 7 are added See pages 45 46 K factor Input If set to Global Advanced Setup Screen 4 page 41 is added If set to Recipe Recipe Setup Screen 5 page 46 is added Minimum Material Fill Volume Enter 0 9999 cc 36 Verification Screen Warning switching ta source Llobal source recipe for Flush and Fill Input This will overwrite recipe data Are you sure Fic 37 Verification Screen Verification This screen appears if Flush and Fill Input or K factor Input are changed from Recipe to Global in Option Screen 1 312779E Option Screen 2 External Color Change Auto Dump Flow Rate Monitor Solvent Push Enable Options 38 Option Screen 2 External Color Change If set to Off Color Catalyst Purge Time and Color Cat alyst Fill Time appear in Advanced Setup Screen 1 page 39 or Recipe Setup Screen 2 page 44 depend ing on whether Flush and Fill Inputs are set to Global or Hecipe If set to On these fields are removed from the screens Auto Dump If the auto dump feature is being used set to On Once the auto dump is enabled the gun flush box is enabled and the potlife a
97. gure 94 Configure Screen 4 dynamic dosing selected 86 3 Selecting DD in System Configure Screen 4 makes the DD Setup mode available See FIG 95 To enable DD setup mode select On in the DD Setup mode drop down menu This disables Off Ratio alarms E 3 and E 4 allowing uninterrupted setup and tuning NOTE Do not use the material mixed when in DD setup mode as it may not be on ratio due to the disabled alarms NOTE If DD setup mode is not turned Off at the end of setup it will automatically turn off 3 minutes after initia tion of a Mix command Dose Size cc DD setup mode nm Dose Time Alarm s Ur 95 Configure Screen 4 dynamic dosing setup mode enabled Configure 312779E Balancing A B Pressure If component B pressure is too high it will push the com ponent A stream aside during B injection The valve will not open long enough causing a High Ratio alarm If component B pressure is too low it will not be injected in sufficient volume The valve will stay open too long causing a Low Ratio alarm Selecting the correct component B restrictor size and balancing the A B pressures will keep the system in the proper pressure range resulting in a consistent mix ratio FiG 97 shows the A to B pressure balance read at the proportioner inlet It is recommended that the compo nent B pressure be 5 15 higher than the component A pressure to keep the system in the control r
98. he catalyst valve to the Dump B valve e The catalyst change solvent valve and the Dump B valve open during the Purge Time e The catalyst change solvent valve closes when the Purge Time expires Catalyst Fill Step P3 P4 e This sequence fills the line with the new catalyst all the way to the Dump B valve e The new catalyst valve and the Dump B valve open during the Fill Time e The new catalyst valve and the Dump B valve close when the Fill Time expires 312779E Color Change First Purge Step MO M1 Select the First Purge Source air solvent or 3rd valve and First Purge Time For most applications air is selected The system purges the old material from the dose valves to the gun using only the selected purge media usually air The selected purge valve opens during the First Purge Time and closes when the time expires Chop Cycle Step M1 M2 Select the Chop air solvent or valve and Chop Times The air purge valve opens only during the air chop cycle and the solvent or 3rd valve opens only during the solvent chop cycle The number of chop cycles is determined by dividing the Total Chop Time by the sum of the Air and Solvent Chop Times Final Purge Step M2 M3 Select the Final Purge Source air solvent or 3rd valve and Final Purge Time For most applications solvent is selected The system fills the line with solvent from the dose valves to the gun using only the select
99. he screen are viewable only If needed you can manually edit the K factors in Advanced Setup Screen 4 page 41 or Recipe Setup Screen 5 page 46 Always purge sampling valves after calibrating meters Use one of the following methods Follow the Purging Sampling Valves and Tubes procedure page 98 e Place the sampling valve fluid tubes into a com patible cleaning fluid TSL or solvent or cap them NOTE If fluid hardens in sampling tubes replace them with 5 82 in or 4 mm OD tubing Make sure both sampling valves are closed and both fluid shutoff valves are fully open Before you begin production clear the system of solvent and prime it with material a Goto Mix mode b Trigger the gun into a grounded metal pail until mixed material flows from the gun nozzle To begin operation see Start Up page 89 107 Color Change Color Change Color Change Procedures Multiple Color Systems 1 Shut off air to the gun 2 Place the gun in the gun flush box if used and close the lid 3 Goto Standby mode remove Mix input 4 Select the new recipe Begin the color change sequence 5 Ifa flush box is not used trigger the gun manual or automatic into a grounded metal pail until the color change sequence is complete S NOTE The color change timer does not start until a Gun Trigger input is seen and fluid flow is detected If no flow is detected within 2 mi
100. i xcu 9 450cc min 4 43 cc min Manual Override Active Recipe 3 Mew Recipe Manual Override 2 Flow Rate Range 0 1200 4 Flaw Set Point Flow Ctrl Calibration Start Global FC Data Copy Usage Job Total Grand Total A 0ce Liters B 0 Liters 0 Liters enulvent 0 Liters Job 0 solvent Level Control Reset Solvent Are you sure you want to reset solvent total Alarms Date Time Alarm 01 02 03 04 05 Run Mode Screens Press the Setup key to enter Setup mode Level Contral Liters Alarm Level Current Volume 4 Color 1 10 Color 2 10 Catalyst 1 10 Solvent 10 Level Control T112802a 23 Run Mode Screens Status Screen e Use the Up or Down 7 keys to scroll through the Run screens Press the Setup key to enter the Setup screens from the Status screen e other keys have no function in this Status screen 10 20 2010 8 7 51 12 psi Vat 450 31 4 Gy Fic 12 Status Screen Key to FiG 12 D Active Recipe shows the active recipe NOTE At power up the system defaults to Recipe 61 which is not a valid recipe number 2 Target Ratio for the active recipe The ratio can be from 0 0 1 50 0 1 in 0 1 increments 3 Actual Ratio in hundredths calculated after each dose of A and B 4 Potlife Time
101. iN Air Purge B Solvent Purge UX Final Purge one of these ard Flush Valve TR ER EE BEEN Dispense B Triggers M Trigger s by Operator First Purge Time 0 gt 1 Chop Time air solvent or air 3rd flush 1 gt 2 Final Purge Time M2 gt M3 Mixed Fill Time M3 gt M4 Notes Load tables from new recipe Purge from old recipe Fill from new recipe Fic 109 Color Change Chart 1 ProMix 2KS Recipe Change Chart 2 A1 to A2 B1 to B2 with Dump Valves and 3rd Flush Valve L me sequenes ene Dumpa S E Color Change Solvent mm Catalyst Change Solvent 2 X X Color Change A Catalyst Change B St WV D S S S S Purge Time 0 gt 1 m Fill Time 1 gt 2 st Purge Time P2 gt P3 CastFillTimeP3PA st Fill Time P3 gt P4 Purge Fill Timers are independent of Mixed Material Purge Timers This line defines when the Mixed Fill Time Air Chop Time begins The longer of the two timers Solvent Chop Time defines when the Mixed Fill Time First Purge one of these 3rd Flush Chop Time begins Air Purge olvent Purge Final Purge one of these rd Flush Valve Two Second Solvent Purge Dispense A by Trigger s by Operator M2 M5 5 Second Initial Purge Time 0 gt 1 First FirstPurgeTimeMI gt M2 Time M1 gt M2 Chop Time air solvent or air 3rd flush M2 gt
102. ials being used Verify that the I O inputs are working properly If using discrete check by viewing Advanced Setup Screen 6 and Advanced Setup Screen 7 page 42 If using network communication ensure the commands are being sent by viewing the Status Screen page 24 and Advanced Setup Screen 6 and Advanced Setup Screen 7 page 42 for inputs NOTE See the Graco Gateway manual for Flow Control Modbus addresses 5 72 See Flow Control Startup Flow Control Startup 1 Set Flow Control to in Configure Screen 5 Flow Control On t special Outputs Solvent Monitor Browser IP 192 158 178 L oantigure Fic 77 Configure Screen 5 2 n Advanced Setup Screen 1 turn Manual Over ride On The Flow Control Override field will appear Flow Control Override eit Manual Override n Gun 1 Potlife Volume aa cc Dolor Catalyst Purge Sec Color Catalust Fill SeC Advanced Calibration 78 Advanced Setup Screen 1 312779E Set Flow Control Override to Open See FIG 79 and Table 10 On the Manual Override Screen the Flow Set Point field will display as a percentage open see FIG 80 or Flow Control Override Manual Override 1 PotliPe Volume Catalyst Purge Catalyst Fill Fic 79 Flow Control Override Menu Table 10 Flow Control Override Selections Description Off Normal operation Open Flow control regulator is o
103. ill display followed by Status Screen See page 22 gt At power up the system defaults to Recipe 61 which is not a valid recipe number Initiate a color change to Recipe 0 or a valid recipe num ber 1 60 bottom left corner the system status dis plays which can be Standby Mix Purge or an alarm notification 10 20 2010 Pol id 3 3 V 7 6 450cc mn 4 43Ucc min 4 Fic 101 Status Screen 3 Verify that the EasyKey is working The active rec ipe number and Standby mode should be displayed 4 fthis is the first time starting up the system purge it as instructed in Purging Fluid Supply System page 96 The equipment was tested with lightweight oil which should be flushed out to avoid contaminat ing your material 5 Make sure that the EasyKey is in Standby remove Mix input 6 Adjust component A and B fluid supplies as needed for your application Use low est pressure possible Me ing pressure shown on the system identification label or the lowest rated component in the system 7 Do exceed the maximum rated work system RE cations require about 80 psi 552 kPa 5 5 bar air pressure to operate properly Do not use less than 75 psi 517 kPa 5 2 bar 89 System Operation 10 Purge air from the fluid lines a Shut off air to the gun by clos ing the air regulator or shutoff valve for the gun atomizing air Za Manual P gun shown
104. ime M2 gt M3 Mixed Fill Time M3 gt M4 Notes Load tables from new recipe Purge from old recipe Fill from new recipe 1st On Start 1st On Length Duration 2nd 2nd On Length Special Output 1 Fic 122 Color Change Chart 14 312779E Color Change 111 Color Change Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B First Purge one of these olvent Purge 3rd Flush Purge Dispense A ProMix 2KS Recipe Change Chart 15 Same A Same B Time Sequence Air Chop Time Solvent Chop Time 3rd Flush Chop Time 4 gt Final Purge of these A B Gun Trigger s by Operator First Purge Time 0 gt 1 Chop Time air solvent or air 3rd flush 1 22 Final Purge Time 2 53 Mixed Fill Time 3 54 Notes Purge from old recipe Fill from new recipe FIG 123 Color Change Chart 15 112 Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B First Purge one of these 3rd Flush Purge Dispense A Dispense B Gun Trigger s by Operator First Purge Time 0 gt 1 Chop Time air solvent or air 3rd flush 1 22 Final Purge Time 2 53 Wait for External Color Change Ready signal before advance to step 4 3 54 Mixed Fill Time 4 55 Notes Purge from old recipe Fill from new recipe Recipe Change Purge Active Output Fic 124 Color Change Chart 16 p lE 1 2 3 4 Load tables from new recipe ProMix 2
105. imum working air pressure 100 psi 0 7 MPa 7 bar be RR HERO SR RE er es 75 100 psi 0 5 0 7 MPa 5 2 7 bar Air filler inlet size 3 8 npt f Air filtration for air logic and purge air 5 micron minimum filtration required clean and dry air Air filtration for atomizing air user supplied 30 micron minimum filtration required clean and dry air Mixing ratio 0 1 1 50 1 up to 1 user selectable Fluids handled one or two component solvent and waterborne paints polyurethanes epoxies acid catalyzed varnishes moisture sensitive isocyanates Viscosity range of 20 5000 cps Fluid filtration user supplied 100 mesh minimum Fluid flow rate range G3000 G250 75 3800 cc min 0 02 1 00 gal min G3000HR G250HR 38 1900 cc min 0 01 0 50 gal min Coriolis 20 3800 cc min 0 005 1 00 gal min 53000 Solvent Meter accessory 38 1900 cc min 0 01 0 50 gal min Fluid inlet sizes Flow 1 4 npt f Dose Valve Color Valve Adapters 1 4 npt f
106. initiate Mix mode maintain O lPuge 00 Purge EE M bit to 1 to initiate Set bit to 1 to initiate Purge sequence maintained sequence maintained 5 tary External CC Set bit to 1 to initiate External Color Change Ready _ EI Calibrate 999 bit to 1 to initiate Flow Control Calibrate input momentary 13 Gun Trigger Set bit to 1 to indicate the gun is actually triggered maintain while gun is triggered remove when gun is closed 14 o Ress Am Serb ta T ta dear an active Alarm momeman 15 ojo o oo o o o o o o o o0 o Remote Stop Seibitoremoteystopunt momenay _ NOTE Shaded cells relate to the flow charts on pages 55 59 60 312779E ProMix 2KS Integration Specifics Table 6 ProMix 2KS Outputs Modbus Register 40041 Bit Digital Input Binary 202 ML ncicates Purge or ofer Change fs In prog ress gt lolollolololololololololo a e armen m M DM 1 0 0 Ready CC Fill Active 1 indicates the Fill portion of a Color Change is in progress FCalActive 1 indicates the Flow Control Calibrate routine is progress 5 1 Flow Rate Alarm 1 indicates the Flow Rate Alarm Warning is active Special 1 1 indicates the Special 1 output is on monitor only Special 2 1 indicates the Special 2 output is on monitor only 1 Special 3 1 indicates the
107. ins Air Purge Ne 3rd Flush Valve XI Gun Flush Box Output 1 MO M1 M2 M3 M4 First Purge Time 0 gt 1 Chop Time air solvent or air 3rd flush 1 gt 2 Final Purge Time M2 gt M3 Mixed Fill Time M3 gt M4 Notes Load tables from new recipe Purge from old recipe Fill from new recipe Fic 115 Color Change Chart 7 ProMix 2KS Recipe Change Chart 8 A1 A2 same B without Dump Valves 2 GFBs Valve Time Sequence Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Air Chop Time B Solvent Chop Time 3rd Flush Chop Time gt Final Purge of these 3rd Flush Valve Dispense A A A Cad 5 Gun Flush Box Output 1 m 0 1 2 3 4 5 6 Color Purge Time 0 gt 1 First Purge Time 2 53 Notes Load tables from new recipe Purge from old recipe Fill from new recipe Fic 116 Color Change Chart 8 108 312779E Color Change ProMix 2KS Recipe Change Chart 9 A1 A2 same B without Dump Valves 1 GFB Valve Time Sequence Dump A Dump B Color Change Solvent Color Change A Catalyst Change B Air Chop Time Solvent Chop Time 3rd Flush Chop Time gt Final Purge one of these 3rd Flush Valve Dispense A A A Gun Flush Box Output 1 0 1 2 3 4 5 6 Color Purge Time 0 gt 1 Mixed Fill Time 5 56 Notes Load tables from new recipe Purge from old recipe Fill from new recipe Fic 117 Color
108. is driven High See Advanced Setup Screen 5 on page 41 for specifics on setting up these values Each of the specials can be monitored but can only be controlled through the times entered within the setup screens of the EasyKey or by managing the proper registers on the network The following ProMix 2KS inputs should never be on High at the same time e Start e Start e Color Change Start The Recipe Bits 0 6 are always on at the same time The only time these bits are recognized is when the Color Change Start input is High The Recipe Bits should be loaded and stay loaded for the current rec ipe Do not change the Recipe Bits until a color change is required again Inconsistent results are possible if this is not followed 312779E System Operation General Operating Cycle d Dose Valve B DVB opens and fluid flows into the integrator and is aligned proportionately with Sequential Dosing component A 1 The system enters and loads the desired color Flow Meter MB monitors the fluid volume dispensed and sends electrical pulses to the 2 The system enters Mix mode to begin operation ProMix 2KS controller 3 The ProMix 2KS controller sends signals to activate the solenoid valves The solenoid valves activate Dose Valves A and B Fluid flow begins when the Gun Trigger input is seen f When the target volume is dispensed Dose Valve B closes 5 The components are pre mixed in the in
109. ital Inputs page 52 54 Analog Inputs Flow Command This is the positive side of the O 10 Vdc signal See Common under Digital Inputs page 52 This input corresponds to the Flow Range setting in Advanced Setup Screen 5 page 41 For example if the setting is 0 300 cc min the 0 Vdc analog input is 0 cc min therefore the 10 Vdc analog input is 300 cc min Table 4 Sourcing Sinking Inputs and Outputs Do Alarm Output 7 7 312779E ProMix 2 5 Integration Specifics Automation Flow Charts Start Mix Mode Process See FIG 65 Table 5 and Table 6 Start Mix Mode Process Is Mix Ready bit 1 Must be Alarm Condi Set Mix bit 1 tion or Active Recipe 61 See Alarm Pro cessing on page 59 or Startup from Rec ipe 61 see NOTE Is Mix Active bit 2 1 NOTE At power up the system YES defaults to Recipe 61 which is not a valid recipe number Initiate a color change to Recipe 0 or a valid recipe number 1 60 ProMix 2KS in Mix Mode Complete Mix Active 1 while the ProMix 2KS is in Mix mode 65 Start Mix Mode Process Flow Chart 312779E 55 ProMix 2 5 Integration Specifics Mixing Mode Process See FIG 66 Table 5 and Table 6 Mixing Mode Process Mixing Mode is desired PLC is polling to ensure Mixing Mode is main tained Is Mix Active bit 2 1 Mixing Process active Check Alarm Condition is Alarm Go t
110. ith all systems Hazardous Area FLUID PANEL CONTROL BOX FLUID PANEL CONTROL 3 BOARD PWR RED OM BLACK I saw 4 1 r SHELD GRN PWR RED COM BLACK SIG WHITE SHIELD GRN L pwr rep PLAK SG WHT SHIELD GRN O Cn In HAZARDOUS AREA 3X CABLE eee 6 eem 1 5 METERS gt GROUND lt V P ANALOG OUT WHT TERMINAL E PRESS GRN i UNUSED EN 12 V RED 2 UNUSED CHASES BARE UNUSED VR VANS 4 UNUSED 5 UNUSED 6 UNUSED ILI LI 6 STD 3 100 OPTIONS GRD BLK 3 2 12VDC RED 5 SHIELD BARE 4 CAN H WHT 1 L BLU 50 STD 3 C 4 5 GRD 3 20 A RED CONTROL 5 44 SHIELD BARE 5 BOARD 4 emm 3 1 TH CAN L BL S MANIFOLD 6 C BLACK a e H RED DUMPB SII ed T a 2 L BLACC 1 LJ RED GFB 2 AE 6 BLACK 5 RD lt DUMPA se 4L NOT USED iM MANIFOLD 6 BLACK 4 men F 2 1L RD SZ ee 6 BLACK 5
111. k Reset Alarm Set Bit to 1 to Clear an Active Alarm momentary Digital inputs tied together on the I O board see FIG 64 T Digital inputs tied together on the EasyKey Display Board 1 3 4 5 7 Multiple connection points for convenience Qo 4 312779E ProMix 2KS Integration Specifics Table 8 Discrete Terminal Connections Terminal Terminal Location Details also see pages 60 and 61 Digital Outputs J4 Remote I O Board Digital Output Common Power 77 J 4 Remote I O Board Purge CC Active 1 Indicates Purge or Color Change is in progress 44 Remote Board Mix Active 1 Indicates Mix is in progress 44 Remote I O Board Mix Ready 1 Indicates No Alarms and OK to Mix 44 Remote Board CC Fill Active 1 Indicates the Fill Portion of a Color Change is in progress 94 Remote I O Board FCalActive 1 Indicates the Flow Control Calibrate rou tine is in progress J4 Remote Board Flow Rate 1 Indicates the Flow Rate Alarm Warning is active 1 2 3 4 5 7 8 94 Remote I O Board Digital Output Common Power J5 Remote Board Digital Output Common Power 45 Remote Board Special 4 1 Indicates the Special 4 Output is Digital Output Common Power 10 Pin Terminal Block General Alarm Output 1 Indicates the General Alarm Output is 10 Pin Terminal Block Digital Output Common Power 2 27 7 10 Pin Ter
112. l 1KS is also available as a selection For further information see ProControl 1KS operation manual 3A1080 Dump Valve A This field only appears if the system includes an optional dump valve A If dump valve A is included set to On Dump Valve B This field only appears if the catalyst change option is detected from the cc board meaning that dump valve B is present On is the only setting 3rd Flush Valve Off is default If optional 3rd flush valve is used set to On 312779E Setup Mode Configure Screen 4 SEC Dose Size Dose ime Alarm 31 Configure Screen 4 Configure Dose Size Select the total dose size cc from the pulldown menu 100 50 25 10 or select DD to turn on dynamic dosing See page 85 Example For a total dose size of 50 cc and a ratio of 4 0 1 the component A dose size is 40 cc and component B dose size is 10 cc NOTE Increase the dose size in applications with higher flow rates or wider ratios Decrease the dose size for a better mix under low flow conditions 33 Setup Mode DD Setup Mode See FIG 32 and Fic 33 Selecting DD makes the Dynamic Dosing Setup mode field appear Select On to enable DD setup mode or Off to disable See page 86 for further information Dose Dose Time Alarm EEN Configure 32 Configure Screen 4 dynamic dosing selected Dose Size 00 setup mode Dose lime Alarm Configure
113. larm is active for 2 minutes the system will automatically flush out the old material Flow Rate Monitor This field only appears if Flow Control is set to Off in Configure Screen 5 page 34 If set to On Recipe Setup Screen 6 on page 46 is added enabling setting of high and low flow limits If set to Off flow rate monitoring is disabled and Rec ipe Setup Screen 6 on page 46 will not appear Solvent Push Enable To enable the Solvent Push feature select Solvent or Valve available if 3rd Flush Valve in Configure Screen 3 page 33 is set to To disable the Solvent Push feature set to Off 312779E Setup Mode 37 Setup Mode Advanced Setup Screens NOTE See FIG 39 for a map of the Advanced Setup Screens Detailed screen descriptions follow Flow Control Override Manual Override Gun 1 Potlife Volume Advanced Setup screens 2 3 4 and 8 appear depending on selections made in Option First Purge Source Chop Type Final Purge Source Air Chop Time sec Solvent Chop Time sec Advanced Calibration First Purge Time Total Chop Time Final Purge Time Fill Time Advanced Calibration K Factar cc pulse A Meter 0 119 B Meter 0 119 solvent Meter 0 119 Advanced Calibration Flow Rate Range Tolerance Alarm Time Advanced Calibration OFC Calibrate OFC Cal Active Flow Input 2 9 Volts Input L1Salvent Push O Recipe O Recipe O
114. lint free cloth A communication cable or connector failed Replace cable 2 POTLIFE ALARM The potlife time has been exceeded for the mixed mate rial Press the Alarm Reset key to stop the audible alarm Purge the system with solvent fresh mixed mate NOTICE rial or a new color To prevent mixed material from curing in the equip ment do not shut off power Follow one of the solu tions at right e Solvent Purge See Purging Mixed Material on page 95 The system purges until the preset purge time is complete New Mixed Material Purge Go to Mix mode and spray the required volume to restart the timer Color Change Perform a color change see page 102 116 312779E Alarm Troubleshooting Table 17 Alarm Troubleshooting E 3 RATIO HIGH ALARM Sequential Dosing System The mix ratio is higher than the set tolerance on the previous dose cycle Dynamic Dosing System The mix ratio is higher than the set tolerance for an A to B component volume comparison There is too little restriction in the system Check that the system is fully loaded with material Check that the supply pump s cycle rate is set prop erly Check that the spray tip nozzle is properly sized for the flow and application and that it is not worn Check that the fluid regulator is set properly If the alarm occurs during start up after purging the flow Restrict gun needle travel to slow down the initial fluid rate was pro
115. lves low pressure G3000HR A and 1 8 in Coriolis B 1 8 in Coriolis A and B Intrinsically Safe IS System Install per IS Control Drawing No 289833 EasyKey Interface IS Associated Apparatus for use in non hazardous location with IS Connection to Smart Fluid Plate IS Apparatus for use in Class Division 1 Group D T3 Hazardous Locations Read Instruction Manual Warning Substitution of components may impair intrinsic safety PART NO SERIES APPROVED Intrinsically safe 20 C to 50 SERIAL D WPR bw GRACO INC Box 1441 PSI 3 7 Minneapolis MN GRACO 55440 U S A FiG 1 Identification Label Wall Mount Fluid Station Systems 0 No Valves single catalyst 1 Two Valves low pressure 2 Four Valves low pressure Label Location on EasyKey T112418a Configured Part Number 312779E Hazardous Location Approval System Configuration and Part Numbers Models using G3000 G3000HR or intrinsically safe Coriolis meter for both and B meters are approved for installation in a Hazardous Location Class Div Group D or Zone Group Maximum Working Pressure Maximum working pressure rating is dependent on the fluid component options selected The pressure rating is based on the rating of the lowest rated fluid component Refer to the component pressure ratings below Example Model AD110Y has a maximum working pressure of 190 psi 1 31 MPa
116. m output i e general alarm see if Mix Active is still High and if SO start a timer A typical example would be to ensure all parts are sprayed within a specific flow rate range A maximum predetermined time would be set to allow a Low or High flow condition to exist continuously e Shutdown or go to Standby after the flow rate alarm time expires Job Complete Input Every time a momentary Job Complete input is seen by the ProMix 2KS a job log will be recorded logging the A and B meter volumes cc with a time and date stamp The volumes will then be reset to 0 Volume totals accumulated since the last reset NOTE A Color Change accomplishes the same Job Complete Reset functions The Complete input is commonly used to record material usage for a specific set of parts These volumes are sprayed material vol umes 82 For Applications with Dump Valves for quick purges color changes at or near the gun ProMix 2KS has four specials that can each be turned off and on twice throughout a color change sequence See Advanced Setup Screen 8 on page 42 or Recipe Setup Screen 7 on page 46 For example a dump valve at a gun on a robot could be opened at the appropriate times to facilitate fast color changes Another output could be used to automatically drive an air operated fluid regulator High during the Purge or Color Change process NOTE With integrated Flow Control the flow control regulator automatically
117. minal Block Potlife Alarm 1 Indicates the Potlife Alarm Output is on 10 Pin Terminal Block Flow Rate Analog In 0 10 0 10VDC input for Flow Setpoint relative to VDC flow range set in 2KS Flow Range Screen 10 Pin Terminal Block Flow Rate Common to Pin 9 Common side of Flow Setpoint from Terminal 9 6 Pin Terminal Block RS485 Integration A 6 Pin Terminal Block RS485 Integration B 6 Pin Terminal Block RS485 Integration Shield Ground 1 2 4 5 6 7 10 Communication to External PLC Controller 6 Pin Terminal Block RS485 Network A 6 Pin Terminal Block RS485 Network B 6 Pin Terminal Block RS485 Network Shield Ground Digital outputs tied together the I O board see FIG 64 Digital outputs tied together on the EasyKey Display Board 1 2 3 4 5 Communication to Multiple EasyKeys only Multiple connection points for convenience 312779E 65 ProMix 2KS Integration Specifics Table 9 ProMix 2KS Recipe Bits Number Recipe Bits 543 1 2 1 1 1 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 0 1 0 1 0 1 1 1 0 1 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 1 1 Number 10 11 12 13 14 15 16 17 18 19
118. mul tiple times to ensure it is thoroughly clean e Always clean the fluid inlet strainers after flushing e Check with your material manufacturer for chemical compatibility Most materials use ISO on the A side but some use ISO on the B side 11 Glossary of Terms Glossary of Terms Air Chop the process of mixing air and solvent together during the flush cycle to help clean the lines and reduce solvent usage Air Chop Time duration of each activation of the air purge valve during a chop sequence User settable from 0 0 99 9 seconds Analog relating to or being a device in which data are represented by continuously variable measurable physical quantities such as length width voltage or pressure Chop Time refers to the total length of the chop sequence during a purge User settable from 0 999 sec onds Closed Loop Flow Control refers to the process when the flow rate is adjusted automatically to maintain a constant flow Color Catalyst Dump refers to the time required to flush the lines from the color or catalyst change module to the mix manifold during a color or catalyst change Color Catalyst Fill refers to the time required to fill the lines from the color or catalyst change module to the mix manifold Coriolis Meter a non intrusive flow meter often used in low flow applications or with light viscosity shear sensi tive or acid catalyzed materials This meter uses vibra tion to meas
119. munication between the Color Change Module and the Fluid Station is interrupted tor must make at least 5 complete turns to ensure a good connection If the power LED still does not light the cable or board is bad e Check the color change board DIP switch settings See the Installation manual e Check the fluid plate board DIP switch setting An incorrect setting will not cause E 12 alarms but a correct setting will help prevent E 12 caused by elec trical noise See the Installation manual e Check EasyKey software version displayed at power up for all versions and when the lock key is pressed for version 2 02 000 and above If older than 1 06 002 upgrade Be sure to save settings through BWI or AWI before upgrading as they will be erased e The sticker on the color change board shows the software part number and version for example 151270 1 01 If the version is older than 1 01 replace the board ifall software versions and DIP switch settings are correct and you still have E 12 alarms then the sys tem has a bad connection bad cable or bad circuit board Use a multimeter on the CAN connectors to test whether there is a good connection between systems If there is you have a bad circuit board If there is not you have a bad connector connection or cable Communication between the Color Change Module and Verify condition of fuse and replace if necessary See the Fluid Station is interrupted The fluid cont
120. nal Purge Source Air Chop Time sec Solvent Chop Time Recipe Recipe Color Catalyst Purge 5 First Purge Time Total Chop Time Final Purge Time Calibration Recipe Minimum Flush Volume Exiting Fill Source Exiting Fill Time sec Calibration Recipe special Fic 49 Recipe Screens 312779E Recipe Ratio Ratio Tolerance Color Valve Catalyst Valve Calibration Recipe Minimum Flush Volume Potlfe Time minutes Coler Catalust Purge 5 sec Coler Catalust Fill 5 sec Calibration Recipe First Purge Source Chop Tupe Final Purge Source Air Chop Time sec Solvent Chop Time Recipe Recipe First Purge Time sec Total Chop Time sec Final Purge Time sec Fil Time sec Calibration Recipe K Factar cc pulse Meter 0 119 B Meter 0 119 Solvent Meter 0 119 Calibration Set Up Home ProMis 265 Recipe amp Advanced Setup System Configuration EK 2 04 0093 1 1 La FP 2 04 009 AK zK Manual C2 Vb S 0 1042 0198 IP 192 166 176 1 00204AA3604F Meter A Meter Calibration Measured Actual Volume Volume Occ ec K Factar 0 119 cc pulse Calration Recipe Flow Rate Monitor Low Flow Limit cemin High Flow Limit cc min Recipe special n Purge Lenath On Fill Recipe screens 3 4 5 6 and 7 appear depending on selections
121. nd increase as necessary to reach the desired flow rate Flow Control Calibration This field allows you to calibrate flow control for each recipe The system must be in Mix mode and receiving a Gun Trigger signal Press the Enter key to view the menu then select Start or Abort See FIG 15 The flow rate will drop to 0 then incrementally increase until it reaches the maximum flow rate To view the progress go to the Status Screen page 24 The sys tem will populate the data for the current recipe To copy this data to all recipes see Global Flow Control Data Copy page 26 Manual Override Active Recipe Recipe Manual Override Standby 2 Flow Rate Range Set Point Flow Ctrl Calibration LEE ED Global FC Data 15 Flow Control Calibration 25 Run Mode Screens Global Flow Control Data Copy This field allows you to copy flow control data from the active recipe to all recipes Press the Enter i key to view the menu then select Start or Abort See FIG 16 Manual Lverride Active Recipe Recipe Manual Override Flow Rate Range Flow Set Paint SASL ec min Flow Ctrl Calibration Em nn Global FC Data Copy EE Bm Fic 16 Global FC Data Copy t 2 cc min 4 i uo Totals Screen Job Total 0 cc cc 0 cc 0 cc brang Total Liters Liters Liters Liters Usaqe H B olve
122. nform Verify that the recipe specifications and the hardware conform Verify that the Autokey is set properly Set level control data correctly MB Overflow Modbus Overflow Occurs if the Mod Verify the Modbus protocol to the EasyKey bus connection to a PLC experiences data overflow 124 312779E Alarm Troubleshooting Table 17 Alarm Troubleshooting E 20 PURGE INITIATE ALARM Cause System detects atomizing air to the gun when purge Shut off gun air selected For systems with gun flush box gun is the box Place in gun flush box Verify that gun flush box is when purge is selected operating properly For systems with auto dump on gun is not in the box Place gun in gun flush box Verify that gun flush box is when auto dump is initiated operating properly For systems with a gun flush box Fuse F2 is blown Verify condition of fuse and replace if necessary See Repair Parts manual E 21 MATERIAL FILL ALARM For systems with minimum mixed material fill volume Check for restrictions or leaks in the fluid supply system entered the system detects that fill volume is not achieved during mixed material fill time Check if the fill volume is properly configured e Adjust fill volume e Adjust fill time For systems without color change and with minimum Verify condition of fuse and replace if necessary See mixed material fill volume entered Fuse F1 is blown Repair Part
123. nt Job 0 eRe 1 Solvent Level Control 17 Totals Screen This screen shows the job totals grand totals and job number Use the tabs to reset job totals Job Complete reset solvent totals Rst Solvent or go to Level Control Screen page 27 Solvent Totals and the Rst Solvent tab only appear if Meter is selected under Solvent Monitor in Configure Screen 5 on page 34 NOTE Grand totals are not resettable 26 Reset Total Screen Job Lomplete Are uou sure want to reset job totals Enter job number or press enter to accept default FiG 18 Reset Total Screen If job is reset job number will increment by one for default Reset Solvent Screen Reset Solvent Are uou sure want to reset solvent total Fic 19 Reset Solvent Total Screen The screen will ask if you want to reset solvent total Select Yes or No 312779E Alarms Screen ime Alarm Fic 20 Alarms Screen Two screens show the last 10 alarms Use the Up or Down 7 keys to scroll between the two screens See Table 16 on page 115 for a list of alarm codes Level Control Screen Level Lontral Liters Alarm Level Current Volume Color 1 10 Color 2 10 Latalust 1 10 Salvent Level Control Fic 21 Level Control Screen This screen shows the current volume for each fluid Adjust the current volumes on this screen or use the tab to go to Usage Totals Screen page 26
124. nty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FI
125. nutes the color change operation aborts The system enters Standby mode remove Mix input at the ous color 6 When you are ready to spray remove the gun from the gun flush box if used and close its door manual and semi automatic systems only NOTE The gun flush box door must be closed for the atomizing air valve to open 7 Enter Mix gt gt mode to start spraying Single Color Systems 1 Follow procedure for Purging Fluid Supply Sys tem page 96 2 Load the new color See Start Up page 89 3 Enter Mix mode to start spraying 102 Color Change Sequences FiG 109 through 126 illustrate various color change sequences See Table 15 to determine which figure to reference based on the recipe change and system con figuration The time sequences are detailed in the fol lowing paragraphs NOTE For software version 2 04 xxx and older the sys tem uses the color catalyst purge and fill times from the new recipe NOTE See Setup Mode on page 28 to select purge sources and set desired purge chop and fill times NOTES e The system uses old recipe data for the purge cycle However it opens the new color catalyst valve based on the new recipe data e The system uses the new recipe data for the fill cycle e For the one gun flush box option the spray gun must be inserted in the GFB during the entire color change cycle purge and fill The GFB trigger output
126. o Start Mix Mode General bit 1 Process page 55 Go to Alarm Process ing page 59 Fic 66 Mixing Mode Process Flow Chart 56 312779E ProMix 2KS Integration Specifics Purge Mode Process See FIG 67 Table 5 and Table 6 NO YES Is Mix Ready bit 1 Must be Alarm Condition or Active Recipe 61 See Alarm Processing Set Purge bit 1 on page 59 or Startup from Recipe 61 see NOTE below NO YES Is Purge CC Active bit 1 Wait for Mix Ready ProMix 2 5 Purge CC Mode Is Mix Ready Process Started bit 1 NOTE At power up the system defaults to Recipe 61 which is not a valid recipe number Initiate a color change to Recipe 0 or a YES ProMix 2KS Purge valid recipe number 1 60 Process Complete Fic 67 Purge Mode Process Flow Chart 312779E 57 ProMix 2 5 Integration Specifics Color Change Mode Process See FIG 68 Table 5 and Table 6 Color Change Process basic Do nothing YES Spraying at Is Active Recipe NO to desired recipe Register 40005 desired recipe Load ccNewRecipe Register 40046 with recipe number to Color Change to 0 through 60 is valid Is Purge CC Active bit 1 Ensure Color NO Change bit is seen Set ColorChange CC bit 1 by ProMix 2KS MS Clear ColorChange CC bit momentary input CC process started Wait for Mix Ready Is Mix R
127. o or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com For patent information see www graco com patents TO PLACE AN ORDER contact your Graco distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Original instructions This manual contains English MM 312779 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2009 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Revision E February 2014
128. on EK EasyKey 2 00 012 EasyKey software version FP Fluid Plate 2 00 012 Fluid Plate software version BC Booth Control Booth Control not installed not detected or not oper ational Booth Control software version 1 00 or 1 01 Booth Control software version 2 XX 1 XX Color Change Module software version 1 00 or 1 01 2 XX Color Change Module software version 2 XX C1 C2 Color Change Color Change Module 1 2 not installed not detected Modules 1 and 2 or not operational AK Autokey 2K Manual No AutoKey installed or detected System operates in 2K Manual Mode only 2K Auto 2K AutoKey detected System can operate in 2K Man ual Semi automatic or Automatic Mode 3K Auto 3K AutoKey detected System can operate in 3K Man ual Semi automatic or Automatic Mode XP XPORT V6 6 0 2 Example of XPORT network module software version Other versions are acceptable MC Micro Controller 1042 0198 Example of fluid plate micro controller version Other versions are acceptable IP Internet Address 192 168 178 5 Example of the address EasyKey is set to for basic and advanced web interface reporting MAC address 00204AAD1810 Example of internet MAC address Each EasyKey will have a different value in this format 30 312779E System Configuration Screens NOTE See FiG 27 for a map of the System Configura tion Screens Detailed screen descriptions follow Enter Password Display Units Buzzer All Alarms
129. ot be on at the same time Once the Mix Ready output goes High with no alarms then the PLC has assurance that the requested color change has taken place with the requested recipe being the current active recipe If any error occurs during the process the requested recipe will not be loaded and the old recipe will remain active NOTE It is not possible to read the active recipe through Discrete alone Only by monitoring net worked registers through the Gateway is it possible to view the active recipe Proper management of the alarm status outputs during the color change process will ensure the active recipe is what is expected Purge To start a Purge no color change drive the Purge Start input High maintained while ensuring Mix Ready output is High ensuring no active alarms An exception is Potlife alarm see Color Change above if alarms are present The Purge CC Active output is High for the entire Purge process Ensure there are no alarms during this process Fill Active is High when Mix is on When complete Mix Ready output will be High indicating a completed purge NOTE No change is made to the active recipe Gun Trigger Input This input is sent and expected every time the gun is actually triggered and this input is turned off when the gun is not triggered Never tie this input with any other signal Without this input some critical mixing alarms are eliminated IMPORTANT This input must be provided
130. pened to a desired percentage Pressure Flow control regulator is opened to a calibrated pressure NOTE Set the Flow Control Override to Pressure to use the Pressure Flow Control Mode see page 77 Manual Uverride Active Recipe 51 New Recipe Stand Manual Override Flow Rate Range Flow set Point Global FC Data Copy Fic 80 Flow Set Point as a Percentage 312779E Integrated Flow Control 4 Onthe Manual Override Screen drive the regula tor to a percentage open that starts fluid flow Fluid pressure should be above 12 psi 08 MPa 0 84 bar see the Status Screen Observe the fluid flow rate at this pressure This is the achievable low end flow rate for the system s given restriction If a lower flow rate is required increase the restriction between the flow control regulator and the spray gun NOTE If the lowest flow rate achieved is well below 12 psi 08 MPa 0 84 bar add restriction to achieve fluid pressure closer to 12 psi Pressures below 12 psi can be inconsistent 5 Drive the regulator to 100 open This is the maxi mum achievable flow rate based on the low flow requirement and the flow control module s functional range 6 When an acceptable operating range is achieved turn Flow Control Override Off n 359 lt Flow Control Override Manual Override Lun 1 Potlite Volume Color Catalyst Purge SEC Color Catalyst Fill Advanced Calibration
131. puts without any input from an outside control Minimum Material Fill Volume system monitors material fill volume E 21 Alarm occurs if minimum vol ume is not achieved Minimum material fill volume is user settable 0 9999 Mix when cross linking of the resin A and catalyst B Occurs Mix Input Signal refers to system mode status where system begins a dose sequence each time the mix sig nal is made High Mixed Material Fill Time the amount of time that is required to load mixed material from the dose valves to the applicator gun Modbus TCP a type of communication protocol used to communicate Digital I O signals over an ethernet Network Station a means to identify a particular indi vidual proportioning or flow control system Overdose Alarm when either the resin A or catalyst component dispenses too much material and the system cannot compensate for the additional material Potlife Time the amount of time before a material becomes unsprayable Potlife Volume the amount of material that is required to move through the mix manifold hose and applicator before the potlife timer is reset 312779E Glossary of Terms Purge when all mixed material is flushed from the sys tem Purge Time the amount of time required to flush all mixed material from the system Purge Volume Alarm E 11 Alarm occurs if minimum flush volume is not achieved Ratio Tolerance the settable perc
132. r 87 System Operation Table 12 Dynamic Dosing Troubleshooting Guide for complete system troubleshooting see Table 17 beginning on page 116 Warning Alarm Message Solution B Pressure Too Low see FIG 96 Increase B pressure Clean restrictor or use a larger size Verify B valve is opening properly B Pressure Too High e Increase A pressure or decrease B pressure e Use a smaller restrictor Off Ratio Low e Increase A pressure or decrease B pressure e Use a smaller restrictor Off Ratio High Increase B pressure Clean restrictor or use a larger size Verify B valve is opening properly Mix Manifold Valve Settings To open dose or purge valves turn hex nut E counter clockwise To close turn clockwise See Table 13 and FIG 99 11581 Fic 99 Valve Adjustment Table 13 Mix Manifold Valve Settings Seting uncon Dose see Hex nut E 1 1 4 turns out Limits maximum fluid flow rate into integrator FIG 99 from fully closed and minimizes valve response time Purge see Hex nut E 1 1 4 turns out Limits maximum fluid flow rate into integrator FIG 99 from fully closed and minimizes valve response time Shutoff SVA Fully open during Run Mix Closes component A and B ports to integrator and SVB operation during ratio check or meter calibration Open see FIG 91 ports during Run Mix operation Sampling Fully closed during Run Mix Open to dispense component A and B while RVA and operation calibr
133. r shows remaining potlife time in min utes Two times are shown if there are two guns manual or semi automatic mode only 5 Status Bar shows current alarm or operation mode standby mix purge recipe change or the current alarm NOTE If the auto key board is removed from the EasyKey display board the Status Bar will read Auto key not found This indicates that the auto matic mode is not operable 24 6 Target Flow Rate and Current Flow Rate in cc min 7 Animation when the gun is triggered the gun appears to spray and the component A or B hose lights up showing which component dose valve is open Current Date and Time 9 Screen Number and Scroll Arrows displays the current screen number and the total number of screens in a group The Up and Down arrows on the right edge of the screen indicate the scroll feature The total number of screens in some groups may vary depending on system configuration selections 40 Current Flow Control Data fluid output pressure and voltage of analog signal used for driving the fluid regulator V P 41 Lock Symbol indicates that Setup screens password protected See page 29 312779E Manual Override Screen Manual Override Active Recipe 3 t New Recipe Manual Override 7 Flow Rate Range T min Set Point 3 cemin Flaw Ctrl Calibration Start Global FC Data Copy Fic 13 Manual Override Screen This screen will
134. r Graco Part No 280555 53000 Solvent Meter Kit See manual 308778 1 See 108 Install the solvent meter MS on the side of the fluid station as explained in the ProMix 2KS Installation Manual 2 Toenable Solvent Push select Solvent or 3rd Valve as desired See Option Screen 2 page 37 NOTE If you are using a 3rd purge valve instead of the solvent purge valve to run the Solvent Push feature connect the solvent supply line from the solvent meter to the inlet of the 3rd purge valve 3 Press and hold the Mix gt for 5 seconds to turn on Solvent Push The green Mix LED will light and the Recipe LED will blink The system will close the Dose Valves DVA DVB and open the Solvent Purge Valve SPV Key DVA is closed DVA Component A Dose Valve DVB Component B Dose Valve MS Solvent Meter required SPV Solvent Purge Valve APV Air Purge Valve SMC Solvent Meter Cable SS Solvent Supply Line FiG 108 Solvent Push Setup 312779E N Al NA E System Operation 4 The system will dispense solvent to push the mixed material out to the gun The Booth Control display alternately shows dashes and the percent remaining 0 99 of the 50 of the potlife volume NOTE To manually interrupt Solvent Push press the Standby key Solvent Purge Valve SPV or 3rd purge valve will close To re enter Solvent Push press the Mix gt 5 When the total solvent dispensed excee
135. r2 0 1 or2 0 1 or2 0 1 or2 0 1 or2 0 1 or2 0 1 or2 0 1 or2 0 1 or2 0 1 or2 0 1 or2 0 1 or2 0 1 or2 0 1 or2 0 1 or2 o lt D 42 Yes Z Y Yes or 61 0 or 61 0 or 61 0 or 61 0 or 61 D o lt D 42 Yes Z5 OJO Yes Yes O EET Yes or No lt D 42 Yes lt D 42 Na Na Na Yes Yes Yes Yes Yes OJO O o NOTES Fig 118 and FIG 119 show both color and catalyst change If the color or catalyst is not changing disregard that portion of the chart Fia 120 and FIG 121 show color change If the color is not changing disregard that portion of the chart 122 page 111 shows a recipe change with Special Outputs FiG 124 page 112 shows an External Color Change 04 312779 Color Change ProMix 2KS Recipe Change Chart 1 A1 to A2 B1 to B2 with Dump Valves Valve Time Sequence aS Dump 5 Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Color Color Fill Time 1 gt 2 Catalyst Purge Time P2 gt P3 Catalyst Fill Time P3 gt P4 lt lt Purge Fill Timers independent of Mixed Material Purge Timers This line defines when the Mixed Fill Time Air Chop Time begins The longer of the two timers Solvent Chop Time defines when the Mixed Fill Time First Purge one of these 3rd Flush Chop Time begins
136. ray at the same time Kp refers to the speed at which fluid flow reaches its set point Kp D L Target Flow Rate Ki Ki refers to the degree fluid flow over shoots its set point 117119 NOTE Ki and dependent on each other If one changes the other must change Fic 89 Kp Ki Graph 312779 77 Integrated Flow Control Flow Control Troubleshooting Problem Flow Command does not produce fluid output Test the system as follows to determine if the problem is mechanical or electrical 1 Install a 0 100 psi 0 0 7 MPa 0 7 0 bar 1 8 npt m air pressure gauge not supplied as follows a For module 249849 Remove the plug from the 1 8 npt f air gauge port and install the gauge oee FiG 71 on page 67 b Formodule 24H989 Install a 1 8 npt m x 1 8 npt fbe tee in the air outlet port Install the gauge in one branch of the tee and the air outlet fitting in the other See FIG 72 on page 67 2 Setthe system to Manual Override Open mode see steps 2 5 under Flow Control Startup on pages 72 73 Set the Open value to 50 See FIG 90 Manual Uyverride Set Open Active Recipe B1 value to 50 4 Recipe Manual Override Flow Rate Range Flow Set Point Global FC Data Copy Fic 90 Set Open to 50 Percent 4 Ensure that the gun is triggered Increase the Open value on the EasyKey then decrease The gauge reading should also increase then dec
137. re Screen 6 on page 35 e Flow Control e e Gun 1 Trigger NOTE In Semi automatic mode only the Proportioning field is available NOTE The Manual Override function enables you to operate the system before the automation PLC is available Manual Override still requires some communi cation through Discrete or Network Communica tions Although Manual Override is not intended to be the main mode of control it can be used if proper Gun Trigger Input is provided Display Board O e Fic 62 EasyKey Control Boards 312779E c Discrete I O Discrete I O requires 24 Vdc power supply which must be supplied on site The ProMix 2KS does not supply power for Discrete I O See Table 4 on page 54 70 page 63 and Table 8 on page 64 for inputs and outputs Understanding these inputs and outputs is necessary to properly inte grate the ProMix 2KS to the automation Input and output connections are made at the Discrete terminal strips FIG 63 and the discrete I O board FiG 64 inside the EasyKey Also see the System Electrical Schematic on page 128 Review the Color Change Charts FIG 109 FiG 126 A full understanding of the color change sequenc
138. rease 78 312779E Integrated Flow Control Gauge reading increases and The problem is mechanical Clear any clogs decreases as 96 Open value is changed and fluid flow does not e restriction plugged hose restrictions change or is not present e plugged gun tip Clean and or repair fluid regula tor e fluid regulator failure Gauge reading does not increase The problem is electrical Measure the voltage to the regu and decrease as Open value is lator at one of two places changed Fuse F2 is blown e At J5on the fluid control disconnected wires or cables board measure across the white pin 1 and black pin 6 pressure control failure wire connections The volt age should be in the range of V P valve failure 0 3 3 for 096 10096 Open command approximately flow control board failure 1 65 Vdc for 5096 Open At J2 on the flow control board of the module mea sure across the red pin 1 and black pin 2 wire con nections The voltage should be in the range of 0 21 Vdc for 0 100 Open com mand approximately 12 Vdc for 5096 Open If voltage is not present check if fuse F2 on the fluid control board is blown If voltage is present ensure the cable is properly connected to the module circuit board If cable is properly connected replace pressure control VP valve and flow control board sequentially to isolate failure See manual 3A2097 312779E 79 System
139. reen see FIG 85 The sta 8 When calibration is complete the Status Screen tus bar at the bottom of the screen will indicate that will change from Mix Calibration to Mix The unit Mix Calibration is in progress should have built a complete table for the flow rate range selected in step 2 NOTE If the voltage reached 3 3 V flow control wide 10 20 2010 open but the unit did not reach the top of the selected hol flow rate range the delivery system is not providing enough volume Do one of the following e the volume is acceptable change the flow rate range accordingly e fthe volume is not acceptable increase the deliv 43Ucc min 4 ery pressure Increasing the pressure may affect Mix Calibration your low flow rate setting Fic 85 Status Screen 9 De trigger the gun 10 Set Manual Override to Standby 6 Trigger the gun and make sure the gun trigger input is high 11 To copy the data table to all recipes see Global FC Data Copy page 76 This loads a starting point for 7 Onthe Status Screen see 85 the voltage will each recipe and continuous learning will create a start at 0 and increase incrementally to 3 3 V The unique data table when the recipe is run flow rate will also begin to increase during calibra tion but this may not show for the first few voltage NOTE If you want to do a flow calibration for each rec increases ipe do not do a Global FC Data
140. reen 1 Configure Language Defines the language of the screen text Select English default Spanish French German Italian Dutch Jap anese Kanji Korean and Chinese Simplified Password The password is only used to enter Setup mode The default is 0 which means no password is required to enter Setup If a password is desired enter a number from 1 to 9999 NOTE Be sure to write down the password and keep it in a secure location Display Units Select the desired display units cc liter default e cc gallon Buzzer All Alarms As shipped the alarm buzzer will sound only for the Pot life Alarm E 2 Off is default Set to On to have the buzzer sound for all alarms Screen Timeout Select the desired screen timeout in minutes 0 99 5 is the default 32 Configure Screen 2 Month Tear Time Date Format 29 Configure Screen 2 Configure Month Enter current month Day Enter current day Year Enter current year four digits Time Enter current time in hours 24 hour clock and minutes Seconds are not adjustable Date Format Select mm dd yy or dd mm yy 312779E Configure Screen 3 ProaMiks Automatic Un 3rd Flush Valve Fic 30 Configure Screen 3 Configure Run Mode Select the Run mode application from the pulldown menu Automatic default Semi Automatic uses a manual spray gun or Manual NOTE ProContro
141. rol board Repair Parts manual fuse is blown E 13 HIGH FLOW ALARM or 14 LOW FLOW ALARM may also be set as Warnings Fluid system is producing too much or too little flow Troubleshoot fluid system for restrictions leaks exhausted fluid supply incorrect settings etc Increase or decrease flow rate as required 122 312779E Alarm Troubleshooting Table 17 Alarm Troubleshooting E 15 SYSTEM IDLE WARNING Cause Mix input is high but the gun has not been triggered for 2 If not painting clear alarm and resume operation minutes If painting shut down and inspect fluid meter E 16 SETUP CHANGE WARNING Cause The system setup parameters have been changed No action required See Event Log available through advanced web interface 17 POWER WARNING Cause The power to the system has been cycled No action required See Event Log available through advanced web interface Voltage becoming too low due to weak power supply Replace power supply See Repair Parts manual Power wires are disconnected or making intermittent Check that all wires are securely connected Ensure that contact wires are not stretched too tightly Reset button has been pushed 51 on EasyKey display No action required See Event Log available through board S3 on Autokey advanced web interface Software update is initiated on EasyKey No action required See Event Log available through advanced web interface E 18 DEFAULTS LOA
142. s manual E 22 TANK A LOW ALARM E 23 TANK B LOW ALARM or E 24 TANK S LOW ALARM The tank volume reaches the low level threshold The EasyKey screen will display the alarm and prompt the user to do one of the following e Hefill tank volume to clear the alarm e Resume mixing by selecting Spray 25 of remain ing volume If this selection is chosen a second alarm will occur after 25 of the remaining volume is mixed Refill tank volume to clear the alarm 312779E 125 Alarm Troubleshooting Table 17 Alarm Troubleshooting E 25 AUTO DUMP COMPLETE ALARM Cause A potlife alarm is active for more than 2 minutes the gun Be sure to spray all mixed material before potlife expires flush box is enabled and gun is in the gun flush box and an auto dump flush sequence is complete E 26 COLOR CATALYST PURGE ALARM System detects no meter pulses or a disruption in meter Check that meter cable is connected pulses lasting longer than 1 second throughout the Color Catalyst purge time duration Clean or repair meter E 27 COLOR CATALYST FILL ALARM System detects no meter pulses or system must detect Check that meter cable is connected at least 10cc of material from each side throughout the Color Catalyst fill time duration Clean or repair meter Gun dump valve or correct color catalyst valve not Open the valve open Exhausted fluid supply Check fluid level and refill if necessary Switch settings 53 56
143. t the Calibra tion screen Press the Down Arrow 7 select Purge from the menu Press the Enter di key Dose A solvent purge valve B side and color change solvent valves if used will open Meter Actual Volume k F actor 0 119 cc pulse Recipe 107 Calibration Screen Meter Calibration Measured volume 0 98 7 To avoid splashing slowly open the sampling valves and dispense solvent until the valves and tubes are clean NOTE When performing a calibration purge the solvent valve s close automatically after 2 minutes or when Abort is selected on the screen 8 Close sampling valves NOTE Select Abort on Calibration screen to cancel current calibration and close dose or purge valves 9 Fully open both fluid shutoff valves 10 a single color system reconnect component fluid supply line to flow meter A NOTE After calibration it is necessary to clean out con taminated mix material Do a manual purge and resume the recipe just tested or do Recipe 0 then go on to the next recipe 312779E Solvent Push Feature The Solvent Push feature enables the user to save some mixed material by pushing it out to the gun with solvent The quantity saved is 50 of the potlife volume entered in Advanced Setup Screen 1 on page 39 If there are 2 guns the smaller potlife volume is used Solvent Push requires an accessory solvent meter MS Orde
144. tegrator 4 Components A and B are introduced into the fluid then uniformly blended in the static mixer SM integrator Fl one at a time as follows mE NOTE To control output from the static mixer to the a Dose Valve A DVA opens and fluid flows into gun install an optional fluid pressure regulator the integrator 6 Components A and B are alternately fed into the b Flow Meter A MA monitors the fluid volume integrator as long as the Gun Trigger input is seen dispensed and sends electrical pulses to the ProMix 2KS controller The controller monitors these pulses and signals 7 Ifthe Gun Trigger input is not seen for two minutes the system switches to Idle mode which closes the mix manifold dose valves c When the target volume dispenses Dose Valve A closes 8 When the Gun Trigger input is seen again the Pro Mix 2KS continues the process where it left off NOTE The dispense volume of component A and B is based on the mix ratio and dose size set by the user and calculated by the ProMix 2KS controller NOTE Operation can be stopped at any time by going to Standby mode remove Mix input Table 11 Sequential Dosing Operation _ mE NN RN 312779E 83 System Operation DVA Fl DVB MB MA AT APV TI12556b RVA SVA SM SVB SPV Key MA Component A Meter SVB Component B Shutoff Valve DVA Component A Dose Valve MS Solvent Meter accessory RVA Component A Sampling Valve SP
145. the flow loop The flow meters verify that the target flow rate is achieved and feeds this information back to the ProMix 2KS The ProMix 2KS adjusts the voltage to the V P to maintain the actual flow Step 2 and Step 3 repeat continuously to maintain pres sure and flow 312779E Integrated Flow Control Step 3 Flow Input 4 4 Fluid Pressure Sensor Step 1 ProMix 2KS receives flow rate setpoint EE eee from PLC robot dl E zi 1 Analog Signal to V P A Air Line V P Voltage Air A Pressure Valve 4 4 lt 4 lt 4 lt Step 2 Pressure Input 17118 Fic 75 2KS Flow Control Pressure Loop and Flow Loop 249849 Module Step 3 Flow Input Step 1 E us l setpoint from Jr Nip inet PLC robot Remote Wi MT C HH Air Line V P Voltage Air Pressure Valve 118958 Fic 76 2KS Flow Control Pressure Loop and Flow Loop 24H989 Module 312779 71 Integrated Flow Control Flow Control Setup 1 Install the intrinsically safe flow regulator FC as explained in the ProMix 2KS Installation Manual Ensure that the analog signal is 0 10 or is properly provided through network communication Calibrate the system s flow meters see page 100 This ensures that the K factors are tuned to the range of mater
146. this function Potlife Time Enter the potlife time 0 to 999 minutes Entering 0 dis ables this function Color Catalyst Purge This field only appears if the system includes a color change module and Flush and Fill Input is set to Rec ipe in Option Screen 1 page 36 Enter the purge time to 99 seconds It refers to the amount of time required to flush the lines from the color or catalyst mod ule to the dose valve or dump valve Color Catalyst Fill This field only appears if the system includes a color change module and Flush and Fill Input is set to Rec ipe in Option Screen 1 page 36 Enter the fill time 0 to 99 seconds It refers to the time required to fill the lines from the color or catalyst module to the dose valve or dump valve 312779E Recipe Setup Screen 3 Recipe First Purge Source Chop Type Final Purge Source Air Chop Tine 2 0 sec Solvent Chop Time 2 0 sec MESE Calibration 52 Recipe Setup Screen 3 This screen appears only if Flush and Fill Input is set to Recipe in Option Screen 1 page 36 First Purge Source Select Air Solvent or 3rd Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 33 Chop Type Select Air Solvent or Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 33 This refers to the process of mix ing air and solvent or air an
147. 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 2 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 in your system installation man ual Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding setup or usage of the system can cause electric shock Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment Connect only to ground
148. twork ID Configure Fic 35 Configure Screen 6 Automatic mode shown Flow Control This field only appears if Run Mode is set to Automatic in Configure Screen 3 page 33 and Flow Control is set to On in Configure Screen 5 page 34 Select Dis crete or Network Proportioning Select Discrete or Network Gun 1 Trigger Select Discrete or Network if Run Mode is set to Automatic in Configure Screen 3 page 33 AFS is added as a selection if Run Mode is set to Semi auto matic in Configure Screen 3 page 33 Gun 2 Trigger Displays AFS if Number of Guns is set to 2 in Config ure Screen 4 page 33 Control Network ID Used for the Graco Gateway network system See Graco Gateway manual 312785 for further information 312779E Setup Mode 35 Setup Mode Option Screens NOTE See FIG 27 on page 31 for a map of the Option Screens Detailed screen descriptions follow NOTE Each screen displays the current screen number and the total number of screens in the group Option Screen 1 Flush Valume Check Flush and Fill Input K Factor Input Mir Material Fill Volume Options 36 Option Screen 1 Flush Volume Check This field only appears if Solvent Monitor is set to Meter in Configure Screen 5 page 34 If set to On Minimum Flush Volume will appear in Recipe Setup Screen 2 page 44 Flush and Fill Input If set to Global Color Catalyst Pur
149. uid together during the flush cycle to help clean the lines and reduce solvent usage Final Purge Source Select Air Solvent or Flush Valve available only if 3rd Flush Valve is set to On in Configure Screen 3 on page 33 Air Chop Time Enter the air chop time 0 0 to 99 9 seconds Solvent Chop Time 3rd Flush Valve Chop Time Enter the solvent or 3rd flush valve chop time 0 0 to 99 9 seconds 40 Advanced Setup Screen 3 First Purge Time Total Chop Time Final Purge Time Mixtec Fill Time Advanced Calibration 43 Advanced Setup Screen 3 This screen appears only if Flush and Fill Input is set to Global in Option Screen 1 page 36 If Number of Guns is set to 2 in Configure Screen 4 page 33 a Gun 2 column will appear in this screen First Purge Time Enter the first purge time 0 to 999 seconds Total Chop Time Enter the total chop time 0 to 999 seconds Final Purge Time Enter the final purge time 0 to 999 seconds Mixed Material Fill Time Enter the mixed material fill time 0 to 999 seconds It refers to the amount of time that is required to load mixed material from the dose valves to the applica tor gun 312779E Advanced Setup Screen 4 K Factar H Meter B Meter solvent Meter cc pulse 0 119 0 119 Advanced Calibration FIG 44 Advanced Setup Screen 4 This screen appears only if K factor Input is set to Global in Option Screen 1 pag
150. ultiple color single catalyst systems Select Recipe 0 and press Enter 0 purge the component A side The color change LED blinks while Recipe runs and turns solid after purge sequence is complete 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 fluid integrator e Multiple color multiple catalyst systems Select Recipe 0 and press Enter 0 purge the component A side and the component B side The color change LED blinks while Recipe 0 runs and turns solid after purge sequence is complete Repeat to thoroughly clean the fluid integrator 6 Reinstall the Fluid Station cover 7 Shutoff the solvent fluid supply 8 Disconnect the solvent supply lines and reconnect the component A and B fluid supplies 9 See page 89 for Start Up procedure 312779E System Operation 97 System Operation Purging Sampling Valves and Tubes Follow this procedure after meter calibration 1 Goto Standby mode remove Mix input 2 See Fic 106 page 94 Close both fluid shutoff valves and sampling valves 3 Route the sampling tubes into a grounded waste container 4 single color system attach a solvent supply line to Flow Meter A inlet 5 Onthe EasyKey press Setup key and access the Advanced Setup screens 6 Press the Right Arrow key to selec
151. ure flow Digital Input and Output a description of data which is transmitted as a sequence of discrete symbols most commonly this means binary data represented using electronic or electromagnetic signals Discrete refers to data that constitutes a separate entity and has direct communication to another control Dose Size the amount of resin A and catalyst B that is dispensed into an integrator Dose Time Alarm the amount of time that is allowed for a dose to occur before an alarm occurs Dynamic Dosing Component A dispenses constantly Component B dispenses intermittently in the necessary volume to attain the mix ratio 12 Ethernet a method for directly connecting a computer to a network or equipment in the same physical location Fiber Optic Communication the use of light to trans mit communication signals Final Purge Source source of the media used in the final purge cycle User settable to air purge valve sol vent purge valve or 3rd purge valve Final Purge Time duration of the final purge cycle User settable from 0 999 seconds First Purge Source source of the media used in the first purge cycle User settable to air purge valve sol vent purge valve or 3rd purge valve First Purge Time duration of the first purge cycle User settable from 0 999 seconds Flow Control Resolution a settable value that allows the flow control system to maximize its performance The value is base
152. ve Settings page 89 for adjustment guidelines e Fluid pressure is high and air pressure is low e Adjust air and fluid pressure See recommended air pressure above 118 312779E Alarm Troubleshooting Table 17 Alarm Troubleshooting E 5 OVERDOSE A B DOSE TOO SHORT ALARM and E 6 OVERDOSE B A DOSE TOO SHORT ALARM E 5 the A dose overshoots and when combined with B is too large for the mix chamber capacity E 6 the B dose overshoots and forces an A side dose that when combined with B is too large for the mix chamber capacity Valve seal or needle seat are leaking Check 17 Totals Screen on page 26 If A and B are dosing simul taneously sequential dosing only there is a leak Flow meter fluctuations caused by pressure pulsations Check for pressure pulsations Close all the manifold valves Turn on the circulating pumps and all the booth equipment such as fans and conveyors Check if the ProMix 2KS is reading any fluid flow If the ProMix 2KS shows there is fluid flow and there are no leaks from the gun or any other seals or fit tings the flow meters are probably being affected by pressure pulsations Close the fluid shutoff valve between the fluid supply system and the flow meter The flow indication should stop If necessary install pressure regulators or a surge tank on the fluid inlets to the ProMix 2KS to reduce the fluid supply pressure Contact your Graco distrib utor for information
153. while this output is High these are typically High Low Flow Warnings Always monitor this output and the alarm outputs to provide feedback of the actual status of the ProMix 2 5 See the Modbus charts in the Graco Gateway manual 312785 Mix Ready This output will remain High while there are no alarms and the ProMix 2KS is ready to go to Mix mode General Alarm This output will remain High when any alarm is active See Table 16 on page 115 for a com plete list of alarms NOTE It is important to monitor this output along with Mix Active to understand the alarm s true meaning Alarm Potlife This output will remain High along with the Alarm output when the potlife time has been reached for the active recipe The Mix Active output will drop Low even if the Mix Start input is High This out put will remain High until the potlife volume is dispensed or the ProMix 2KS completes a Purge or a Color Change The Alarm Reset input will not stop this output but will silence the audible alarm on the EasyKey NOTE The Alarm Reset 5 key will also reset the audible alarm To dispense the potlife volume the ProMix 2KS Start input must be turned Off then back to High to spray material At this point Mix Active Alarm and Alarm Potlife outputs will be High until the potlife vol ume is sprayed Digital Out Supply This is the supply for the digital out puts It is the same supply for the digital inputs See Common under Dig
154. will be on during the recipe change cycle e For the two gun flush box option both spray guns must be inserted in the GFBs during the entire color change cycle purge and fill The system will turn each GFB trigger output on and off based on the preset time for each gun e For Special Outputs options the system will turn each output on and off based on the preset times Each Special Output has two different start times and durations e For systems without dump valves the First Purge begins after the Color Catalyst Change steps are completed e Dump Valve is required for a Catalyst Change system e When going from Recipe X to Recipe 0 only the purge cycle data from Recipe 0 is used e When going from Recipe 0 to Recipe X only the fill cycle data from Recipe X is used 312779E Color Purge Dump Step PO P1 e This sequence flushes out the color with solvent from the color valve to the Dump A valve e The color change solvent valve and the Dump A valve open during the Purge Time e The color change solvent valve closes when the Purge Time expires Color Fill Step P1 P2 e This sequence fills the line with the new color all the way to the Dump A valve e The new color valve and the Dump A valve open during the Fill Time e new color valve the Dump A valve close when the Fill Time expires Catalyst Purge Dump Step P2 P3 e This sequence flushes out the catalyst with solvent from t

Graco 312779E User's Manual

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