Operation
ProMix® 2KS
312779E
EN
Plural Component Proportioner
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).
mum working pressure. Equipment approval labels are
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
with all systems.
Automatic System with RoboMix Fluid Station
Automatic System with Wall Mount Fluid Station
TI12552a
TI12553a
#
53
0359
II 2 G
Download from Www.Somanuals.com. All Manuals Search And Download.
Related Manuals
Related Manuals
Equipment Approvals
Equipment approvals appear on the following labels
Component Manuals in English
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.
Manual
Description
312778
ProMix 2KS Automatic System
Installation
EasyKey and Fluid Station Label
312780
ProMix 2KS Automatic System
Repair-Parts
ATEX Certificate is listed here
312781
312782
312783
312787
312784
310745
312786
312785
308778
Fluid Mix Manifold
ꢋꢎꢘꢄꢙꢚ&ꢛꢜꢏ
ꢅꢆꢈꢉꢌꢆꢇꢌꢋꢂꢏꢏꢘꢄꢓꢂꢕꢁꢄꢚꢅꢓꢛꢄꢓꢘꢇꢈꢁꢖꢙꢄꢄꢅꢆꢇꢈꢂꢏꢏꢄ
Dispense Valve
ꢗꢁꢉꢄꢅꢓꢄꢜꢍꢆꢈꢉꢍꢏꢄꢝꢉꢂꢞꢌꢆꢑꢄꢟꢍꢙꢄꢠꢡꢢꢡꢣꢣꢙ
ꢗꢝꢞꢟꢠꢎꢘꢡꢙꢟꢇꢋꢎꢘꢢꢘꢎꢠꢙꢘꢡꢞꢎ
ꢤꢂꢇꢘꢥꢁꢘꢄꢅꢆꢈꢁꢉꢕꢂꢋꢁꢄꢅꢓꢄꢦꢇꢇꢍꢋꢌꢂꢈꢁꢃ
ꢦꢗꢗꢂꢉꢂꢈꢊꢇꢄꢕꢍꢉꢄꢊꢇꢁꢄꢌꢆꢄꢆꢍꢆꢄꢧꢂꢨꢂꢉꢃꢍꢊꢇ
ꢏꢍꢋꢂꢈꢌꢍꢆꢩꢄꢞꢌꢈꢧꢄꢅꢓꢄꢜꢍꢆꢆꢁꢋꢈꢌꢍꢆꢄꢈꢍꢄꢓꢖꢂꢉꢈꢄ
Color Change Valve Stacks
Color Change Module Kit
Gun Flush Box Kits
ꢥ
ꢒꢏ
ꢪꢏꢊꢌꢃꢄꢫꢏꢂꢈꢁꢄꢅꢓ
ꢐꢄꢃꢴꢅꢔꢗꢆꢃꢃꢁꢵ
ꢈꢈꢇꢛꢇꢰ
ꢈꢡꢠꢎꢙꢡꢨꢙꢟꢌꢝꢝꢩꢇꢨꢌꢪꢞ
ꢞꢫꢬꢙꢢꢭꢞꢡꢠꢇꢪꢘꢎꢇꢥꢝꢌꢨꢨꢇꢈꢮ
ꢓꢙꢯꢇꢂꢮꢇꢰꢎꢘꢬꢢꢇꢓꢮꢇꢔꢱ
ꢔꢌꢇꢲꢇꢳꢛꢃꢤꢥꢇꢠꢘꢇꢣꢃꢤꢥ
ꢦꢗꢗꢂꢉꢂꢈꢊꢇꢄꢕꢍꢉꢄꢊꢇꢁꢄꢌꢆꢒ
ꢜꢏꢂꢇꢇꢄꢅꢩꢄꢝꢌꢬꢌꢇꢌꢍꢆꢄꢭꢩꢄꢮꢉꢍꢊꢗꢄꢝꢄꢯꢣ
ꢰꢂꢨꢂꢉꢃꢍꢊꢇꢄꢱꢍꢋꢂꢈꢌꢍꢆꢇ
ꢗꢚꢇꢙꢌꢇꢈꢈꢅꢇꢔꢱ
Gun Air Shutoff Kit
ꢀꢁꢂꢃꢄꢅꢆꢇꢈꢉꢊꢋꢈꢌꢍꢆꢄꢎꢂꢆꢊꢂꢏ
ꢐꢂꢉꢆꢌꢆꢑꢒꢄꢓꢊꢔꢇꢈꢌꢈꢊꢈꢌꢍꢆꢄꢍꢕꢄꢋꢍꢖꢗꢍꢆꢁꢆꢈꢇ
ꢖꢂꢘꢄꢌꢖꢗꢂꢌꢉꢄꢌꢆꢈꢉꢌꢆꢇꢌꢋꢄꢇꢂꢕꢁꢈꢘꢙ
Dump Valve and Third Purge Valve Kits
Network Communication Kits
ꢄꢅꢆꢇꢅꢈꢉꢇꢊꢋꢉ
ꢀꢁ
ꢁ
ꢂꢃꢃ
ꢋꢅꢉꢔꢇꢕꢖꢀ
ꢏꢗꢉꢈꢗꢏ
ꢏꢗꢉꢈꢅꢑ
ꢄꢋꢌ
ꢍꢌꢎ
ꢋꢏꢈ
ꢄꢅꢆꢇꢐꢑꢒꢈꢓꢇꢊꢋꢉ
G3000/G3000HR/G250/G250HR Flow
Meter
ꢄꢐꢰꢀꢇꢷꢉꢀ
ꢰꢉꢅꢥꢖꢇꢈꢕꢥꢀ
ꢋꢀꢖꢀꢇꢶꢘꢚꢇꢂꢵꢵꢂ
ꢄꢙꢡꢡꢞꢌꢢꢘꢝꢙꢨꢮꢇꢄꢕꢇ
ꢣꢣꢵꢵꢃꢇꢒꢀꢏꢀꢅꢀ
ꢄꢅꢆꢇꢔꢗꢄꢋꢍꢇꢣꢌꢎꢃꢤꢥꢇꢦꢂꢛꢋꢛꢏꢤꢈꢐꢧ
ꢄꢋꢌ
313599
313212
313290
313542
313386
Coriolis Flow Meter
Gun Flush Box Integration Kit
Floor Stand Kit
Beacon Kit
Fluid Station Label
Basic Web Interface/Advanced Web
Interface
®
FLUID PANEL
ProMix 2KS
.7MAX AIR WPR
7
100
PSI
PART NO.
SERIES SERIAL MFG. YR.
406800
15V825 Discrete I/O Board Kit
MPa
bar
Intrinsically safe equipment
for Class I, Div 1, Group D, T3
US
Ta = -20°C to 50°C
GRACO INC.
C
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
FM08ATEX0073
II 2 G
Install per 289833
Ex ia IIA T3
Artwork No. 293538
TI13581a
ATEX Certificate is listed here
EasyKey Label
®
POWER REQUIREMENTS
ProMix 2KS
VOLTS
AMPS
85-250 ~
2 AMPS MAX
50/60 Hz
SERIES NO. MFG. YR.
PART NO.
Intrinsically safe connections
GRACO INC.
for Class I, Div 1, Group D
US
Ta = -20°C to 50°C
C
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
Install per 289833
II (2) G
[Ex ia] IIA
Um: 250 V
FM08ATEX0072
TI13582a
ATEX Certificate is listed here
312779E
3
Download from Www.Somanuals.com. All Manuals Search And Download.
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 FIG. 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
System
A and B Meter
Color Valves
Catalyst Valves
Flow
Control
A
D = EasyKey with LCD Display 0 = No Meters
1 = G3000 (A and B)
0 = No Valves
(single color)
0 = No Valves
(single catalyst)
N = No
Y = Yes
1 = Two Valves
(low pressure)
1 = Two Valves
(low pressure)
2 = G3000HR (A and B)
3 = 1/8 in. Coriolis (A) and
G3000 (B)
2 = Four Valves
(low pressure)
2 = Four Valves
(low pressure)
4 = G3000 (A) and 1/8 in.
Coriolis (B)
3 = Seven Valves
(low pressure)
5 = 1/8 in. Coriolis (A) and
G3000HR (B)
4 = Twelve Valves
(low pressure)
6 = G3000HR (A) and 1/8 in.
Coriolis (B)
7 = 1/8 in. Coriolis (A and B)
ꢋꢎꢘꢄꢙꢚ&ꢇꢛꢜꢏ
ꢅꢆꢈꢉꢌꢆꢇꢌꢋꢂꢏꢏꢘꢄꢓꢂꢕꢁꢄꢚꢅꢓꢛꢄꢓꢘꢇꢈꢁꢖꢙꢄꢄꢅꢆꢇꢈꢂꢏꢏꢄ
ꢗꢁꢉꢄꢅꢓꢄꢜꢍꢆꢈꢉꢍꢏꢄꢝꢉꢂꢞꢌꢆꢑꢄꢟꢍꢙꢄꢠꢡꢢꢡꢣꢣꢙ
ꢗꢝꢞꢟꢠꢎꢘꢡꢙꢟꢇꢋꢎꢘꢢꢘꢎꢠꢙꢘꢡꢞꢎ
ꢤꢂꢇꢘꢥꢁꢘꢄꢅꢆꢈꢁꢉꢕꢂꢋꢁꢄꢅꢓꢄꢦꢇꢇꢍꢋꢌꢂꢈꢁꢃ
ꢦꢗꢗꢂꢉꢂꢈꢊꢇꢄꢕꢍꢉꢄꢊꢇꢁꢄꢌꢆꢄꢆꢍꢆꢄꢧꢂꢨꢂꢉꢃꢍꢊꢇ
ꢏꢍꢋꢂꢈꢌꢍꢆꢩꢄꢞꢌꢈꢧꢄꢅꢓꢄꢜꢍꢆꢆꢁꢋꢈꢌꢍꢆꢄꢈꢍꢄꢓꢖꢂꢉꢈꢄ
ꢪꢏꢊꢌꢃꢄꢫꢏꢂꢈꢁꢄꢅꢓ
ꢥ
ꢒꢏ
ꢐꢄꢃꢴꢅꢔꢗꢆꢃꢃꢁꢵ
ꢈꢈꢇꢛꢇꢰ
ꢈꢡꢠꢎꢙꢡꢨꢙꢟꢌꢝꢝꢩꢇꢨꢌꢪꢞ
ꢞꢫꢬꢙꢢꢭꢞꢡꢠꢇꢪꢘꢎꢇꢥꢝꢌꢨꢨꢇꢈꢮ
ꢓꢙꢯꢇꢂꢮꢇꢰꢎꢘꢬꢢꢇꢓꢮꢇꢔꢱ
ꢦꢗꢗꢂꢉꢂꢈꢊꢇꢄꢕꢍꢉꢄꢊꢇꢁꢄꢌꢆꢒ
ꢗꢚꢇꢙꢌꢇꢈꢈꢅꢇꢔꢱ
Label Location
on Fluid Station
Label Location
on EasyKey
ꢜꢏꢂꢇꢇꢄꢅꢩꢄꢝꢌꢬꢌꢇꢌꢍꢆꢄꢭꢩꢄꢮꢉꢍꢊꢗꢄꢝꢄꢯꢣ
ꢔꢌꢇꢲꢇꢳꢛꢃꢤꢥꢇꢠꢘꢇꢣꢃꢤꢥ
ꢰꢂꢨꢂꢉꢃꢍꢊꢇꢄꢱꢍꢋꢂꢈꢌꢍꢆꢇ
ꢀꢁꢂꢃꢄꢅꢆꢇꢈꢉꢊꢋꢈꢌꢍꢆꢄꢎꢂꢆꢊꢂꢏ
ꢐꢂꢉꢆꢌꢆꢑꢒꢄꢓꢊꢔꢇꢈꢌꢈꢊꢈꢌꢍꢆꢄꢍꢕꢄꢋꢍꢖꢗꢍꢆꢁꢆꢈꢇ
ꢖꢂꢘꢄꢌꢖꢗꢂꢌꢉꢄꢌꢆꢈꢉꢌꢆꢇꢌꢋꢄꢇꢂꢕꢁꢈꢘꢙ
TI12423a
TI12418a
ꢄꢅꢆꢇꢅꢈꢉꢇꢊꢋꢉ
ꢀꢁ
ꢁ
ꢂꢃꢃ
Maximum Fluid
Working Pressure
is listed here
ꢋꢅꢉꢔꢇꢕꢖꢀ
ꢏꢗꢉꢈꢗꢏ
ꢏꢗꢉꢈꢅꢑ
ꢄꢋꢌ
ꢍꢌꢎ
ꢋꢏꢈ
ꢄꢅꢆꢇꢐꢑꢒꢈꢓꢇꢊꢋꢉ
Configured Part Number
ꢄꢐꢰꢀꢇꢷꢉꢀ
ꢰꢉꢅꢥꢖꢇꢈꢕꢥꢀ
ꢋꢀꢖꢀꢇꢶꢘꢚꢇꢂꢵꢵꢂ
ꢄꢙꢡꢡꢞꢌꢢꢘꢝꢙꢨꢮꢇꢄꢕꢇ
ꢣꢣꢵꢵꢃꢇꢒꢀꢏꢀꢅꢀ
ꢄꢅꢆꢇꢔꢗꢄꢋꢍꢇꢣꢌꢎꢃꢤꢥꢇꢦꢂꢛꢋꢛꢏꢤꢈꢐꢧ
ꢄꢋꢌ
FIG. 1: Identification Label, Wall Mount Fluid Station Systems
4
312779E
Download from Www.Somanuals.com. All Manuals Search And Download.
System Configuration and Part Numbers
Hazardous Location Approval
Models using a G3000, G3000HR, or intrinsically safe Coriolis meter for both A and B meters are approved for
installation in a Hazardous Location - Class I, Div I, Group D, T3 or Zone I Group IIA T3.
Maximum Working Pressure
Maximum working pressure rating is dependent on the fluid component options selected. The pressure rating is
based on the rating of the lowest rated fluid component. Refer to the component pressure ratings below.
Example: Model AD110Y has a maximum working pressure of 190 psi (1.31 MPa, 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 N]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000 psi (27.58 MPa, 275.8 bar)
Meter Option 1 and 2 (G3000 or G3000HR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000 psi (27.58 MPa, 275.8 bar)
Meter Option 3, 4, 5, 6, and 7 (one or two Coriolis Meters) . . . . . . . . . . . . . . . . . 2300 psi (15.86 MPa, 158.6 bar)
Color Change Option 1, 2, 3 and 4 and
Catalyst Change Option 1 and 2 (low pressure valves) . . . . . . . . . . . . . . . . . . . . . . . 300 psi (2.07 MPa, 20.6 bar)
Flow Control Option Y (Yes). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190 psi (1.31 MPa 13.1 bar)
Flow Meter Fluid Flow Rate Range
G3000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-3800 cc/min. (0.02-1.0 gal./min.)
G3000HR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-1900 cc/min. (0.01-0.50 gal./min.)
Coriolis Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3800 cc/min. (0.005-1.00 gal./min.)
S3000 Solvent Meter (accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-1900 cc/min. (0.01-0.50 gal./min.)
Standard Features
Feature
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
5
Download from Www.Somanuals.com. All Manuals Search And Download.
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 FIG. 2
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.
RoboMix
System
Control and Display
A and B Meter
Color Valves
Catalyst Valves
Flow
Control
R
D = EasyKey with LCD Display 0 = No Meters
1 = G250 (A and B)
2 = G250HR (A and B)
0 = No Valves
(single color)
0 = No Valves
(single catalyst)
N = No
Y = Yes
1 = Two Valves
(low pressure)
1 = Two Valves
(low pressure)
2 = Four Valves
(low pressure)
2 = Four Valves
(low pressure)
3 = Seven Valves
(low pressure)
4 = Twelve Valves
(low pressure)
ꢋꢎꢘꢄꢙꢚ&ꢇꢛꢜꢏ
ꢅꢆꢈꢉꢌꢆꢇꢌꢋꢂꢏꢏꢘꢄꢓꢂꢕꢁꢄꢚꢅꢓꢛꢄꢓꢘꢇꢈꢁꢖꢙꢄꢄꢅꢆꢇꢈꢂꢏꢏꢄ
ꢗꢁꢉꢄꢅꢓꢄꢜꢍꢆꢈꢉꢍꢏꢄꢝꢉꢂꢞꢌꢆꢑꢄꢟꢍꢙꢄꢠꢡꢢꢡꢣꢣꢙ
ꢤꢂꢇꢘꢥꢁꢘꢄꢅꢆꢈꢁꢉꢕꢂꢋꢁꢄꢅꢓꢄꢦꢇꢇꢍꢋꢌꢂꢈꢁꢃ
ꢦꢗꢗꢂꢉꢂꢈꢊꢇꢄꢕꢍꢉꢄꢊꢇꢁꢄꢌꢆꢄꢆꢍꢆꢄꢧꢂꢨꢂꢉꢃꢍꢊꢇ
ꢏꢍꢋꢂꢈꢌꢍꢆꢩꢄꢞꢌꢈꢧꢄꢅꢓꢄꢜꢍꢆꢆꢁꢋꢈꢌꢍꢆꢄꢈꢍꢄꢓꢖꢂꢉꢈꢄ
ꢪꢏꢊꢌꢃꢄꢫꢏꢂꢈꢁꢄꢅꢓ
ꢗꢝꢞꢟꢠꢎꢘꢡꢙꢟꢇꢋꢎꢘꢢꢘꢎꢠꢙꢘꢡꢞꢎ
ꢥ
ꢒꢏ
ꢐꢄꢃꢴꢅꢔꢗꢆꢃꢃꢁꢵ
ꢈꢈꢇꢛꢇꢰ
Label Location on
RoboMix Fluid Station
Label Location
on EasyKey
ꢈꢡꢠꢎꢙꢡꢨꢙꢟꢌꢝꢝꢩꢇꢨꢌꢪꢞ
ꢞꢫꢬꢙꢢꢭꢞꢡꢠꢇꢪꢘꢎꢇꢥꢝꢌꢨꢨꢇꢈꢮ
ꢓꢙꢯꢇꢂꢮꢇꢰꢎꢘꢬꢢꢇꢓꢮꢇꢔꢱ
ꢔꢌꢇꢲꢇꢳꢛꢃꢤꢥꢇꢠꢘꢇꢣꢃꢤꢥ
ꢦꢗꢗꢂꢉꢂꢈꢊꢇꢄꢕꢍꢉꢄꢊꢇꢁꢄꢌꢆꢒ
ꢗꢚꢇꢙꢌꢇꢈꢈꢅꢇꢔꢱ
ꢜꢏꢂꢇꢇꢄꢅꢩꢄꢝꢌꢬꢌꢇꢌꢍꢆꢄꢭꢩꢄꢮꢉꢍꢊꢗꢄꢝꢄꢯꢣ
ꢰꢂꢨꢂꢉꢃꢍꢊꢇꢄꢱꢍꢋꢂꢈꢌꢍꢆꢇ
TI12512b
TI12418a
ꢀꢁꢂꢃꢄꢅꢆꢇꢈꢉꢊꢋꢈꢌꢍꢆꢄꢎꢂꢆꢊꢂꢏ
ꢐꢂꢉꢆꢌꢆꢑꢒꢄꢓꢊꢔꢇꢈꢌꢈꢊꢈꢌꢍꢆꢄꢍꢕꢄꢋꢍꢖꢗꢍꢆꢁꢆꢈꢇ
ꢖꢂꢘꢄꢌꢖꢗꢂꢌꢉꢄꢌꢆꢈꢉꢌꢆꢇꢌꢋꢄꢇꢂꢕꢁꢈꢘꢙ
ꢄꢅꢆꢇꢅꢈꢉꢇꢊꢋꢉ
Maximum Fluid
Working Pressure
is listed here
ꢀꢁ
ꢁ
ꢂꢃꢃ
ꢋꢅꢉꢔꢇꢕꢖꢀ
ꢏꢗꢉꢈꢗꢏ
ꢏꢗꢉꢈꢅꢑ
ꢄꢋꢌ
ꢍꢌꢎ
ꢋꢏꢈ
Configured Part Number
ꢄꢅꢆꢇꢐꢑꢒꢈꢓꢇꢊꢋꢉ
ꢄꢐꢰꢀꢇꢷꢉꢀ
ꢰꢉꢅꢥꢖꢇꢈꢕꢥꢀ
ꢋꢀꢖꢀꢇꢶꢘꢚꢇꢂꢵꢵꢂ
ꢄꢙꢡꢡꢞꢌꢢꢘꢝꢙꢨꢮꢇꢄꢕꢇ
ꢣꢣꢵꢵꢃꢇꢒꢀꢏꢀꢅꢀ
ꢄꢅꢆꢇꢔꢗꢄꢋꢍꢇꢣꢌꢎꢃꢤꢥꢇꢦꢂꢛꢋꢛꢏꢤꢈꢐꢧ
ꢄꢋꢌ
FIG. 2: Identification Label, RoboMix Fluid Station Systems
6
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System Configuration and Part Numbers
Hazardous Location Approval
Models using a G250 or G250HR for both A and B meters are approved for installation in a Hazardous Location -
Class I, Div I, Group D, T3 or Zone I Group IIA T3.
Maximum Working Pressure
Maximum working pressure rating 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 FIG. 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
Feature
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
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Accessories
Accessories
Accessory
15V354 Third Purge Valve Kit
15V202 Third Purge Valve Kit
15V536 Solvent Flow Switch Kit
15V213 Power Cable, 100 ft (30.5 m)
15G710 Fiber Optic Cable, 100 ft (30.5 m)
15G614 Flow Control Extension Cable, 40 ft (12.2 m)
15U955 Injection Kit for Dynamic Dosing
15V034 10 cc Integrator Kit
15V033 25 cc Integrator Kit
15V021 50 cc Integrator Kit
24B618 100 cc Integrator Kit
15W034 Strobe Light Alarm Indicator Kit
15V331 Gateway Ethernet Communication Kit
15V963 Gateway DeviceNet Communication Kit
15V964 Gateway Profibus Communication Kit
15V337 Advanced Web Interface
280555 S3000 Solvent Flow Meter Kit
8
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Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and
warnings not covered in this section may appear throughout the body of this manual where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
•
•
Use equipment only in well ventilated area.
Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
•
•
Keep work area free of debris, including solvent, rags and gasoline.
Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
•
Ground all equipment in the work area. See Grounding instructions 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 grounded 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.
•
Only models with a G3000, G250, G3000HR, G250HR, or intrinsically safe Coriolis meter are
approved for installation in a Hazardous Location - Class I, Div I, Group D, T3 or Zone I Group IIA
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
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Warnings
WARNING
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
•
•
•
•
•
Tighten all fluid connections before operating the equipment.
Do not point gun at anyone or at any part of the body.
Do not put your hand over the spray tip.
Do not stop or deflect leaks with your hand, body, glove, or rag.
Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
•
•
Do not operate the unit when fatigued or under the influence of drugs or alcohol.
Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
•
•
Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS forms from distributor or retailer.
Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-
facturer’s replacement parts only.
•
•
•
•
•
•
Do not alter or modify equipment.
Use equipment only for its intended purpose. Call your distributor for information.
Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
Do not kink or over bend hoses or use hoses to pull equipment.
Keep children and animals away from work area.
Comply with all applicable safety regulations.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
•
•
•
Read MSDS’s to know the specific hazards of the fluids you are using.
Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
Always wear chemically impermeable gloves when spraying or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
•
•
•
•
Protective eyewear
Clothing and respirator as recommended by the fluid and solvent manufacturer
Gloves
Hearing protection
10
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Important Two-Component Material Information
Important Two-Component Material Information
Isocyanate Conditions
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.
Spraying or dispensing materials containing isocya-
nates creates potentially harmful mists, vapors, and
atomized particulates.
Read material manufacturer’s warnings and mate-
rial MSDS to know specific hazards and precautions
related to isocyanates.
NOTE: The amount of film formation and rate of crystal-
lization varies depending on the blend of ISO, the
humidity, and the temperature.
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 exposing ISO to moisture:
•
Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere. Never
store ISO in an open container.
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.
•
•
Use moisture-proof hoses specifically designed for
ISO, such as those supplied with your system.
Never use reclaimed solvents, which may contain
moisture. Always keep solvent containers closed
when not in use.
Material Self-ignition
•
•
Never use solvent on one side if it has been con-
taminated from the other side.
Always lubricate threaded parts with ISO pump oil
or grease when reassembling.
Some materials may become self-igniting if applied
too thickly. Read material manufacturer’s warnings
and material MSDS.
Changing Materials
•
When changing materials, flush the equipment mul-
tiple times to ensure it is thoroughly clean.
Keep Components A and B
Separate
•
•
Always clean the fluid inlet strainers after flushing.
Check with your material manufacturer for chemical
compatibility.
•
Most materials use ISO on the A side, but some use
ISO on the B side.
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
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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.
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-
Air Chop Time- duration of each activation of the air
purge valve during a chop sequence. User settable from
0.0-99.9 seconds.
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.
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.
Final Purge Time- duration of the final purge cycle.
User settable from 0-999 seconds.
Chop Time- refers to the total length of the chop
sequence during a purge. User settable from 0-999 sec-
onds.
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
Closed Loop Flow Control - refers to the process
when the flow rate is adjusted automatically to maintain
a constant flow.
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 based on maximum desired flow rates.
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.
Flow Rate Analog Signal - the type of communication
Color/Catalyst Fill - refers to the time required to fill the
lines from the color or catalyst change module to the mix
manifold.
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.
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 measure flow.
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).
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.
Grand Total - a non-resettable value that shows the
total amount of material dispensed through the system.
Discrete I/O - refers to data that constitutes a separate
entity and has direct communication to another control.
Gun Trigger Input Signal - used to manage ratio
assurance dose times and flow control processes.
Dose Size - the amount of resin (A) and catalyst (B) that
is dispensed into an integrator.
Intrinsically Safe (IS) - refers to the ability to locate cer-
tain components in a hazardous location.
Dose Time Alarm - the amount of time that is allowed
for a dose to occur before an alarm occurs.
Idle - if the gun is not triggered for 2 minutes the system
enters Idle mode. Trigger the gun to resume operation.
Dynamic Dosing - Component A dispenses constantly.
Component B dispenses intermittently in the necessary
volume to attain the mix ratio.
12
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Glossary of Terms
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.
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.
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.
Purge Volume Alarm - E-11 Alarm occurs if minimum
flush volume is not achieved.
Ki - refers to the degree fluid flow over shoots its set
point.
Ratio Tolerance - the settable percent of acceptable
variance that the system will allow before a ratio alarm
occurs.
Kp - refers to the speed in which the fluid flow reaches
its set point.
Sequential Color Change - the process when a color
change is initiated and the system automatically flushes
the old color and loads a new color.
Manual Mode - when the proportioning or flow control
system is controlling the inputs without any input from
an outside control.
Sequential Dosing - Components A and B dispense
sequentially in the necessary volumes to attain the mix
ratio.
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 cc).
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.
Mix - when cross-linking of the resin (A) and catalyst (B)
occurs.
Solvent Fill - the time required to fill the mixed material
line with solvent.
Mix Input Signal- refers to system mode status where
system begins a dose sequence each time the mix sig-
nal is made “High”.
Solvent Push - enables the user to save some mixed
material by pushing it out to the gun with solvent.
Requires an accessory solvent meter.
Mixed Material Fill Time - the amount of time that is
required to load mixed material from the dose valves to
the applicator/gun.
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.
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-
V/P - refers to the voltage to air pressure device in the
vidual proportioning or flow control system.
flow control module.
Overdose Alarm - when either the resin (A) or catalyst
(B) 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.
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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).
•
Can proportion at ratios from 0.1:1 to 50:1 in 0.1
increments.
Has user selectable ratio assurance and can main-
tain up to +/-1% accuracy, depending on materials
and operating conditions.
•
Color change options are available for low pressure
(300 psi [2.1 MPa, 21 bar]) air spray and high pres-
sure (3000 psi [21 MPa, 210 bar]) systems with up
to 30 color change valves and up to 4 catalyst
change valves.
•
•
Models are available to operate air spray or
air-assisted systems with a capacity of up to 3800
cc/min.
NOTE: Optional accessories are available for in
field installation to achieve 30 colors.
Component Identification and Definition
SeeTable 1, and FIG. 3 for the wall mount system components and FIG. 5 for the RoboMix system components.
Table 1: Component Descriptions
Component
Description
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.
EasyKey (EK)
Includes air control solenoids, flow switches, and mountings for the fluid flow meters, and
the fluid manifold assembly. Its control board manages all proportioning functions.
Wall Mount Fluid
Station (ST, used on
ADxxxx and AExxxx
Models only)
Includes air control solenoids, flow switches, fluid flow meters, and the fluid manifold
assembly to control and monitor fluid dispensing. Its control board manages all propor-
tioning functions.
RoboMix Fluid
Station (RS, used
on RDxxxx and
RExxxx Models
only)
•
•
•
Pneumatically Operated Dose Valves for component A and B
Purge Valves for solvent and air purge
Sampling Valves for calibrating the flow meters and performing ratio checks (Wall
Mount Panel only)
Fluid Manifold (FM)
•
•
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.
➜ Static Mixer has 24 elements to uniformly blend the materials downstream
of the fluid integrator.
14
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Overview
Table 1: Component Descriptions
Component
Description
The following optional flow meters are available from Graco:
Flow Meters (MA,
MB, MS)
•
G3000 is a general purpose gear meter typically used in flow ranges of 75-3800
cc/min. (0.02–1.0 gal/min.), pressures up to 4000 psi (28 MPa, 276 bar), and 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 meter, 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 a 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.
S3000 is a gear meter used for solvents in flow ranges of 38-1900 cc/min. (0.01–0.50
gal/min.), pressures up to 3000 psi (21 MPa, 210 bar), and viscosities of 20–50 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.
Color Change
Valves (ACV) and
Color Change
Module (CCM)
An optional component. It is available as a catalyst change valve stack for either low or
high pressure with up to 4 catalyst change valves. Each stack includes one additional
valve for solvent to clean the fluid line between catalyst changes.
Catalyst Change
Valves (BCV)
Used to communicate between the EasyKey and Wall Mount Fluid Station or RoboMix.
Dual Fiber Optic
Cable (FO)
Used to provide power to the Wall Mount Fluid Station or RoboMix.
Fluid Station Power
Supply Cable (PS)
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.
Flow Control
Regulator
Assembly (FC)
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Overview
Wall Mount System Components
EK
ACV
CCM
PS*
BCV
MS
FC
FO*
ST
MA
FM
MB
*
See the ProMix 2KS
Repair-Parts manual for
optional cable lengths.
TI12553a
FIG. 3. Wall Mount System, shown with G3000 Meters, Color/Catalyst Change, Accessory Solvent Meter, and
Flow Control
16
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Overview
DVA
FI
DVB
MB
MS
MA
RVB
AT
APV
RVA
SVA
SM
SVB
SPV
TI12556b
FIG. 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
FI
Fluid Integrator
AT
Air Purge Valve Air Supply Tube
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Overview
RoboMix System Components
EK
ACV
CCM
BCV
Air Controls
Purge Air
PS*
RoboMix
Control Air
FO*
FC
RS
*
See the ProMix 2KS
Repair-Parts manual for
optional cable lengths.
TI12552a
FIG. 5. RoboMix System shown with Color/Catalyst Change and Flow Control
18
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Overview
Air Logic In
Cable Path
B Supply (1/4 npt)
A Supply (1/4 npt)
Ground Screw
Air Purge
TI12511b
Solvent Supply
(1/4 npt)
A Dump Out
B Dump Out
Cover is removed for clarity
MB
DVB
MA
TI12579b
DVA
FIG. 6: Details of RoboMix Fluid Station
312779E
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EasyKey Display and Keyboard
EasyKey Display and Keyboard
Keypad
LCD Display
TI11630A
Navigation Keys
Alarm Reset Key
FIG. 7. EasyKey Display and Keypad
Display
Table 2: EasyKey Keypad Functions (see FIG. 7)
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.
Key
Function
Setup: press to enter or exit Setup mode.
Enter: if cursor is in menu box, press Enter
key to view menu. Press Enter to save a
value either keyed in from the numerical
keypad or selected from a menu.
Keypad
Used to input numerical data, enter setup screens, scroll
through screens, and select setup values.
Up Arrow: move to previous field or menu
item, or to previous screen within a group.
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.
Down Arrow: move to next field or menu
item, or to next screen within a group.
Left Arrow: move to previous screen group.
Right Arrow: move to next screen group.
Alarm Reset: resets alarms.
20
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EasyKey Display and Keyboard
ACPower
Switch
Fiber Optic Strain
Relief Port
Audible Alarm
Main Power
Access Port
Ground Screw
I/S Power
Graco Web
Interface
Discrete I/O Cable
Connector Ports
TI12638a
TI12657a
FIG. 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
➜ View software version
➜ Download
I/S Power
Power circuit to Fluid Station.
• Job and alarm logs
• Material usage report
• Setup values (can also upload)
➜ Clear job, alarm, and material usage reports
➜ Upload a custom language to view on
screen
Potlife Exceeded Audible Alarm
Alerts the user when a Potlife Exceeded alarm occurs.
➜ Restore factory defaults
➜ Restore setup password
Clear by pressing the Alarm Reset
key.
See manual 313386 for more information.
NOTE: 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.
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Run Mode Screens
Run Mode Screens
NOTE: See FIG. 11 for a map of the Run screens.
Detailed screen descriptions follow.
.
Splash Screen
At power up, the Graco logo and software revision will
display for approximately 5 seconds, followed by the
FIG. 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.
FIG. 10. Fluid Plate Programming Screen
22
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Run Mode Screens
Press the Setup
key to
enter Setup mode.
TI12802a
FIG. 11. Run Screens Map
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Run Mode Screens
6
7
Status Screen
Target Flow Rate and Current Flow Rate: in
cc/min.
•
Use the Up
or Down
keys to scroll through the
Run screens.
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.
•
•
Press the Setup
key to enter the Setup screens
from the Status screen.
8
9
Current Date and Time
The other keys have no function in this Status
screen.
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.
1
2
3
11
8
10
7
9
10
11
Current Flow Control Data: fluid output pressure
and voltage of analog signal used for driving the
fluid regulator V/P.
6
4
Lock Symbol: indicates that Setup screens are
5
FIG. 12. Status Screen
Key to FIG. 12:
1
Active Recipe: shows the active recipe.
NOTE: At power up the system defaults to Recipe
61, which is not a valid recipe number.
2
3
4
Target Ratio: for the active recipe. The ratio can be
from 0.0:1–50.0:1, in 0.1 increments.
Actual Ratio: in hundredths, calculated after each
dose of A and B.
Potlife Timer: 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
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Run Mode Screens
Flow Rate Range
Manual Override Screen
This screen displays the flow rate range selected on
Flow Set Point
The Flow Set Point is user settable. If Flow Control
Override is set to “Off” or “Pressure” in Advanced
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% and increase as
necessary to reach the desired flow rate.
FIG. 13. Manual Override Screen
This screen will appear if Manual Override is set to “On”
active recipe, new/go to recipe, and manual override
mode.
Flow Control Calibration
This field allows you to calibrate flow control for each
recipe. The system must be in Mix mode and receiving a
Flow Set Point, Flow Control Calibration (Start/Abort),
and Global Flow Control Data Copy (Start/Abort).
Gun Trigger signal. Press the Enter
menu, then select Start or Abort. See FIG. 15.
key to view the
The flow rate will drop to 0, then incrementally increase
until it reaches the maximum flow rate. To view the
tem will populate the data for the current recipe. To copy
this data to all recipes, see Global Flow Control Data
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 FIG. 14.
FIG. 15. Flow Control Calibration
FIG. 14. Manual Override Menu
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Run Mode Screens
Global Flow Control Data Copy
Reset Total Screen
This field allows you to copy flow control data from the
active recipe to all recipes. Press the Enter
key to
view the menu, then select Start or Abort. See FIG. 16.
FIG. 18. Reset Total Screen
If job is reset, job number will increment by one for
default.
FIG. 16. Global FC Data Copy
Reset Solvent Screen
Totals Screen
FIG. 19. Reset Solvent Total Screen
FIG. 17. Totals Screen
The screen will ask if you want to reset solvent total.
Select Yes or No.
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
Solvent Totals and the Rst Solvent tab only appear if
“Meter” is selected under Solvent Monitor in Configure
NOTE: Grand totals are not resettable.
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Run Mode Screens
threshold, the EasyKey screen will display the Tank
Level Low alarm and prompt the user to do one of the
following:
Alarms Screen
1. Refill tank volume to clear the alarm.
2. Resume mixing by selecting “Spray 25% of Remain-
der.” 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.
FIG. 20. Alarms Screen
Two screens show the last 10 alarms. Use the Up
or
Down
keys to scroll between the two screens.
See Table 16 on page 115 for a list of alarm codes.
FIG. 22. Tank Level Low Screen (Tank A Shown)
Level Control Screen
FIG. 21. Level Control Screen
This screen shows the current volume for each fluid.
Adjust the current volumes on this screen, or use the tab
Level values may be adjusted using the advanced web
interface.
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Setup Mode
Setup Mode
NOTE: See FIG. 23 for a map of the Setup screens.
Detailed screen descriptions follow.
Press the Setup
key to enter Setup mode.
Press the Setup
key to
enter Setup mode.
This screen appears only if a
password is activated.
To access System Configuration
Press the Setup
key to exit
Setup mode and return to the Status
screen.
This screen appears momentarily
if a password is activated.
TI12803a
FIG. 23. Setup Screens Map
28
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Setup Mode
Password Screen
Set Up Home Screen
If a password has been activated (see Configure
You must enter the password to access the Set Up
Home Screen. Entering the wrong password returns the
NOTE: If you forget the password, you can reset the
password (to 0), using the ProMix Web Interface (see
manual 313386).
FIG. 26. Set Up Home Screen
This screen displays when you enter Setup mode. From
selected screen set.
key to go to the
The screen also displays software versions and internet
addresses of various components. The values shown in
See Table 3 for further information.
FIG. 24. Password Screen
NOTE: If a password is activated, Setup Locked dis-
plays momentarily after exiting Setup mode and return-
symbol appears
FIG. 25. Setup Locked Screen
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Setup Mode
Table 3: Component Software Versions
Display(mayvary
from examples
Component
shown)
Description
EK (EasyKey)
2.00.012
2.00.012
-.-
EasyKey software version.
Fluid Plate software version.
FP (Fluid Plate)
BC (Booth Control)
Booth Control not installed, not detected, or not oper-
ational.
1.XX
2.XX
Booth Control software version 1.00 or 1.01.
Booth Control software version 2.XX.
C1/C2 (Color Change -.-
Modules 1 and 2)
Color Change Module 1/2 not installed, not detected,
or not operational.
1.XX
Color Change Module software version 1.00 or 1.01.
Color Change Module software version 2.XX.
2.XX
AK (Autokey)
2K-Manual
No AutoKey installed or detected. System operates in
2K Manual Mode only
2K-Auto
3K-Auto
V6.6.0.2
2K AutoKey detected. System can operate in 2K Man-
ual, Semi-automatic, or Automatic Mode.
3K AutoKey detected. System can operate in 3K Man-
ual, Semi-automatic, or Automatic Mode.
XP (XPORT)
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)
MAC (MAC address)
192.168.178.5
00204AAD1810
Example of the address EasyKey is set to for basic
and advanced web interface reporting.
Example of internet MAC address. Each EasyKey will
have a different value in this format.
30
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Setup Mode
System Configuration Screens
tion Screens. Detailed screen descriptions follow.
NOTE: Each screen displays the current screen number
and the total number of screens in the group.
TI12804a
FIG. 27. System Configuration and Option Screens Map
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Setup Mode
Configure Screen 1
Configure Screen 2
FIG. 29. Configure Screen 2
FIG. 28. Configure Screen 1
Language
Month
Enter current month.
Defines the language of the screen text. Select English
(default), Spanish, French, German, Italian, Dutch, Jap-
anese (Kanji), Korean, and Chinese (Simplified).
Day
Enter current day.
Password
Year
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.
Enter current year (four digits).
Time
Enter current time in hours (24 hour clock) and minutes.
Seconds are not adjustable.
NOTE: Be sure to write down the password and keep it
in a secure location.
Date Format
Display Units
Select mm/dd/yy or dd/mm/yy.
Select the desired display units:
•
•
cc/liter (default)
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
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Setup Mode
Configure Screen 3
Configure Screen 4
FIG. 31. Configure Screen 4
Dose Size
FIG. 30. Configure Screen 3
Run Mode
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.
Select the Run mode application from the pulldown
menu: Automatic (default), Semi-Automatic (uses a
manual spray gun), or Manual.
Example:
NOTE: ProControl 1KS is also available as a selection.
For further information, see ProControl 1KS operation
manual 3A1080.
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.
Dump Valve A
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.
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.
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Setup Mode
DD Setup Mode
Configure Screen 5
Dynamic Dosing Setup mode field appear. Select On to
enable DD setup mode, or Off to disable. See page 86
for further information.
FIG. 34. Configure Screen 5
Flow Control
FIG. 32. Configure Screen 4, dynamic dosing
selected
This field only appears if Run Mode is set to “Automatic”
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
FIG. 33. Configure Screen 4, dynamic dosing setup
mode enabled
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.
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
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
Enter the number of gun flush boxes (Off, 1, or 2).
34
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Setup Mode
Configure Screen 6
FIG. 35. Configure Screen 6 (Automatic mode shown)
Flow Control
This field only appears if Run Mode is set to “Automatic”
crete” or “Network.”
Proportioning
Select “Discrete” or “Network.”
Gun 1 Trigger
Select “Discrete” or “Network” if Run Mode is set to
added as a selection if Run Mode is set to “Semi-auto-
Gun 2 Trigger
Displays AFS if Number of Guns is set to “2” in Config-
Control Network ID
Used for the Graco Gateway network system. See
Graco Gateway manual 312785 for further information
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Setup Mode
Verification Screen
Option Screens
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
FIG. 37. Verification Screen
Verification
This screen appears if Flush and Fill Input or K-factor
Input are changed from “Recipe” to “Global” in Option
FIG. 36. Option Screen 1
Flush Volume Check
This field only appears if Solvent Monitor is set to
If set to “On”, Minimum Flush Volume will appear in
Flush and Fill Input
If set to “Global”, Color/Catalyst Purge and Color/Cata-
If set to “Recipe”, Color/Catalyst Purge and Color/Cata-
K-factor Input
is added.
added.
Minimum Material Fill Volume
Enter 0-9999 cc.
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Setup Mode
Option Screen 2
FIG. 38. Option Screen 2
External Color Change
If set to “Off”, Color/Catalyst Purge Time and Color/Cat-
ing on whether Flush and Fill Inputs are set to “Global”
or “Recipe”).
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 alarm 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
added, enabling setting of high and low flow limits.
If set to “Off,” flow rate monitoring is disabled and Rec-
Solvent Push Enable
To enable the Solvent Push feature, select “Solvent” or
“3rd Valve” (available if 3rd Flush Valve in Configure
To disable the Solvent Push feature, set to “Off.”
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Setup Mode
Advanced Setup Screens
Advanced Setup screens 2, 3,
4, and 8 appear depending on
selections made in Option
screens 1 and 2. Screen 5
appears if Flow Control is set
to “On” in Configure screen 5.
TI12805a
FIG. 39. Advanced Setup Screens Map
38
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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
Manual Override
This field only appears if Run Mode is set to “Automatic”
Set to “On” to override all outside control. If selected, the
the Flow Control Override field appears (see above).
Advanced Setup Screen 1
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
1/4
5.43
9.648
21.71
FIG. 40. Advanced Setup Screen 1
Flow Control Override
3/8
Integrator manifold and mixer volume = 75 cc
Spray Gun Volume = 20 cc
This field only appears if Flow Control is set to “On” in
is set to “On” (see below). The selections made will
25. Choose the desired selection as defined below:
(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
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.
Selection
Description
Off
Normal operation
% Open
Flow control regulator is opened to a
desired percentage.
Pressure
Flow control regulator is opened to a
calibrated pressure.
Color/Catalyst Fill
This field only appears if the system includes a color
change module and Flush and Fill Input is set to
(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.
FIG. 41. Flow Control Override Menu
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Setup Mode
Advanced Setup Screen 2
Advanced Setup Screen 3
FIG. 42. Advanced Setup Screen 2
FIG. 43. Advanced Setup Screen 3
This screen appears only if Flush and Fill Input is set to
This screen appears only if Flush and Fill Input is set to
First Purge Source
Select “Air,” “Solvent,” or “3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
First Purge Time
Chop Type
Enter the first purge time (0 to 999 seconds).
Select “Air/Solvent” or “Air/3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
ing air and solvent (or air and 3rd flush fluid) together
during the flush cycle, to help clean the lines and reduce
solvent usage.
Total Chop Time
Enter the total chop time (0 to 999 seconds).
Final Purge Time
Enter the final purge time (0 to 999 seconds).
Final Purge Source
Mixed Material Fill Time
Select “Air,” “Solvent,” or “3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
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.
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
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Setup Mode
Advanced Setup Screen 4
Advanced Setup Screen 5
FIG. 45. Advanced Setup Screen 5 (Automatic Mode
with Flow Control Only)
FIG. 44. Advanced Setup Screen 4
This screen appears only if K-factor Input is set to
This screen appears only if Flow Control is set to “On” in
K-factor A Meter
Flow Rate Range
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).
Enter the flow rate range (0-300, 0-600, or 0-1200). This
determines the flow control PID loop resolution.
Flow Rate Tolerance
K-factor B Meter
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.
Enter the k-factor (cc/pulse) for flow meter B.
K-factor Solvent Meter
Flow Rate Ki
This field only appears if Solvent Monitor in Configure
(cc/pulse) for the solvent flow meter.
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).
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Setup Mode
Advanced Setup Screen 6
Advanced Setup Screen 8
FIG. 46. Advanced Setup Screen 6
FIG. 48. Advanced Setup Screen 8
This screen shows the status of recipe analog inputs
and digital outputs. If box is shaded the input recipe is
active.
This screen appears only if Flush and Fill Input is set to
34. The I/O board has four programmable outputs.
Advanced Setup Screen 7
FIG. 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
puts.
42
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Setup Mode
Recipe Setup Screens
NOTE: See FIG. 49 for a map of the Recipe screens. Detailed screen descriptions follow.
Recipe 0 Screens
Recipe screens 3, 4, 5, 6,
and 7 appear depending on
selections made in Option
screens 1 and 2
TI12806a
FIG. 49: Recipe Screens Map
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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
Recipe Setup Screen 2
Recipe Setup Screen 1
FIG. 51. Recipe Setup Screen 2
Minimum Flush Volume
This field only appears if Flush Volume Check is set to
mum flush volume (0 to 999 cc). Entering 0 disables this
function.
FIG. 50. Recipe Setup Screen 1
Ratio
Potlife Time
Enter the potlife time (0 to 999 minutes). Entering 0 dis-
ables this function.
Enter the mix ratio of component A over component B
(0.0:1 to 50:1).
Color/Catalyst Purge
This field only appears if the system includes a color
change module and Flush and Fill Input is set to “Rec-
(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.
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)
Color/Catalyst Fill
This field only appears if the system includes a color
change module. Enter the color valve number (1 to 30).
This field only appears if the system includes a color
change module and Flush and Fill Input is set to “Rec-
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.
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
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Setup Mode
Recipe Setup Screen 3
Recipe Setup Screen 4
FIG. 53. Recipe Setup Screen 4
FIG. 52. Recipe Setup Screen 3
This screen appears only if Flush and Fill Input is set to
This screen appears only if Flush and Fill Input is set to
First Purge Source
Select “Air,” “Solvent,” or “3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
First Purge Time
Enter the first purge time (0 to 999 seconds).
Chop Type
Total Chop Time
Select “Air/Solvent” or “Air/3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
ing air and solvent (or air and 3rd flush fluid) together
during the flush cycle, to help clean the lines and reduce
solvent usage.
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
Final Purge Source
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.
Select “Air,” “Solvent,” or “3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
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).
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Setup Mode
Recipe Setup Screen 5
Recipe Setup Screen 6
FIG. 55. Recipe Setup Screen 6
FIG. 54. Recipe Setup Screen 5
This screen appears only if Flow Rate Monitor is set to
This screen appears only if K-factor Input is set to “Rec-
Flow Rate Monitor
K-factor A Meter
Select the desired flow rate monitoring (Off, Warning, or
Alarm).
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).
Low Flow Limit
K-factor B Meter
Enter the low flow rate limit (1 to 3999 cc/min).
Enter the k-factor (cc/pulse) for flow meter B.
High Flow Limit
K-factor Solvent Meter
Enter the high flow rate limit (1 to 3999 cc/min).
This field only appears if Solvent Monitor is set to
k-factor (cc/pulse) for the solvent flow meter.
Recipe Setup Screen 7
FIG. 56. Recipe Screen 7
This screen appears only if Flush and Fill Input is set to
34. The I/O board has four programmable outputs.
46
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Setup Mode
Recipe 0 Screens
NOTE: See FIG. 49 on page 43 for a map of the Recipe
Final Purge Source
0 screens. Detailed screen descriptions follow.
Select “Air,” “Solvent,” or “3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
Recipe 0 is typically used:
•
in multiple color systems to purge out material lines
without loading a new color
Air Chop Time
•
at the end of a shift to prevent hardening of cata-
lyzed material.
Enter the air chop time (0.0 to 99.9 seconds).
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
Solvent Chop Time/3rd Flush Valve Chop Time
Enter the solvent or 3rd flush valve chop time (0.0 to
99.9 seconds).
Recipe 0 Screen 2
Recipe 0 Screen 1
FIG. 58. Recipe 0 Screen 2
FIG. 57. Recipe 0 Screen 1
First Purge Source
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).
Select “Air,” “Solvent,” or “3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
First Purge Time
Chop Type
Enter the first purge time (0 to 999 seconds).
Select “Air/Solvent” or “Air/3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
ing air and solvent (or air and 3rd flush fluid) together
during the flush cycle, to help clean the lines and reduce
solvent usage.
Total Chop Time
Enter the total chop time (0 to 999 seconds).
Final Purge Time
Enter the final purge time (0 to 999 seconds).
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Setup Mode
Recipe 0 Screen 3
Recipe 0 Screen 4
FIG. 60. Recipe 0 Screen 4
FIG. 59. Recipe 0 Screen 3
This screen appears only if Flush and Fill Input is set to
34. The I/O board has four programmable outputs.
This screen only appears if Solvent Monitor is set to
Minimum Flush Volume
This field only appears if Flush Volume Check is set to
mum flush volume (0 to 999 cc).
Exiting Fill Source
This field only appears if 3rd Flush Valve is set to “On” in
“Solvent,” or “3rd Valve.”
Exiting Fill Time
This field only appears if Exiting Fill Source is set to
“Air,” “Solvent,” or “3rd Valve.” Enter the time in sec-
onds.
48
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Setup Mode
Calibration Screen
FIG. 61. Calibration Screen
Use this screen to calibrate a meter. Set to “Meter A,”
“Meter B,” or “Solvent Meter” (available if Solvent Moni-
•
•
•
Start - start calibration
Abort - stop calibration
Purge - purge sampling valves after calibration
calibrate meter.
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Setup Mode
50
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ProMix 2KS Integration Specifics
ProMix 2KS Integration Specifics
Discrete I/O vs Network
Communications
The ProMix 2KS Automatic system does not use a
Booth Control. Instead, it uses Discrete I/O or Network
Communications to drive the system. Each method can
be used exclusively, or both at the same time.
Discrete I/O
Discrete I/O requires a 24 Vdc power supply which must
be supplied on site. The ProMix 2KS does not supply
power for Discrete I/O.
these inputs and outputs is necessary to properly inte-
grate the ProMix 2KS to the automation.
In Automatic mode, the following fields can be set to
Input and output connections are made at the Discrete
I/O terminal strips (FIG. 63) and the discrete I/O board
•
•
•
Flow Control
Proportioning
Gun 1 Trigger
full understanding of the color change sequence is nec-
essary to properly drive the inputs and monitor the out-
puts.
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 I/O 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.
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 I/O
function in detail.
Display Board
Barrier Board
Terminal Strips
(see FIG. 63)
TI12496a
FIG. 62: EasyKey Control Boards
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ProMix 2KS Integration Specifics
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.
Digital Inputs
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.
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.
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.
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.
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 leave Idle mode and resume mixing mate-
rial where it left off.
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-
tion of each input and output.
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.
I/O Terminal Strip Detail
Color Change Start: This is a momentary input, 100
msec minimum. When recognized by the ProMix 2KS,
the Color Change sequence will begin, starting at the
Color/Catalyst Dump.
Pin 1
RS485 Integration A
RS485 Integration B
RS485 Integration Ground
RS485 Network A
RS485 Network B
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.
RS485 Network Ground
Pin 1
Flow Control Calibrate
Gun Trigger
Digital Common
Remote Stop
Alarm Reset
INPUTS
General Alarm
OUTPUTS
Digital Common
Potlife Alarm
Flow Rate Analog In
Flow Rate Analog Common
TI12958a
FIG. 63: EasyKey Terminal Strips
NOTE: This also applies if using the Modbus Registers
(see the Modbus Map table in manual 312785).
52
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ProMix 2KS Integration Specifics
JLS
Digital Output Common/Power
Flow Rate Alarm Output
Flow Control Calibrate Active
Fill Active
Mix Ready Output
Mix Active Output
Purge/Recipe Change Active Output
Digital Output Common/Power
Recipe Change Input
Recipe Bit 5 Input
Recipe Bit 4 Input
Recipe Bit 3 Input
Recipe Bit 2 Input
Recipe Bit 1 Input
Recipe Bit 0 Input
Digital Input Common
FIG. 64: 255766 Discrete I/O Board
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ProMix 2KS Integration Specifics
Digital Outputs
Analog Inputs
Flow Command: This is the positive side of the 0 – 10
52.) This input corresponds to the Flow Range setting in
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.
Purge_CC_Active: This output will remain High during
the manual Purge or Color Change purge sequence.
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.
Table 4: Sourcing/Sinking Inputs and Outputs
Inputs (Automation Sourcing)
Mix_Active: This output will remain High while the Pro-
Mix 2KS is in Mix mode. There may be alarm outputs
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 2KS. (See the Modbus charts in the Graco
Gateway manual 312785.)
1
2
3
4
5
Flow Control Calibration
Gun Trigger
Black
White
Red
+
+
-
Digital In Common
Remote Stop
Green
Brown
+
+
Alarm Reset
Mix_Ready: This output will remain High while there are
no alarms and the ProMix 2KS is ready to go to Mix
mode.
Outputs (Automation Sourcing)
6
7
8
Alarm Output
Blue
+
-
Digital Out Common
Pot Life
Orange
Yellow
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.
+
Outputs (Automation Sinking)
6
7
8
Alarm Output
Blue
-
+
-
NOTE: It is important to monitor this output along with
Mix_Active to understand the alarm’s true meaning.
+24 Volts
Pot Life
Orange
Yellow
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.
Automation
9
Flow Rate Analog In
Purple
Gray
+
-
10
Flow Rate Analog Common
NOTE: The Alarm Reset
key will also reset the
audible alarm.
To dispense the potlife volume, the ProMix 2KS
Mix_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
54
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ProMix 2KS Integration Specifics
Automation Flow Charts
Start Mix Mode Process
Start Mix
Mode Process
NO
YES
Is Mix Ready
bit = 1?
Must be Alarm Condi-
tion or Active Recipe
61. See Alarm Pro-
or Startup from Rec-
ipe 61 (see NOTE
Set Mix bit = 1
NO
Is Mix Active
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
valid recipe number (1-60).
YES
ProMix 2KS in Mix
Mode (Complete)
Mix Active = 1 while
the ProMix 2KS is in
Mix mode
FIG. 65. Start Mix Mode Process Flow Chart
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ProMix 2KS Integration Specifics
Mixing Mode Process
Mixing Mode
Process
Mixing Mode is desired.
PLC is polling to ensure
Mixing Mode is main-
tained.
NO
YES
Is Mix Active
bit = 1?
Mixing Process active
NO
Check Alarm
Condition: is Alarm_
General bit = 1?
Go to Start Mix Mode
YES
Go to Alarm Process-
FIG. 66. Mixing Mode Process Flow Chart
56
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ProMix 2KS Integration Specifics
Purge Mode Process
Start
NO
YES
Is Mix Ready
bit = 1?
Must be Alarm
Condition or Active
Recipe 61. See
Set Purge bit = 1?
Startup from Recipe
61 (see NOTE below).
NO
YES
Is Purge_CC_Active
bit = 1?
ProMix 2KS in
Purge_CC Mode
(Process Started)
NO
(Wait for Mix Ready)
Is Mix Ready
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
valid recipe number (1-60).
ProMix 2KS Purge
Process (Complete)
YES
FIG. 67. Purge Mode Process Flow Chart
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ProMix 2KS Integration Specifics
Color Change Mode Process
ColorChange
Process
(basic)
Do nothing.
Spraying at
desired recipe.
YES
NO
Is Active Recipe =
to desired recipe?
(Register 40005).
Load ccNewRecipe
(Register 40046) with
recipe number to Color
Change to (0 through
60 is valid).
Is
NO
Ensure Color-
Change bit is seen
by ProMix 2KS
Set ColorChange (CC)
bit = 1.
Purge_CC_Active
bit = 1?
YES
Clear ColorChange (CC)
bit (momentary input).
CC process started.
(Wait for Mix Ready)
NO
Is Mix Ready
bit = 1?
YES
ProMix 2KS Color
Change Process
(Complete)
Check Alarm
Condition: is Alarm_
General bit = 1?
NO
YES
Process Alarm. See
page 59.
FIG. 68. Color Change Mode Process Flow Chart
58
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ProMix 2KS Integration Specifics
Alarm Processing
Alarm Processing
An Alarm Condition
has been found
previously.
Alarm_General = 1.
Check if Potlife
Alarm: is Alarm_
Potlife bit = 1?
NO
YES
Two options:
Determine the exact alarm
from Table 7 on page 62
and solve what caused the
alarm, as required.
• Purge or Color Change to remove
mixed material in the line.
• 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.
Reset the alarm.
Reset_Alarm = 1.
NO
YES
Go to next process,
as desired.
Is Mix Ready
bit = 1?
FIG. 69. Alarm Processing Flow Chart
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ProMix 2KS Integration Specifics
Table 5: ProMix 2KS Digital Inputs (Modbus Register 40040)
Bit
Digital Input Binary
Name
Details
0:5
6
0 0 0 0 0 0 0 0 0 0 X X X X X X Recipe
Binary bits for viewing discrete inputs only.
0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 Color Change Set bit to “1” to initiate Color Change (momentary)
(CC)
7
8
9
0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 Mix
0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 Purge
Set bit initiate Mix mode (maintain)
Set bit to “1” to initiate Purge sequence (maintained)
0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 Job_Complete Set bit to “1” to initiate Job Complete input (momen-
tary)
10
0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 External CC
Ready
Set bit to “1” to initiate External Color Change
(momentary)
11
12
0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 Not Used
0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 FC _Calibrate Set bit to “1” to initiate a Flow Control Calibrate input
(momentary)
13
0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 Gun_Trigger
Set bit to “1” to indicate the gun is actually triggered
(maintain while gun is triggered, remove when gun is
closed)
14
15
0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Reset_Alarm Set bit to “1” to clear an active Alarm (momentary)
1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Remote Stop Set bit to remotely stop unit (momentary)
60
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ProMix 2KS Integration Specifics
Table 6: ProMix 2KS Digital Outputs (Modbus Register 40041)
Digital Input Binary Name Details
Bit
0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 Purge_CC_Active “1” indicates Purge or Color Change is in prog-
ress
1
2
3
0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 Mix_Active
0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 Mix_Ready
0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 CC_Fill_Active
“1” indicates Mix is in progress
“1” indicates No Alarms and OK to Mix
“1” indicates the Fill portion of a Color Change is
in progress
4
5
6
7
8
9
0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 FCalActive
“1” indicates the Flow Control Calibrate routine is
in progress
0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 Flow_Rate_Alarm “1” indicates the Flow Rate Alarm/Warning is
active
0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 Special_1
0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 Special_2
0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 Special_3
0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 Special_4
“1” indicates the Special_1 output is on (monitor
only)
“1” indicates the Special_2 output is on (monitor
only)
“1” indicates the Special_3 output is on (monitor
only)
“1” indicates the Special_4 output is on (monitor
only)
10
11
12
0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 Not Used
0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 Not Used
0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 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.
13
0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 Alarm_Potlife
“1” indicates a Potlife Alarm is in process.
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ProMix 2KS Integration Specifics
Table 7: ProMix 2KS Active Alarms (Modbus Register 40010)
Bit
Digital Input Binary
Name
Details
Low Byte: 0
Low Byte: 0
Low Byte: 0
Low Byte: 0
Low Byte: 0
Low Byte: 0
Low Byte: 0
Low Byte: 0
Low Byte: 0
Low Byte: 0
Low Byte: 0
Low Byte: 0
Low Byte: 0
Low Byte: 0
Low Byte: 0
Low Byte: 0
Low Byte: 0
High Byte: 0
High Byte: 0
High Byte: 0
High Byte: 0
High Byte: 0
High Byte: 0
High Byte: 0
High Byte: 0
High Byte: 0
High Byte: 0
High Byte: 0
High Byte: 0
High Byte: 0
High Byte: 0
High Byte: 0
High Byte: 0
0000 0000 0000 0000
0000 0000 0000 0001
0000 0000 0000 0010
0000 0000 0000 0100
0000 0000 0000 1000
0000 0000 0001 0000
0000 0000 0010 0000
0000 0000 0100 0000
0000 0000 1000 0000
0000 0001 0000 0000
0000 0010 0000 0000
0000 0100 0000 0000
0000 1000 0000 0000
0001 0000 0000 0000
0010 0000 0000 0000
0100 0000 0000 0000
1000 0000 0000 0000
0000 0000 0000 0001
0000 0000 0000 0010
0000 0000 0000 0100
0000 0000 0000 1000
0000 0000 0001 0000
0000 0000 0010 0000
0000 0000 0100 0000
0000 0000 1000 0000
0000 0001 0000 0000
0000 0010 0000 0000
0000 0100 0000 0000
0000 1000 0000 0000
0001 0000 0000 0000
0010 0000 0000 0000
0100 0000 0000 0000
1000 0000 0000 0000
No Bits Set
No Active Alarms
Comm_Error
Potlife_Alarm
Ratio_High_Alarm
Ratio_Low_Alarm
Overdose_A_Alarm
Overdose_B_Alarm
Dose_Time_A_Alarm
Dose_Time_B_Alarm
Mix_In_Setup_Alarm
Remote_Stop_Alarm
Purge_Volume_Alarm
CAN_Comm_Error_Alarm
High_Flow_Alarm
Low_Flow_Alarm
System_Idle_Alarm
Setup_Change_Alarm
Power_On_Alarm
Defaults_Loaded_Alarm
IO_Alarm
Purge_Initiate_Error
Material_Fill_Alarm
Tank_A_Low_Alarm
Tank_B_Low_Alarm
Tank_S_Low_Alarm
Auto_Dump_Complete
Color/Catalyst_Purge_Alarm
Color/Catalyst_Fill_Alarm
Num_Alarm_Desc
Spare3_Alarm
Spare2_Alarm
Spare1_Alarm
Potlife_Buzzer
62
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ProMix 2KS Integration Specifics
ProMix 2KS EasyKey
Digital Input
PLC Output
(Sourcing)
Input
Common
Output
Input
Common
24
Vdc
ProMix 2KS EasyKey
Digital Output
PLC Input
(Sinking)
24
Vdc
Output
Common
Input
Output
Common
ProMix 2KS EasyKey
Digital Output
PLC Input
(Sourcing)
Output
Common
Input
Output
Common
24
Vdc
FIG. 70. Automation 24 Vdc Sourcing Input Diagram
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ProMix 2KS Integration Specifics
Table 8: Discrete I/O Terminal Connections
Terminal Terminal Location
Name
Digital Inputs
1
2
J2, Remote I/O Board Mix
Set Bit to Initiate Mix Mode (maintain)
J2, Remote I/O Board Purge
Set Bit to “1” to initiate Purge Sequence
(maintained)
3
4
J2, Remote I/O Board Job_Complete
Set Bit to “1” to initiate Job Complete Input
(momentary)
J2, Remote I/O Board External CC Ready
Set Bit to “1” to initiate External Color
Change (maintained)
5
J2, Remote I/O Board Spare
6*
J2, Remote I/O Board Digital Input Common
1*
2
J3, Remote I/O Board Digital Input Common
J3, Remote I/O Board Recipe Bit 0
Set Binary Bits for Recipe to Change To (hold
until changing again)
3
4
5
6
7
8
J3, Remote I/O Board Recipe Bit 1
J3, Remote I/O Board Recipe Bit 2
J3, Remote I/O Board Recipe Bit 3
J3, Remote I/O Board Recipe Bit 4
J3, Remote I/O Board Recipe Bit 5
J3, Remote I/O Board Color Change (CC)
Set Binary Bits for Recipe to Change To (hold
until changing again)
Set Binary Bits for Recipe to Change To (hold
until changing again)
Set Binary Bits for Recipe to Change To (hold
until changing again)
Set Binary Bits for Recipe to Change To (hold
until changing again)
Set Binary Bits for Recipe to Change To (hold
until changing again)
Set Bit to “1” to initiate Color Change
(momentary)
1
2
10 Pin Terminal Block Flow Control Calibrate
10 Pin Terminal Block Gun Trigger
Set Bit to “1” to initiate Flow Control Calibrate
(momentary)
Set Bit to “1” to indicate Gun is Triggered
(fluid flow expected)
3†
4
10 Pin Terminal Block Digital Input Common
10 Pin Terminal Block Remote Stop
Set Bit to “1” to initiate a Remote Stop
(momentary)
5
10 Pin Terminal Block Reset_Alarm
Set Bit to “1” to Clear an Active Alarm
(momentary)
*
† Digital inputs tied together on the EasyKey Display Board.
Multiple connection points for convenience.
64
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ProMix 2KS Integration Specifics
Table 8: Discrete I/O Terminal Connections
Name Details (also see pages 60 and 61)
Terminal Terminal Location
Digital Outputs
1★
J4, Remote I/O Board Digital Output Common/Power
J4, Remote I/O Board Purge_CC Active
2
“1” Indicates Purge or Color Change is in
progress
3
4
5
J4, Remote I/O Board Mix_Active
J4, Remote I/O Board Mix_Ready
J4, Remote I/O Board CC_Fill_Active
“1” Indicates Mix is in progress
“1” Indicates No Alarms and OK to Mix
“1” Indicates the Fill Portion of a Color
Change is in progress
6
J4, Remote I/O Board FCalActive
“1” Indicates the Flow Control Calibrate rou-
tine is in progress
7
J4, Remote I/O Board Flow_Rate
“1” Indicates the Flow Rate Alarm/Warning is
active
8★
J4, Remote I/O Board Digital Output Common/Power
1★
2
J5, Remote I/O Board Digital Output Common/Power
J5, Remote I/O Board Special_1
“1” Indicates the Special_1 Output is on
“1” Indicates the Special_2 Output is on
“1” Indicates the Special_3 Output is on
“1” Indicates the Special_4 Output is on
3
J5, Remote I/O Board Special_2
4
J5, Remote I/O Board Special_3
5
J5, Remote I/O Board Special_4
6★
J5, Remote I/O Board Digital Output Common/Power
6
10 Pin Terminal Block General Alarm Output
10 Pin Terminal Block Digital Output Common/Power
10 Pin Terminal Block Potlife Alarm
“1” Indicates the General Alarm Output is on
“1” Indicates the Potlife Alarm Output is on
7◆
8
9
10 Pin Terminal Block Flow Rate Analog In (0-10
VDC)
0 - 10VDC input for Flow Setpoint relative to
flow range set in 2KS Flow Range Screen
10
10 Pin Terminal Block Flow Rate Common to Pin 9
Common side of Flow Setpoint from Terminal
9
Communications
1
2
3
6 Pin Terminal Block
6 Pin Terminal Block
6 Pin Terminal Block
RS485 Integration A
RS485 Integration B
Communication to External PLC/Controller
RS485 Integration
Shield/Ground
4
5
6
6 Pin Terminal Block
6 Pin Terminal Block
6 Pin Terminal Block
RS485 Network A
RS485 Network B
Communication to Multiple EasyKeys only
RS485 Network Shield/Ground
◆ Digital outputs tied together on the EasyKey Display Board.
Multiple connection points for convenience.
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ProMix 2KS Integration Specifics
Table 9: ProMix 2KS Recipe Bits
Number Recipe Bits
Recipe Bits
Number
5
4
3
2
1
0
5
4
3
2
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
0
1
2
3
4
5
6
7
8
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1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
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Integrated Flow Control
Integrated Flow Control
Flow Control Description
Air-operated
Fluid Pressure
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.
Fluid Regulator
Gauge Port
Fluid Pressure
Sensor
1/8 npt(f)
Fluid Inlet
1/8 npt(f)
Fluid Outlet
Power and
Signal
Cable Input
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.
Air Inlet Fitting,
1/4 in. (6 mm) OD
Tube
Flow Control Components
Circuit Board
V/P (Voltage/Air
Pressure) Valve
249849 Flow Control Module
TI17116a
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.
FIG. 71. Cutaway of 249849 Flow Control Module
Remote Fluid
Air Outlet Fitting,
Pressure
Sensor
1/4 in. (6 mm) OD Tube
24H989 Flow Control Module
Air Pressure
Gauge
(not included)
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.
Power and
Signal
Cable Input
Circuit Board
(hidden)
V/P (Voltage/Air
Pressure) Valve
Air Inlet Fitting,
1/4 in. (6 mm) OD
Tube
TI18956a
FIG. 72. Cutaway of 24H989 Flow Control Module
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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
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.
Flow Control Operation
24H989. The Flow Control System includes two infor-
mation loops:
•
•
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.
The flow loop monitors fluid flow through flow
meter pulses, ensuring accuracy. The gun must be
triggered during the flow loop.
Required air pressure to the flow control module is
70-100 psi (0.35-0.7 MPa, 3.5-7.0 bar).
NOTE:
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.
•
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.
•
If flow 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
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Integrated Flow Control
Flow Input:
Feedback from
Meters A and B
Air-operated
Fluid Regulator
Mixed Material Line
Meter B
Fluid Pressure Sensor
Fluid Control
Board
Meter A
Air Signal to
Regulator
Analog Signal to V/P
Air Line
V/P (Voltage/Air
Pressure) Valve
Pressure Input: Feedback from Fluid Pressure Sensor
TI17118a
FIG. 73. ProMix 2KS Flow Control Schematic Diagram (249849 Module)
Air-operated Remote
Fluid Regulator
Mixed Material Line
Flow Input: Feedback from
Meters A and B
Meter B
Fluid
Control
Board
Fluid Pressure
Sensor
Air Signal to
Regulator
Meter A
Pressure Input:
Analog Signal to V/P
Feedback from
Fluid Pressure
Sensor
Air Line
V/P (Voltage/Air
Pressure) Valve
TI18958a
FIG. 74. ProMix 2KS Flow Control Schematic Diagram (24H989 Module)
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Integrated Flow Control
Flow Control Operating Process Example
Operating Ranges
Step 2: Pressure Loop
Flow Control operating ranges correlate the desired flow
rate to the incoming flow set point signal (see below).
The operating ranges are:
NOTE: The gun must be triggered during the pressure
loop.
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.
•
•
•
•
0-300 cc/min
0-600 cc/min
0-1200 cc/min
0-100% (% 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 3: Flow Loop
NOTE: The gun must be triggered during the flow loop.
Step 1: Flow Set Point Input Signal
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.
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 (5Vdc sig-
nal) from the PLC or robot.
Step 2 and Step 3 repeat continuously to maintain pres-
sure and flow.
Network Communication Input
A network communication signal is either the desired
flow rate (150 cc/min in this example) or the % open.
70
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Integrated Flow Control
Step 3: Flow Input
Fluid Pressure
Sensor
Step 1:
ProMix 2KS receives
a flow rate setpoint
from PLC/robot
Analog Signal to V/P
Air Line
V/P (Voltage/Air
Pressure) Valve
Step 2: Pressure Input
TI17118a
FIG. 75. ProMix 2KS Flow Control Pressure Loop and Flow Loop (249849 Module)
Step 3: Flow Input
Step 1:
ProMix 2KS
receives a
flow rate
Fluid Pressure
Sensor
setpoint from
PLC/robot
Air Line to
Remote
Fluid
Regulator
Analog Signal to V/P
Step 2: Pressure Input
Air Line
V/P (Voltage/Air
Pressure) Valve
TI18958a
FIG. 76. ProMix 2KS Flow Control Pressure Loop and Flow Loop (24H989 Module)
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Integrated Flow Control
Flow Control Setup
Flow Control Startup
1. Install the intrinsically safe flow regulator (FC) as
explained in the ProMix 2KS Installation Manual.
2. Ensure that the analog signal is 0-10 Vdc, or is
properly provided through network communication.
This ensures that the K-factors are tuned to the
range of materials being used.
4. Verify that the I/O inputs are working properly. If
using discrete I/O, check by viewing Advanced
the commands are being sent by viewing the Status
inputs.
FIG. 77. Configure Screen 5
ride On. The Flow Control Override field will appear.
NOTE: See the Graco Gateway manual for Flow Control
Modbus addresses.
FIG. 78. Advanced Setup Screen 1
72
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Integrated Flow Control
Flow Set Point field will display as a percentage
tor to a percentage open that starts fluid flow. Fluid
pressure should be above 12 psi (.08 MPa, 0.84
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.
FIG. 79. Flow Control Override Menu
6. When an acceptable operating range is achieved,
turn Flow Control Override Off.
Table 10: Flow Control Override Selections
Selection
Description
Off
Normal operation
% Open
Flow control regulator is opened to a
desired percentage.
Pressure
Flow control regulator is opened to a
calibrated pressure.
NOTE: Set the Flow Control Override to “Pressure” to
FIG. 81. Advanced Setup Screen 1
FIG. 80. Flow Set Point as a Percentage
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Integrated Flow Control
Flow Control Calibration
Flow Control Calibration is an automatic routine that
establishes a pressure vs flow profile between low and
unique to each recipe or may be globally copied to all
recipes.
Turn Manual Override On.
.
NOTE: Calibration cannot be done in recipe 0 or 61.
1. Load a color.
Select the flow rate range that best covers the larg-
est flow target for your application (for example,
0-1200).
FIG. 83. Advanced Setup Screen 1
Set Manual Override to Mix, and set Flow Ctrl Cali-
bration to Start.
FIG. 82. Advanced Setup Screen 5 (Automatic Mode
with Flow Control Only)
FIG. 84. Manual Override Screen
74
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Integrated Flow Control
tus bar at the bottom of the screen will indicate that
Mix Calibration is in progress.
will change from Mix Calibration to Mix. The unit
should have built a complete table for the flow rate
NOTE: If the voltage reached 3.3 V (flow control wide
open) but the unit did not reach the top of the selected
flow rate range, the delivery system is not providing
enough volume. Do one of the following:
7
•
•
If the volume is acceptable, change the flow rate
range accordingly.
If the volume is not acceptable, increase the deliv-
ery pressure. Increasing the pressure may affect
your low flow rate setting.
Mix Calibration
9. De-trigger the gun.
FIG. 85. Status Screen
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
each recipe, and continuous learning will create a
unique data table when the recipe is run.
start at 0 and increase incrementally to 3.3 V. The
flow rate will also begin to increase during calibra-
tion, but this may not show for the first few voltage
increases.
NOTE: If you want to do a flow calibration for each rec-
30
(0.21, 2.1)
25
(0.17, 1.7)
20
(0.14, 1.4)
15
(0.10, 1.0)
10
(.07, 0.7)
5
(.035, 0.35)
0
0
50
100
150 200
250 300
350
Flow (cc/min)
FIG. 86. Typical Flow Calibration (0-300 cc/min range)
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Integrated Flow Control
Global FC Data Copy
Setting Ki and Kp
Set Global FC Data Copy to Start on the Manual Over-
ing point for all recipes, enabling Continuous Learning
and Kp.
•
•
The default value for Ki is 40.
The default value for Kp is 400.
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.
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
FIG. 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).
FIG. 88. Advanced Setup Screen 5 (Automatic Mode
with Flow Control Only)
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
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Integrated Flow Control
This mode may be used with a ProMix 2KS connected
both to a robot with flow control and to a manual gun.
Because there are two flow paths, the meters cannot be
used to close the flow loop. Therefore the robot can run
a calibration by itself. When calibration is complete, set
to “Pressure.” The robot will run in open loop mode, and
the manual gun can spray at the same time.
Pressure Flow Control Mode
When the Flow Control Override is set to “Pressure”, the
system will only drive to the pressure associated with
the flow rate request of the saved calibration table. It will
not close the loop with the flow meters.
Kp refers to the speed at which fluid flow reaches its set point.
Kp
Target Flow Rate
Ki refers to the degree fluid flow over shoots its set point.
Ki
TI17119a
NOTE: Ki and Kp are dependent on each other. If one changes the other must change.
FIG. 89. Kp/Ki Graph
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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.
b. For module 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
2. Set the system to Manual Override, % Open mode;
3. Set the % Open value to 50. See FIG. 90.
Set % Open
value to 50
50
FIG. 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 decrease.
78
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Integrated Flow Control
Result of the Test
Cause
Solution
1. Clear any clogs.
Gauge reading increases and
decreases as % Open value is
changed and fluid flow does not
change or is not present.
The problem is mechanical:
•
•
•
restriction/plugged hose
plugged gun tip
2. Remove restrictions.
3. Clean and/or repair fluid regula-
tor.
fluid regulator failure
Gauge reading does not increase
and decrease as % Open value is
changed.
The problem is electrical:
1. Measure the voltage to the regu-
lator at one of two places:
•
•
•
•
•
Fuse F2 is blown
•
At J5 on the fluid control
disconnected wires or cables
pressure control failure
V/P valve failure
board, measure across the
white (pin 1) and black (pin 6)
wire connections. The volt-
age should be in the range of
0-3.3 Vdc for 0%-100% Open
command (approximately
1.65 Vdc for 50% Open).
flow control board failure
•
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 50% Open).
2. If voltage is not present, check if
fuse F2 on the fluid control board
is blown.
3. If voltage is present, ensure the
cable is properly connected to
the module circuit board.
4. If cable is properly connected,
replace pressure control, VP
valve, and flow control board
sequentially to isolate failure. See
manual 3A2097.
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System Operation
System Operation
Operation Modes
Mix
System mixes and dispenses material (apply Mix input).
Standby
Stops the system (remove Mix input).
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
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
80
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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
Typical PLC Interaction with
ProMix 2KS
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 not 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.
This section describes a typical interaction when a local
PLC is directly connected to the Discrete I/O connec-
tions of the ProMix 2KS.
a detailed explanation of inputs and outputs.
Start Mixing
NOTE: It is not possible to read the active recipe
through Discrete I/O 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.
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 High the
Mix_Start input, keep it High and monitor the Mix_Active
output to ensure the ProMix 2KS followed through on
the request.
Purge
Stop Mixing
To start a Purge (no color change), drive the
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 Mix_Active output goes Low.
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.
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 (>100 msec).
NOTE: No change is made to the active recipe.
Gun Trigger Input
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.
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.
The Alarm Reset Input will silence the audible alarm.
Turn the Color_Change_Start input on momentarily
(>100 msec) while the proper sequence of recipe bits
are set.
IMPORTANT: This input must be provided through Dis-
crete I/O 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 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.
NOTE: The Gun Trigger input has the same effect as
the air flow switch used on manual ProMix 2KS sys-
tems.
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System Operation
For Applications with Dump Valves (for quick
purges/color changes at or near the gun):
Alarm Monitoring/Reset (Discrete I/O)
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:
ProMix 2KS has four specials that can each be turned
off and on twice throughout a color change sequence.
•
Potlife Alarms cannot be reset by the Alarm Reset
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.
input or through the EasyKey Alarm Reset
key. Only a Purge/Color Change or spraying the
Potlife volume will reset a Potlife alarm. (See
Alarm_Potlife output information on page 54.)
NOTE: With integrated Flow Control, the flow control
regulator automatically is driven High. See Advanced
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.
•
When Flow Control is turned on (see Configure
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 Alarm 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.
The following ProMix 2KS inputs should never be on
(High) at the same time:
•
•
•
Mix_Start
Purge_Start
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.
•
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 are
accumulated since the last reset.)
NOTE: A Color Change accomplishes the same Job
Complete Reset functions. The Job_Complete input is
commonly used to record material usage for a specific
set of parts. These volumes are sprayed material vol-
umes.
82
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System Operation
d. Dose Valve B (DVB) opens, and fluid flows into
the integrator and is aligned proportionately with
component A.
General Operating Cycle,
Sequential Dosing
1. The system enters and loads the desired color.
e. Flow Meter B (MB) monitors the fluid volume
dispensed and sends electrical pulses to the
ProMix 2KS controller.
2. The system enters Mix mode to begin operation.
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 integrator,
then uniformly blended in the static mixer (SM).
4. Components A and B are introduced into the fluid
integrator (FI) one at a time as follows.
NOTE: To control output from the static mixer to the
gun, install an optional fluid pressure regulator.
a. Dose Valve A (DVA) opens, and fluid flows into
the integrator.
6. Components A and B are alternately fed into the
integrator as long as the Gun Trigger input is seen.
b. Flow Meter A (MA) monitors the fluid volume
dispensed and sends electrical pulses to the
ProMix 2KS controller. The controller monitors
these pulses and signals.
7. If the Gun Trigger input is not seen for two minutes,
the system switches to Idle mode, which closes off
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
Dose 2
Ratio = 2.0:1
A = 2
Dose 1
Dose 3
B = 1
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System Operation
DVA
FI DVB
MB
MS
MA
RVB
AT
APV
TI12556b
RVA
SVA
SM
SVB
SPV
Key:
MA Component A Meter
DVA Component A Dose Valve
RVA Component A Sampling Valve
SVA Component A Shutoff Valve
MB Component B Meter
SVB Component B Shutoff Valve
MS Solvent Meter (accessory)
SPV Solvent Purge Valve
APV Air Purge Valve
SM Static Mixer
DVB Component B Dose Valve
RVB Component B Sampling Valve
FI
AT
Fluid Integrator
Air Purge Valve Air Supply Tube
FIG. 91. Wall Mount Fluid Station, Sequential Dosing
84
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System Operation
General Operating Cycle, Dynamic Dosing
Overview
Dynamic Dosing System Parameters
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.
The following parameters affect dynamic dosing perfor-
mance:
•
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.
A restrictor injects component B into a continuous
stream of component A. The software controls the dura-
schematic diagram of the process.
•
•
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.
•
Component B Pressure: Ensure precise pressure
regulation. It is recommended that the component B
pressure be 5-15% higher than the component A
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.
ToStatic
Component A (continuous flow)
Proportioned Material
Mixer
Component B (pulsed injection)
FIG. 92. Schematic Diagram of Dynamic Dosing Operation
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System Operation
3. Selecting “DD” in System Configure Screen 4
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.
Select a Component B Restrictor Size
Install the 15U955 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.
NOTE: Do not use the material mixed when in DD setup
mode, as it may not be on ratio due to the disabled
alarms.
Turn On Dynamic Dosing
1. On the EasyKey press the Setup
key to access
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.
the Set Up Home screen. Select “System Configu-
FIG. 93. Set Up Home Screen
FIG. 95. Configure Screen 4, dynamic dosing setup
mode enabled
2. Navigate to System Configure Screen 4. Select
“DD” option from the “Dose Size” drop down menu.
FIG. 94. Configure Screen 4, dynamic dosing
selected
86
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System Operation
Balancing A/B Pressure
e
g
n
a
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.
R
l
B Pressure
Too Low
o
r
t
n
o
C
B Pressure
Too High
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.
A Pressure
B Pressure
FIG. 97. A/B Control Range with Properly Sized
Restrictor
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 range, 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.
e
)
g
l
l
n
a
m
a
R
l
o
o
r
o
t
t
n
(
o
C
s
B Pressure
Too Low
B Pressure
Too High
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.
A Pressure
B Pressure
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.
NOTE: If the restrictor is too small, it may be
necessary to supply more differential pressure
than is available in your system.
FIG. 98. A/B Control Range with Too Large a
Restrictor
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.
FIG. 96. B Pressure Too Low, displayed on EasyKey
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System Operation
Table 12: Dynamic Dosing Troubleshooting Guide
Warning/Alarm Message
Solution
Increase B pressure.
Clean restrictor or use a larger size.
Verify B valve is opening properly.
•
•
•
B Pressure Too High
Off Ratio Low
•
•
Increase A pressure or decrease B pressure.
Use a smaller restrictor.
•
•
Increase A pressure or decrease B pressure.
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.
E
TI11581a
FIG. 99. Valve Adjustment
Table 13: Mix Manifold Valve Settings
Function
Valve
Setting
Dose (see
FIG. 99)
Hex nut (E) 1-1/4 turns out
from fully closed
Limits maximum fluid flow rate into integrator
and minimizes valve response time.
Purge (see
FIG. 99)
Hex nut (E) 1-1/4 turns out
from fully closed
Limits maximum fluid flow rate into integrator
and minimizes valve response time.
Shutoff (SVA Fully open during Run/Mix
Closes component A and B ports to integrator
during ratio check or meter calibration. Open
ports during Run/Mix operation.
and SVB,
operation
Sampling
(RVA and
RVB, see
Fully closed during Run/Mix
operation
Open to dispense component A and B while
calibrating meters. Do not open sampling
valves unless fluid shutoff valves are closed.
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System Operation
➜ Graco logo, software revision, and “Establishing
Communication” will display, followed by Status
Start Up
1. Go through the Pre-Operation Checklist in Table 14.
➜ 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).
Table 14: Pre-Operation Checklist
✓
Checklist
➜ In bottom left corner, the system status dis-
plays, which can be Standby, Mix, Purge, or an
alarm notification.
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.
FIG. 101. Status Screen
Mix manifold valves set
Check that mix manifold valves are set correctly.
Start with the settings recommended in Mix Mani-
needed.
3. Verify that the EasyKey is working. The active rec-
ipe number and Standby mode should be displayed.
4. If this is the first time starting up the system, purge it
oil, which should be flushed out to avoid contaminat-
ing your material.
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
5. Make sure that the EasyKey is in Standby (remove
Mix input).
75-100 psi inlet air supply (0.5-0.7 MPa, 5.2-7 bar)
6. Adjust component A and B fluid supplies
as needed for your application. Use low-
est pressure possible.
2. Turn the AC Power Switch ON (I = ON, 0 = OFF).
7. Do not exceed the maximum rated work-
ing pressure shown on the system identification
label or the lowest rated component in the system.
I = ON
8. Open the fluid supply valves to the
system.
9. Adjust the air pressure. Most appli-
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).
TI12656a
FIG. 100. Power Switch
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System Operation
10. Purge air from the fluid lines.
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.
a. Shut off air to the gun by clos-
ing the air regulator or shutoff
valve for the gun atomizing air.
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.
b. Trigger the gun (man-
ual or automatic) into
a grounded metal pail.
Manual
gun shown
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.
c. Go to Mix mode.
d. If the flow meters over-run because of air in the
system, an alarm will occur and operation stops.
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.
Press the Alarm Reset
alarm.
key to clear
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.
e. Go to Mix mode.
11. Adjust the flow rate.
12. Turn on atomizing air to the gun. Check the spray
pattern as instructed in your spray gun manual.
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.
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.
FIG. 102. Status Screen Flow Rate Display
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System Operation
Shutdown
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.
Overnight Shutdown
1. Leave the power on.
2. Run Recipe 0 to purge solvent through meters and
gun.
Service Shutdown
Relieve pressure when you stop spraying, before
changing spray tips, and before cleaning, checking, or
servicing equipment.
2. Close main air shutoff valve on air supply line and
on ProMix 2KS.
Single Color Systems
3. Shut off ProMix 2KS power (0 position). FIG. 103.
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.
4. If servicing EasyKey, also shut off power at main cir-
cuit breaker.
2. With the gun triggered, push the manual override on
the A and B dose valve solenoids to relieve pres-
sure. See FIG. 104.
NOTE: If a Dose Time alarm (E-7, E-8) occurs,
clear the alarm.
0 = OFF
3. Do a complete system purge, following the instruc-
4. Shut off the fluid supply to the solvent purge valve
(SPV) and the air supply to the air purge valve
(APV), FIG. 106.
TI12657a
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 0.
FIG. 103. Power Switch
NOTE: If a Purge Volume alarm (E-11) occurs, clear
the alarm.
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System Operation
Systems with Color Change and without
Dump Valves
Systems with Color/Catalyst Change and
Dump Valves
NOTE: This procedure relieves pressure through the
NOTE: This procedure relieves pressure through the
sampling valve.
dump valves.
page 91.
2. Close the A side shutoff valve (SVA), FIG. 106.
Open the A side sampling valve (RVA).
2. Shut off all color and catalyst supplies to the valve
stacks.
3. Direct the A side sampling tube into a waste con-
tainer.
3. Press and hold the dump valve A solenoid override,
FIG. 104.
4. See FIG. 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.
4. See FIG. 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 solvent solenoid override until
clean solvent comes from the sampling valve, then
release.
5. Press and hold the dump valve B solenoid override,
FIG. 104.
6. See FIG. 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.
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.
7. Press and hold the dump valve A solenoid override,
FIG. 104.
8. Open the A side shutoff valve (SVA), FIG. 106.
Close the A side sampling valve (RVA).
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.
92
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System Operation
RoboMix Fluid Station
Dose Valve B
Override Button
Dose Valve A
Override Button
TI12655a
Wall Mount Fluid Station
Power
F2
F1
J1
Fiber
Optic
CAN
J13
CAN
J12
J3
1
Dose A
Dose B
Valve Overrides
J9
1
1
1
J14
J15
J8
Dump Valve A
Dump Valve B
Optional Solenoid
Locations
GFB 1
GFB 2
3rd Purge Valve
Solenoid
Dose Valve A
Solenoid
Dose Valve B
Solenoid
Purge Valve A
Solenoid
Purge Valve B
Solenoid
TI12652b
FIG. 104. Fluid Solenoids
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System Operation
Solenoid
Identification
Label
Solenoid
Identification
Label
TI12826a
Solvent Solenoid
Overrides
FIG. 105: Color Change Solenoids
Key:
DVA
FI
DVB
MA Component A Meter
DVA Component A
Dose Valve
MB
RVA Component A
Sampling Valve
SVA Component A
Shutoff Valve
MS
MA
MB Component B Meter
DVB Component B
Dose Valve
RVB
RVB Component B
Sampling Valve
SVB Component B
Shutoff Valve
MS Solvent Meter
(accessory)
AT
SPV Solvent Purge Valve
APV Air Purge Valve
SM Static Mixer
TI12556b
FI
AT
Fluid Integrator
Air Purge Valve Air
Supply Tube
RVA
APV
SVA
SM
SVB
SPV
FIG. 106. Wall Mount Fluid Station
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System Operation
2. Set the solvent supply pressure regulator at a pres-
sure high enough to completely purge the system in
a reasonable amount of time but low enough to
avoid splashing or an injection injury. Generally, a
setting of 100 psi (0.7 MPa, 7 bar) is sufficient.
Purging
3. 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.
instructions in your system Installation manual.
To avoid splashing fluid in the eyes, wear eye protec-
tion.
If the gun flush box is not used, trig-
ger the gun (manual or automatic)
into a grounded metal pail until the
purge sequence is complete.
There are 4 purging procedures in this manual:
•
•
•
•
Purging Mixed Material (below)
When done purging, the EasyKey automatically
switches to Standby mode.
NOTE: If necessary, adjust purge sequence so only
one cycle is required.
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:
Trigger the gun to relieve pressure. Engage trigger
lock.
•
•
•
•
end of potlife
breaks in spraying that exceed the potlife
overnight shutdown
before servicing the fluid manifold assembly, hose
or gun.
5. If spray tip was removed, reinstall it.
6. Adjust the solvent supply regulator back to its nor-
mal operating pressure.
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. Go to 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.
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System Operation
Purging Using Recipe 0
Purging Fluid Supply System
Recipe 0 is typically used:
Follow this procedure before:
•
in multiple color systems to purge out material lines
without loading a new color
at the end of a shift to prevent hardening of cata-
lyzed material.
•
•
•
the first time material is loaded into equipment*
servicing
shutting down equipment for an extended period of
time
•
•
putting equipment into storage
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.
*
Some steps are not necessary for initial flush-
ing, as no material has been loaded into the
system yet.
1. Go to Standby mode (remove Mix input).
1. Go to Standby mode (remove Mix input).
Trigger the gun to relieve pressure.
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 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.
If using an electrostatic gun shut off the electrostatics
before flushing the gun.
2. Attach solvent supply lines as follows:
2. If using a gun flush box, place the gun into the box
and close the lid.
•
•
•
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.
3. Select Recipe 0 and press Enter
.
4. If a gun flush box is not used, trigger
the gun (manual or automatic) into a
grounded metal pail until the purge
sequence is complete.
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.
5. The color change LED blinks while Recipe 0 runs
and turns solid after purge sequence is complete.
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.
6. If the system is not completely clean, you can
repeat Recipe 0 by pressing Enter
.
96
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System Operation
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:
•
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.
•
Multiple color/single catalyst systems:
Select Recipe 0 and press Enter
to purge
the component A side. The color change LED
blinks while Recipe 0 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.
•
Multiple color/multiple catalyst systems:
Select Recipe 0 and press Enter
to 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. Shut off the solvent fluid supply.
8. Disconnect the solvent supply lines and reconnect
the component A and B fluid supplies.
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System Operation
7. To avoid splashing, slowly open the sampling
valves and dispense solvent until the valves and
tubes are clean.
Purging Sampling Valves and Tubes
Follow this procedure after meter calibration.
1. Go to Standby mode (remove Mix input).
NOTE: When performing a calibration purge, the
solvent valve(s) close automatically after 2 minutes
or when Abort is selected on the screen.
2. See FIG. 106, page 94. Close both fluid shutoff
valves and sampling valves.
8. Close sampling valves.
3. Route the sampling tubes into a grounded waste
container.
NOTE: Select Abort on Calibration screen to cancel
current calibration and close dose or purge valves.
4. On a single color system, attach a solvent supply
line to Flow Meter A inlet.
9. Fully open both fluid shutoff valves.
10. On a single color system, reconnect component A
5. On the EasyKey, press Setup
the Advanced Setup screens.
key and access
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.
6. Press the Right Arrow
tion screen. Press the Down Arrow
select Purge from the menu. Press the Enter
key to select the Calibra-
key and
key
.
Dose A, solvent purge valve (B side), and color
change solvent valves (if used) will open.
FIG. 107. Calibration Screen
98
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System Operation
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
there are 2 guns, the smaller potlife volume is used.
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
Solvent Push requires an accessory solvent meter (MS).
Order Graco Part No. 280555 S3000 Solvent Meter Kit.
See manual 308778.
Standby
3rd purge valve will close. To re-enter Solvent Push,
press the Mix key.
key. The Solvent Purge Valve (SPV) or
1. See FIG. 108. Install the solvent meter (MS) on the
side of the fluid station, as explained in the ProMix
2KS Installation Manual.
5. When the total solvent dispensed exceeds 50% of
the potlife volume, the system will go into Standby
2. To enable Solvent Push, select “Solvent” or “3rd
mode.
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.
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.
3. Press and hold the Mix
key for 5 seconds
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).
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
DVB is closed
DVA Component A Dose Valve
DVB Component B Dose Valve
MS Solvent Meter (required)
SPV Solvent Purge Valve
APV Air Purge Valve
MS
SMC Solvent Meter Cable
SS Solvent Supply Line
SMC
TI12556b
SS
SPV is open
FIG. 108. Solvent Push Setup
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Meter Calibration
Meter Calibration
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 4 mm
OD tubing.
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.
5. On the EasyKey, press the Setup
setup screens.
key to access
6. Select Recipe & Advanced Setup and press the
Enter key to select.
Calibrate the meter:
•
The first time the system is operated.
•
Whenever new materials are used in the system,
especially if the materials have viscosities that differ
significantly.
•
•
At least once per month as part of regular mainte-
nance.
Whenever a flow meter is serviced or replaced.
NOTE:
•
updated automatically after the calibration pro-
cedure is completed.
7. Press the Right Arrow
key to select the Cali-
key to select
bration Screen. Press the Enter
either Dose Valve A or B. Press the Down Arrow
key and select Start from the menu. Start only one
at a time.
•
K-factor values on the screen are viewable only.
If needed, you can manually edit the K-factors
•
•
All values on this screen are in cc, independent
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.)
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Meter Calibration
8. Dispense component A or B into beaker.
12. After the volume for A, B, or Solvent is entered, the
ProMix 2KS controller calculates the new flow meter
NOTE: K-factor values on the screen are viewable
only. If needed, you can manually edit the K-factors
a. To avoid splashing, slowly open sampling
valves.
13. Always purge sampling valves after calibrating
meters. Use one of the following methods.
b. For more accurate calibration, adjust the valve
to dispense at a flow rate similar to your produc-
tion spray flow rate.
•
Follow the Purging Sampling Valves and
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.
•
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 5/32 in. or 4 mm OD tubing.
d. Close sampling valve tightly.
14. Make sure both sampling valves are closed and
both fluid shutoff valves are fully open.
9. The volume that the ProMix measured displays on
the EasyKey.
15. Before you begin production, clear the system of
solvent and prime it with material.
10. Compare the amounts on the EasyKey to the
amount in the beakers.
a. Go to Mix mode.
NOTE: For maximum accuracy, use a gravimetric
(mass) method to determine the actual volumes dis-
pensed.
b. Trigger the gun into a grounded metal pail until
mixed material flows from the gun nozzle.
11. 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
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.
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Color Change
Color Change
Color Change Procedures
Color Change Sequences
reference, based on the recipe change and system con-
figuration. The time sequences are detailed in the fol-
lowing paragraphs.
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.
NOTE: For software version 2.04.xxx and older, the sys-
tem uses the color/catalyst purge and fill times from the
new recipe.
3. Go to Standby mode (remove Mix input).
4. Select the new recipe. Begin the color change
sequence.
sources and set desired purge, chop, and fill times.
5. If a gun flush box is not used, trigger
the gun (manual or automatic) into a
grounded metal pail until the color
change sequence is complete.
NOTES:
•
The system uses old recipe data for the purge cycle.
However, it opens the new color/catalyst valve
based on the new recipe data.
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 minutes, the color
change operation aborts. The system enters
•
•
The system uses the new recipe data for the fill
cycle.
For the one gun flush box (GFB) option, the spray
gun must be inserted in the GFB during the entire
color change cycle (purge and fill). The GFB trigger
output will be on during the recipe change cycle.
Standby
mode (remove Mix input) at the previ-
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).
•
For the two gun flush box (GFB) 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.
NOTE: The gun flush box door must be closed for
the atomizing air valve to open.
•
•
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.
7. Enter Mix
mode to start spraying.
Single Color Systems
For systems without dump valves, the First Purge
begins after the Color/Catalyst Change steps are
completed.
•
•
•
Dump Valve B is required for a Catalyst Change
system.
3. Enter Mix
mode to start spraying.
When going from Recipe X to Recipe 0, only the
purge cycle data from Recipe 0 is used.
When going from Recipe 0 to Recipe X, only the fill
cycle data from Recipe X is used.
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Color Change
Color Purge/Dump
First Purge
Step M0-M1
Step P0-P1
Select the First Purge Source (air, solvent, or 3rd valve)
and First Purge Time. For most applications, air is
selected.
•
•
•
This sequence flushes out the color with solvent,
from the color valve to the Dump A valve.
The color change solvent valve and the Dump A
valve open during the Purge Time.
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.
The color change solvent valve closes when the
Purge Time expires.
Chop Cycle
Step M1-M2
Color Fill
Step P1-P2
Select the Chop Type (air/solvent or air/3rd valve) and
Chop Times.
•
•
•
This sequence fills the line with the new color all the
way to the Dump A valve.
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.
The new color valve and the Dump A valve open
during the Fill Time.
The new color valve and the Dump A valve close
when the Fill Time expires.
Final Purge
Step M2-M3
Catalyst Purge/Dump
Step P2-P3
Select the Final Purge Source (air, solvent, or 3rd valve)
and Final Purge Time. For most applications, solvent is
selected.
•
•
•
This sequence flushes out the catalyst with solvent,
from the catalyst valve to the Dump B valve.
The catalyst change solvent valve and the Dump B
valve open during the Purge Time.
The system fills the line with solvent from the dose
valves to the gun, using only the selected purge media
(usually solvent). The selected purge valve opens dur-
ing the Final Purge Time and closes when the time
expires.
The catalyst change solvent valve closes when the
Purge Time expires.
Catalyst Fill
Step P3-P4
Fill
Step M3-M4
•
•
•
This sequence fills the line with the new catalyst all
the way to the Dump B valve.
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.
The new catalyst valve and the Dump B valve open
during the Fill Time.
Purge Active
Step M0-M3
The new catalyst valve and the Dump B valve close
when the Fill Time expires.
The system turns on the Purge/Recipe Change Purge
Active output during steps M0-M3.
Fill Active
Step M3-M4
The system turns on the Recipe Change Fill Active out-
put during step M3-M4.
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Color Change
Table 15: Color Change Chart Reference
Number of
Gun Flush
Boxes
Starting
Recipe
Ending
Recipe
Color
Change
Catalyst
Change
Dump
Valves
3rd Purge
Valve
Refer to Fig.
X
X
X
X
X
X
X
X
X
X
X
0
Yes
Yes
Yes
Yes
No
Yes
Yes
No
Yes
Yes
No
Yes
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
Yes
Yes
Yes
Yes
Yes
0
FIG. 110
FIG. 112
FIG. 114
FIG. 116
FIG. 118*
FIG. 118*
FIG. 120**
FIG. 118*
FIG. 120**
FIG. 118*
FIG. 118*
FIG. 120**
FIG. 118*
FIG. 120**
FIG. 118*
FIG. 126
FIG. 126
X
0
X
0
X
No
Yes
Yes
No
0, 1, or 2
0, 1, or 2
0, 1, or 2
1
X
Yes
No
X
No
X
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
No
Yes
No
X
1
X
Yes
No
Yes
No
2
X
2
X
Yes
No
Yes
Yes
No
0, 1, or 2
0, 1, or 2
0, 1, or 2
0, 1, or 2
0, 1, or 2
0, 1, or 2
0, 1, or 2
0, 1, or 2
0, 1, or 2
0, 1, or 2
0, 1, or 2
0, 1, or 2
0, 1, or 2
0, 1, or 2
0, 1, or 2
0, 1, or 2
0, 1, or 2
0, 1, or 2
0, 1, or 2
0, 1, or 2
0, 1, or 2
X
0
X
0
No
X
0
Yes
No
Yes
No
X
0
No
0 or 61
X
X
X
X
X
0
Yes
Yes
Yes
No
Yes
No
Yes
Yes
No
0 or 61
0 or 61
No
0 or 61
Yes
No
Yes
No
0 or 61
No
0
0
Yes
Yes
Yes
No
Yes
No
Yes
Yes
No
0
0
0
No
0
0
Yes
No
Yes
No
0
0
No
61
0
0
Yes or No
Yes
Yes
Yes
No
Yes or No
Yes
No
Yes or No
Yes
Yes
No
X
X
X
X
X
0
0
No
0
Yes
No
Yes
No
0
No
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.
** FIG. 120 and FIG. 121 show color change. If the color is not changing, disregard that portion of the chart.
FIG. 122 (page 111) shows a recipe change with Special Outputs.
FIG. 124 (page 112) shows an External Color Change.
104
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Color Change
ProMix 2KS Recipe Change
Chart 1: A1 to A2, B1 to B2 with Dump Valves
Valve
Time-Sequence
Dump A
Dump B
A
B
Color Change Solvent
Catalyst Change Solvent
Color Change A
Catalyst Change B
A
A
B
B
P0
P1
P2
P3
P4
Color Purge Time P0->P1
Color Fill Time P1->P2
Catalyst Purge Time P2->P3
Catalyst Fill Time P3->P4
CC Purge/Fill Timers are independent
of Mixed Material Purge Timers. This
line defines when the Mixed Fill Time
begins. The longer of the two timers
defines when the Mixed Fill Time
begins.
Air Chop Time
Solvent Chop Time
First Purge (one of these)
3rd Flush Chop Time
Air Purge
Solvent Purge
3rd Flush Valve
Final Purge (one of these)
Dispense A
Dispense B
A
A
B
B
Gun Trigger(s) by Operator
M0
M1
M2
M3
M4
First Purge Time M0->M1
Chop Time (air/solvent or air/3rd flush) M1->M2
Final Purge Time M2->M3
Mixed Fill Time M3->M4
Notes:
Load tables from new recipe
Purge from old recipe
Fill from new recipe
FIG. 109: Color Change Chart 1
ProMix 2KS Recipe Change
Chart 2: A1 to A2, B1 to B2 with Dump Valves and 3rd Flush Valve
Valve
Time-Sequence
Dump A
Dump B
A
B
Color Change Solvent
Catalyst Change Solvent
Color Change A
A
A
B
Catalyst Change B
B
P0
P1
P2
P3
P4
Color Purge Time P0->P1
Color Fill Time P1->P2
Catalyst Purge Time P2->P3
Catalyst Fill Time P3->P4
CC Purge/Fill Timers are independent
of Mixed Material Purge Timers. This
line defines when the Mixed Fill Time
begins. The longer of the two timers
defines when the Mixed Fill Time
begins.
Air Chop Time
Solvent Chop Time
3rd Flush Chop Time
First Purge (one of these)
Air Purge
Solvent Purge
3rd Flush Valve
Final Purge (one of these)
*Two Second Solvent Purge
Dispense A
Dispense B
A
A
B
B
Gun Trigger(s) by Operator
M0
M1
M2
M3
M4
M5
*Two Second Initial Purge Time M0->M1
First Purge Time M1->M2
Chop Time (air/solvent or air/3rd flush) M2->M3
Final Purge Time M3->M4
Mixed Fill Time M4->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
FIG. 110: Color Change Chart 2
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Color Change
ProMix 2KS Recipe Change
Chart 3: A1 to A2, same B with Dump Valves
Valve
Time-Sequence
Dump A
Dump B
A
Color Change Solvent
Catalyst Change Solvent
Color Change A
Catalyst Change B
A
A
B
P0
P1
P2
P3
P4
Color Purge Time P0->P1
Color Fill Time P1->P2
CC Purge/Fill Timers are independent
of Mixed Material Purge Timers. This
line defines when the Mixed Fill Time
begins. The longer of the two timers
defines when the Mixed Fill Time
begins.
Air Chop Time
Solvent Chop Time
3rd Flush Chop Time
First Purge (one of these)
Air Purge
Solvent Purge
3rd Flush Valve
Final Purge (one of these)
Dispense A
Dispense B
A
A
B
B
Gun Trigger(s) by Operator
M0
M1
M2
M3
M4
First Purge Time M0->M1
Chop Time (air/solvent or air/3rd flush) M1->M2
Final Purge Time M2->M3
Mixed Fill Time M3->M4
Notes:
Load tables from new recipe
Purge from old recipe
Fill from new recipe
FIG. 111: Color Change Chart 3
ProMix 2KS Recipe Change
Chart 4: A1-A2, same B without Dump Valves
Valve
Time-Sequence
Dump A
Dump B
Color Change Solvent
Catalyst Change Solvent
Color Change A
A
A
B
Catalyst Change B
Air Chop Time
Solvent Chop Time
3rd Flush Chop Time
First Purge (one of these)
Air Purge
Solvent Purge
3rd Flush Valve
Final Purge (one of these)
Dispense A
Dispense B
A
A
A
B
B
Gun Trigger(s) by Operator
0
1
2
3
4
5
6
Color Purge Time 0->1
Color Fill Time 1->2
First Purge Time 2->3
Chop Time (air/solvent or air/3rd flush) 3->4
Final Purge Time 4->5
Mixed Fill Time 5->6
Notes:
Load tables from new recipe
Purge from old recipe
Fill from new recipe
FIG. 112: Color Change Chart 4
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Color Change
ProMix 2KS Recipe Change
Chart 5: B1 to B2, same A with Dump Valves
Valve
Time-Sequence
Dump A
Dump B
B
Color Change Solvent
Catalyst Change Solvent
Color Change A
Catalyst Change B
A
B
B
P0
P1
P2
P3
P4
Catalyst Purge Time P0->P1
Catalyst Fill Time P1->P2
CC Purge/Fill Timers are independent
of Mixed Material Purge Timers. This
line defines when the Mixed Fill Time
begins. The longer of the two timers
defines when the Mixed Fill Time
begins.
Air Chop Time
Solvent Chop Time
3rd Flush Chop Time
First Purge (one of these)
Air Purge
Solvent Purge
3rd Flush Valve
Final Purge (one of these)
Dispense A
Dispense B
A
A
B
B
Gun Trigger(s) by Operator
M0
M1
M2
M3
M4
First Purge Time M0->M1
Chop Time (air/solvent or air/3rd flush) M1->M2
Final Purge Time M2->M3
Mixed Fill Time M3->M4
Notes:
Load tables from new recipe
Purge from old recipe
Fill from new recipe
FIG. 113: Color Change Chart 5
ProMix 2KS Recipe Change
Chart 6: A1 to A2, B1 to B2 with Dump Valves, 2 GFBs
Valve
Time-Sequence
Dump A
Dump B
A
B
Color Change Solvent
Catalyst Change Solvent
Color Change A
A
A
B
Catalyst Change B
B
P0
P1
P2
P3
P4
Color Purge Time P0->P1
Color Fill Time P1->P2
Catalyst Purge Time P2->P3
Catalyst Fill Time P3->P4
CC Purge/Fill Timers are independent
of System Purge Timers. This line
defines when the System Fill Time
begins. The longer of the two timers
defines when the System Fill Time
begins.
Air Chop Time
Solvent Chop Time
First Purge (one of these)
3rd Flush Chop Time
Air Purge
Solvent Purge
3rd Flush Valve
Final Purge (one of these)
Dispense A
Dispense B
A
A
B
B
Gun Flush Box Output #1
Gun Flush Box Output #2
M0
M1
M2
M3
M4
First Purge Time M0->M1
Chop Time (air/solvent or air/3rd flush) M1->M2
Final Purge Time M2->M3
Mixed Fill Time M3->M4
Notes:
Load tables from new recipe
Purge from old recipe
Fill from new recipe
FIG. 114: Color Change Chart 6
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Color Change
ProMix 2KS Recipe Change
Chart 7: A1 to A2, B1 to B2 with Dump Valves, 1 GFB
Valve
Time-Sequence
Dump A
Dump B
A
B
Color Change Solvent
Catalyst Change Solvent
Color Change A
Catalyst Change B
A
A
B
B
P0
P1
P2
P3
P4
Color Purge Time P0->P1
Color Fill Time P1->P2
Catalyst Purge Time P2->P3
Catalyst Fill Time P3->P4
CC Purge/Fill Timers are independent
of Mixed Material Purge Timers. This
line defines when the Mixed Fill Time
begins. The longer of the two timers
defines when the Mixed Fill Time
begins.
Air Chop Time
Solvent Chop Time
First Purge (one of these)
3rd Flush Chop Time
Air Purge
Solvent Purge
3rd Flush Valve
Final Purge (one of these)
Dispense A
Dispense B
A
A
B
B
Gun Flush Box Output #1
Gun Flush Box Output #2
M0
M1
M2
M3
M4
First Purge Time M0->M1
Chop Time (air/solvent or air/3rd flush) M1->M2
Final Purge Time M2->M3
Mixed Fill Time M3->M4
Notes:
Load tables from new recipe
Purge from old recipe
Fill from new recipe
FIG. 115: Color Change Chart 7
ProMix 2KS Recipe Change
Chart 8: A1-A2, same B without Dump Valves, 2 GFBs
Valve
Time-Sequence
Dump A
Dump B
Color Change Solvent
Catalyst Change Solvent
Color Change A
A
A
B
Catalyst Change B
Air Chop Time
Solvent Chop Time
First Purge (one of these)
3rd Flush Chop Time
Air Purge
Solvent Purge
3rd Flush Valve
Final Purge (one of these)
Dispense A
Dispense B
A
A
A
B
B
Gun Flush Box Output #1
Gun Flush Box Output #2
0
1
2
3
4
5
6
Color Purge Time 0->1
Color Fill Time 1->2
First Purge Time 2->3
Chop Time (air/solvent or air/3rd flush) 3->4
Final Purge Time 4->5
Mixed Fill Time 5->6
Notes:
Load tables from new recipe
Purge from old recipe
Fill from new recipe
FIG. 116: Color Change Chart 8
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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
Catalyst Change Solvent
Color Change A
Catalyst Change B
A
A
B
Air Chop Time
Solvent Chop Time
3rd Flush Chop Time
First Purge (one of these)
Air Purge
Solvent Purge
3rd Flush Valve
Final Purge (one of these)
Dispense A
Dispense B
A
A
A
B
B
Gun Flush Box Output #1
Gun Flush Box Output #2
0
1
2
3
4
5
6
Color Purge Time 0->1
Color Fill Time 1->2
First Purge Time 2->3
Chop Time (air/solvent or air/3rd flush) 3->4
Final Purge Time 4->5
Mixed Fill Time 5->6
Notes:
Load tables from new recipe
Purge from old recipe
Fill from new recipe
FIG. 117: Color Change Chart 9
ProMix 2KS Recipe Change
Chart 10: Recipe X, 0, OR 61 to Recipe 0 with Dump Valves
Valve
Time-Sequence
Dump A
Dump B
A
B
Color Change Solvent
Catalyst Change Solvent
Color Change A
Catalyst Change B
P0
P1
P2
Color Purge Time P0->P1
Catalyst Purge Time P1->P2
Color/Catalyst Purge Timers are
independent of Mixed Material Purge
Timers.
Air Chop Time
Solvent Chop Time
3rd Flush Chop Time
First Purge (one of these)
Air Purge
Solvent Purge
3rd Flush Purge
Final Purge (one of these)
Dispense A
Dispense B
Gun Trigger(s) by Operator
M0
M1
M2
M3
First Purge Time M0->M1
Chop Time (air/solvent or air/3rd flush) M1->M2
Final Purge Time M2->M3
Notes:
All timing from Recipe 0
FIG. 118: Color Change Chart 10
312779E
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Color Change
ProMix 2KS Recipe Change
Chart 11: Recipe 0 OR 61 to Recipe X with Dump Valves
Valve
Time-Sequence
Dump A
Dump B
A
A
B
B
Color Change Solvent
Catalyst Change Solvent
Color Change A
A
B
Catalyst Change B
Air Purge
Solvent Purge
3rd Flush Purge
Dispense A
Dispense B
A
A
B
B
Gun Trigger(s) by Operator
0
1
2
3
Color Fill Time 0->1
Catalyst Fill Time 1->2
Mixed Fill Time 2->3
Notes:
Load tables from new recipe
Purge from old recipe
Fill from new recipe
FIG. 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
3rd Flush Chop Time
First Purge (one of these)
Air Purge
Solvent Purge
3rd Flush Valve
Final Purge (one of these)
Dispense A
Dispense B
A
Gun Trigger(s) by Operator
0
1
2
3
4
Color Purge Time 0->1
First Purge Time 1->2
Chop Time (air/solvent or air/3rd flush) 2->3
Final Purge Time 3->4
Notes:
All timing from Recipe 0
FIG. 120: Color Change Chart 12
110
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Color Change
ProMix 2KS Recipe Change
Chart 13: Recipe 0 OR 61 to Recipe X without Dump Valves
Valve
Time-Sequence
Dump A
Dump B
Color Change Solvent
Catalyst Change Solvent
Color Change A
A
A
Catalyst Change B
Air Purge
Solvent Purge
3rd Flush Purge
Dispense A
Dispense B
A
A
A
B
B
Gun Trigger(s) by Operator
0
1
2
Color Fill Time 0->1
Mixed Fill Time 1->2
Notes:
Load tables from new recipe
Purge from old recipe
Fill from new recipe
FIG. 121: Color Change Chart 13
ProMix 2KS Recipe Change
Chart 14: A1 to A2, B1 to B2 with All
Valve
Time-Sequence
Dump A
Dump B
A
B
Color Change Solvent
Catalyst Change Solvent
Color Change A
Catalyst Change B
A
A
B
B
P0
P1
P2
P3
P4
CC Purge/Fill Timers are independent
of Mixed Material Purge Timers. This
line defines when the Mixed Fill Time
begins. The longer of the two timers
defines when the Mixed Fill Time
begins.
Color Purge Time P0->P1
Color Fill Time P1->P2
Catalyst Purge Time P2->P3
Catalyst Fill Time P3->P4
Air Chop Time
Solvent Chop Time
3rd Flush Chop Time
First Purge (one of these)
Air Purge
Solvent Purge
3rd Flush Valve
Final Purge (one of these)
Dispense A
Dispense B
A
A
B
B
Gun Trigger(s) by Operator
M0
M1
M2
M3
M4
First Purge Time M0->M1
Chop Time (air/solvent or air/3rd flush) M1->M2
Final Purge Time M2->M3
Mixed Fill Time M3->M4
Notes:
Load tables from new recipe
2nd On/Start 2nd On Length
Purge from old recipe
Fill from new recipe
1st On/Start
1st On Length/Duration
Special Output #1
Special Output #2
Special Output #3
Special Output #4
Recipe Change Purge Active Output
Recipe Change Fill Active Output
FIG. 122: Color Change Chart 14
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Color Change
ProMix 2KS Recipe Change
Chart 15: Same A, Same B
Valve
Time-Sequence
Dump A
Dump B
Color Change Solvent
Catalyst Change Solvent
Color Change A
Catalyst Change B
A
B
Air Chop Time
Solvent Chop Time
3rd Flush Chop Time
First Purge (one of these)
Air Purge
Solvent Purge
3rd Flush Purge
Final Purge (one of these)
Dispense A
Dispense B
A
A
B
B
Gun Trigger(s) by Operator
0
1
2
3
4
First Purge Time 0->1
Chop Time (air/solvent or air/3rd flush) 1->2
Final Purge Time 2->3
Mixed Fill Time 3->4
Notes:
Load tables from new recipe
Purge from old recipe
Fill from new recipe
FIG. 123: Color Change Chart 15
ProMix 2KS Recipe Change
Chart 16: External Color Change Option
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
3rd Flush Chop Time
First Purge (one of these)
Air Purge
Solvent Purge
3rd Flush Purge
Final Purge (one of these)
Dispense A
Dispense B
A
A
B
B
Gun Trigger(s) by Operator
0
1
2
3
4
5
First Purge Time 0->1
Chop Time (air/solvent or air/3rd flush) 1->2
Final Purge Time 2->3
Wait for External Color Change Ready signal
(before advance to step 4) 3->4
Mixed Fill Time 4->5
Notes:
Load tables from new recipe
Purge from old recipe
Fill from new recipe
Recipe Change Purge Active Output
Recipe Change Fill Active Output
FIG. 124: Color Change Chart 16
112
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Color Change
ProMix 2KS Recipe Change
Chart 17: Recipe 0 OR 61 to Recipe X with Dump Valves and 3rd Flush Valve
Valve
Time-Sequence
Dump A
Dump B
A
A
B
B
Color Change Solvent
Catalyst Change Solvent
Color Change A
A
B
Catalyst Change B
Air Purge
Mixed Fill Time does not
Solvent Purge
3rd Flush Purge
begin until the Exiting Fill
Time and Color/Catalyst Fill
Time is complete.
*Exiting Fill
Dispense A
Dispense B
A
A
B
B
Gun Trigger(s) by Operator
0
1
2
3
*Exiting Fill Time 0->2
Color Fill Time 0->1
Catalyst Fill Time 1->2
Mixed Fill Time 2->3
Notes:
Mixed Material Purge Timers from old recipe
Load tables from new recipe
CC Purge/Fill Timers and Mixed Fill Time from new recipe
*Exiting Fill Source and Length are Programmable
FIG. 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
Valve
Time-Sequence
Dump A
Dump B
A
A
Color Change Solvent
Catalyst Change Solvent
Color Change A
A
Catalyst Change B
Air Purge
Solvent Purge
3rd Flush Purge
*Exiting Fill
Dispense A
Dispense B
A
A
A
B
B
Gun Trigger(s) by Operator
0
1
2
3
*Exiting Fill Time 0->1
Color Fill Time 1->2
Mixed Fill Time 2->3
Notes:
Mixed Material Purge Timers from old recipe
Load tables from new recipe
CC Purge/Fill Timers and Mixed Fill Time from new recipe
*Exiting Fill Source and Length are Programmable
FIG. 126: Color Change Chart 18
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Color Change
114
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Alarms and Warnings
Table 16: System Alarm/Warning Codes
Alarms and Warnings
NOTE: Do not use the fluid in the line that was dis-
Code Description
Details
E-1
E-2
E-3
E-4
E-5
Communication Error Alarm
Page 116
Page 116
Page 117
Page 118
Page 119
pensed off ratio as it may not cure properly.
Potlife Alarm
Ratio High Alarm
Ratio Low Alarm
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:
Overdose A/B Dose Too Short
Alarm
E-6
Overdose B/A Dose Too Short
Alarm
Page 119
•
•
all alarms).
Status bar on the EasyKey shows the alarm E-Code
with a description (see Table 16).
E-7
E-8
E-9
Dose Time A Alarm
Dose Time B Alarm
Mix in Setup Alarm
Page 120
Page 120
Page 121
Page 121
Page 121
E-10 Remote Stop Alarm
E-11 Purge Volume Alarm
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).
Alarm
E-13 High Flow Alarm
Page 122
Page 122
Page 123
Page 123
Page 123
Page 123
Page 124
Page 125
Page 125
Page 125
Page 125
Page 125
Page 126
Page 126
Page 126
E-14 Low Flow Alarm
E-15 System Idle Warning
E-16 Setup Change Warning
E-17 Power On Warning
E-18 Defaults Loaded Warning
E-19 I/O Alarm
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
27) to view the last 10 alarms, with date and time
stamps.
E-20 Purge Initiate Alarm
E-21 Material Fill Alarm
E-22 Tank A Low Alarm
E-23 Tank B Low Alarm
E-24 Tank S Low Alarm
E-25 Auto Dump Complete Alarm
E-26 Color/Catalyst Purge Alarm
E-27 Color/Catalyst Fill Alarm
cleared by simply pressing the Alarm Reset
key.
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Alarm Troubleshooting
Alarm Troubleshooting
Table 17. Alarm Troubleshooting
E-1: COMM ERROR
Cause
Solution
Connect power to EasyKey.
Verify that the cable is correctly connected. See Installa-
No power to the EasyKey.
No power to Fluid Station. The intrinsically safe power
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
Station is not connected.
Verify that the cable is correctly connected. See Installa-
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
lint-free cloth.
A communication cable or connector failed.
Replace cable.
E-2: POTLIFE ALARM
Cause
Solution
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-
rial, or a new color:
NOTICE
To prevent mixed material from curing in the equip-
ment, do not shut off power. Follow one of the solu-
tions at right.
•
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
116
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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.
Cause
Solution
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 probably too high.
delivery rate until fluid hoses are loaded with material.
If the alarm occurred after you were spraying for some
time, the pressures from the fluid supplies could be
unbalanced.
Adjust component A and B fluid supply regulator pres-
sures until they are about equal. If the pressures are
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.
•
Air pressure to the valve actuators is too low.
•
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.
•
•
•
Something is restricting the solenoid or tubing and
interrupting valve actuation air.
•
•
•
There may be dirt or moisture in the air supply. Filter
appropriately.
A dose valve is turned in too far.
Refer to Table 13: Mix Manifold Valve Settings,
page 89, for adjustment guidelines.
Fluid pressure is high and air pressure is low.
Adjust air and fluid pressure. See recommended air
pressure above.
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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 comparison.
Cause
Solution
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
time, the pressures from the fluid supplies could be
unbalanced.
Adjust component A and B fluid supply regulator pres-
sures until they are about equal. If the pressures are
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.
•
Air pressure to the valve actuators is too low.
•
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.
•
•
•
Something is restricting the solenoid or tubing and
interrupting valve actuation air.
•
•
•
There may be dirt or moisture in the air supply. Filter
appropriately.
A dose valve is turned in too far.
Refer to Table 13: Mix Manifold Valve Settings,
page 89, for adjustment guidelines.
Fluid pressure is high and air pressure is low.
Adjust air and fluid pressure. See recommended air
pressure above.
118
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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.
Cause
Solution
taneously (sequential dosing only), there is a leak.
Repair the valve (see valve manual 312782).
Sampling valve is leaking.
Tighten or replace valve.
Flow meter fluctuations caused by pressure pulsations. Check for pressure pulsations:
1. Close all the manifold valves.
2. Turn on the circulating pumps and all the booth
equipment (such as fans and conveyors).
3. Check if the ProMix 2KS is reading any fluid flow.
4. 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.
5. Close the fluid shutoff valve between the fluid supply
system and the flow meter. The flow indication
should stop.
6. 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.
Slow actuation of component A or B valves.
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
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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.
Cause
Solution
System is in Mix mode and 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.
Flow meter or cable failed or flow meter clogged.
Increase the dose time setting.
To check meter sensor operation, remove meter cap to
expose sensor. Pass a ferrous metal tool in front of the
sensor.
TI12792a
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.
Slow actuation of component A or B valves.
The supply pump is not turned on.
Turn on the supply pump.
System is in Mix mode with 0 volume entered for Min
and Fuse F1 is blown.
Verify condition of fuse and replace if necessary. See
Repair-Parts manual.
120
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Alarm Troubleshooting
Table 17. Alarm Troubleshooting
E-9: MIX IN SETUP ALARM
Cause
Solution
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
Solution
Automation has requested that the system abort all oper- Abort operations. Troubleshoot automation system.
ations.
E-11: PURGE VOLUME ALARM
Cause
Solution
ProMix 2KS solvent flow switch is not activated while
purging.
Verify that the gun is not shut off and that the solvent flow
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.
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Alarm Troubleshooting
Table 17. Alarm Troubleshooting
E-12: CAN COMM ERROR ALARM
Cause
Solution
Communication between the Color Change Module and
the Fluid Station is interrupted.
•
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-
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.
•
•
Check the color change board DIP switch settings.
See the Installation manual.
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.
•
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.
•
•
The sticker on the color change board shows the
software part number and version, for example
15T270
1.01. If the version is older than 1.01,
replace the board.
If all 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 control board
fuse is blown.
Repair-Parts manual.
E-13: HIGH FLOW ALARM or E-14: LOW FLOW ALARM (may also be set as Warnings)
Cause
Solution
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
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Alarm Troubleshooting
Table 17. Alarm Troubleshooting
E-15: SYSTEM IDLE WARNING
Cause
Solution
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
Solution
The system setup parameters have been changed.
No action required. See Event Log available through
advanced web interface.
E-17: POWER ON WARNING
Cause
Solution
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
contact.
Check that all wires are securely connected. Ensure that
wires are not stretched too tightly.
Reset button has been pushed (S1 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 LOADED WARNING
Cause
Solution
The factory defaults have been installed on the system. No action required. See Event Log available through
advanced web interface.
312779E
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Alarm Troubleshooting
Table 17. Alarm Troubleshooting
E-19: I/O ALARM
Cause
Solution
The Mix 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 Flush the system or perform a color change. If possible,
detects a fluid plate control board reboot or power cycle identify the origin of the reboot or power cycle.
not triggered from the EasyKey. The system reverts to
Recipe 61, and mixed material may be in the lines.
Autokey Lost: Occurs if the Autokey is lost or changed Reinstall the Autokey, or verify that the Autokey is set
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.
properly.
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.
Verify that the source data is from a valid recipe (1-60).
2K/3K Error: Occurs if the recipe data is incompatible
Verify that the Autokey is set properly or that the configu-
with the current Autokey setting (2K or 3K). This is possi- ration file is valid.
ble 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 Verify that the configuration file is valid.
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 hardware conform.
exists. For example, the configuration file specifies 2
color change boards but only 1 is present.
Verify that the configuration file specifications and the
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.
Verify that the recipe specifications and the hardware
conform.
LC Error (Level Control Error): Occurs if level control Verify that the Autokey is set properly.
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 Set level control data correctly.
if level control data includes a valve range exceeding the
capability of the machine.
MB Overflow (Modbus Overflow): Occurs if the Mod- Verify the Modbus protocol to the EasyKey.
bus connection to a PLC experiences data overflow.
124
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Alarm Troubleshooting
Table 17. Alarm Troubleshooting
E-20: PURGE INITIATE ALARM
Cause
Solution
System detects atomizing air to the gun when purge is
selected.
Shut off gun air.
For systems with a gun flush box, gun is not in the box
when purge is selected.
Place gun in gun flush box. Verify that gun flush box is
operating properly.
For systems with auto dump on, gun is not in the box
when auto dump is initiated.
Place gun in gun flush box. Verify that gun flush box is
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
Cause
Solution
For systems with minimum mixed material fill volume
entered, the system detects that fill volume is not
achieved during mixed material fill time.
Check for restrictions or leaks in the fluid supply system.
Check if the fill volume is properly configured:
•
•
Adjust fill volume.
Adjust fill time.
For systems without color change and with minimum
mixed material fill volume entered, Fuse F1 is blown.
Verify condition of fuse and replace if necessary. See
Repair-Parts manual.
E-22: TANK A LOW ALARM, E-23: TANK B LOW ALARM, or E-24: TANK S LOW ALARM
Cause
Solution
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:
•
•
Refill tank volume to clear the alarm.
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
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Alarm Troubleshooting
Table 17. Alarm Troubleshooting
E-25: AUTO DUMP COMPLETE ALARM
Cause
Solution
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
Cause
Solution
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
Cause
Solution
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.
Open the valve.
Exhausted fluid supply.
Check fluid level and refill if necessary.
Switch settings (S3-S6) on color change board do not
match hardware configuration.
Verify that color change board switches are set correctly.
See installation manual.
Fuse F1, F2, or both are blown.
Verify condition of fuses and replace if necessary. See
Repair-Parts manual.
126
312779E
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Schematic Diagrams
Schematic Diagrams
System Pneumatic Schematic
COLOR
VALVE
STACKS
COLOR
CHANGE
CONTROL
AIR EXHAUST MUFFLER
MANIFOLD
COLOR 1
COLOR 2
COLOR 3
12 VDC
COLOR 4
COLOR 5
COLOR 6
COLOR 7
DOSE A
VALVE
OSE
CL
4-WAY SOLENOID
A
A
B
B
5/32 TUBE
OPEN
COLOR 8
12 VDC
COLOR SOLVENT
COLOR 9
DOSE B
VALVE
OSE
CL
4-WAY SOLENOID
COLOR 10
COLOR 11
COLOR 12
CATALYST 1
CATALYST 2
CATALYST 3
CATALYST 4
CATALYST SOLVENT
5/32 TUBE
OPEN
12 VDC
PURGE A
VALVE
OSE
05
CL
4-WAY SOLENOID
A
B
5/32 TUBE
OPEN
3/8 AIR FILTER
MANUAL DRAIN
5 MICRON
12 VDC
WALL MOUNT ONLY
PURGE B
VALVE
COLOR 13
COLOR 14
COLOR 15
COLOR 16
COLOR 17
COLOR 18
COLOR 19
COLOR 20
COLOR 21
COLOR 22
COLOR 23
COLOR 24
COLOR 25
COLOR 26
COLOR 27
COLOR 28
COLOR 29
COLOR 30
OSE
CL
4-WAY SOLENOID
A
A
B
B
5/32 TUBE
OPEN
AIR INPUT
12 VDC
PURGE C
VALVE
OSE
CL
(OPTIONAL)
4-WAY SOLENOID
AIR EXHAUST MUFFLER
12 VDC
5/32 TUBE
OPEN
DUMP A
VALVE
(OPTIONAL)
3-WAY SOLENOID
5/32 TUBE
OPEN
A
A
AIR INPUT
12 VDC
DUMP B
VALVE
(OPTIONAL)
3-WAY SOLENOID
5/32 TUBE
OPEN
MAC
36 SERIES SOLENOID VALVES
12 VDC
GFB 1
VALVE
3-WAY SOLENOID
(OPTIONAL)
5/32 TUBE
OPEN
A
A
12 VDC
GFB 2
VALVE
(OPTIONAL)
3-WAY SOLENOID
5/32 TUBE
OPEN
MANIFOLD
312779E
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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
LINE
FILTER
OPERATOR INTERFACE
L1
N
L1
N
DC OK
+
1
2
L1 85-250 VAC
N
GND
POWER
SUPPLY
L1
+24 VDC
TERMINAL
BLOCK
L1
N
+
N
COMMON
-
GND
GND
COMMON
-
1
2
3
GND LUG
GND N L1
85-250
VAC
1
POWER
ROCKER
SWITCH
2
1A
1B
2A
2B
POWER HARNESS
1
2
3
4
5
UNUSED
OPEN
OPEN
UNUSED
UNUSED
UNUSED
UNUSED
J1
HARNESS
1
+12VDC I/S (RED)
COM (BLACK)
SHIELD
J5
J4
2
3
BARRIER
BOARD
CABLE
1
2
3
+24VDC
OPEN
(50' STD.)/
(100' OPTION)
COMMON
ALARM
J4
DISPLAY
BOARD
1
2
3
4
MEMBRANE
SWITCH
WITH
RIBBON
CABLE
+
-
1
2
J9
3
+
-
4
1
2
3
4
5
6
MIX INPUT
PURGE INPUT
5
RJ45
RJ45
JOB COMPLETE INPUT
EXTERNAL CLR CHG READY
RESET ALARM INPUT
6
3'
J6
J2
7
8
RJ45
RJ45
POWER DIST.
TERMINAL
BLOCKS
DIGITAL INPUT COMMON
9
1
2
3
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
10
11
+
-
J3
J2
+
-
REMOTE
I/O
INTEGRATION
BOARD
1
+
-
DISPLAY
2
1
2
3
4
5
6
7
8
3
DIGITAL OUTPUT COMMON/POWER
PURGE/RECIPE CHG ACTIVE OUTPUT
MIX ACTIVE OUTPUT
+
-
4
5
MIX READY OUTPUT
6
J4
J5
FILL ACTIVE
7
FLOW CAL. ACTIVE
8
FLOW RATE ALARM OUTPUT
DIGITAL OUTPUT COMMON/POWER
9
FLOW CONTROL CAL. (BLK)
GUN TRIGGER (WHT)
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
2
1
2
3
4
5
6
DIGITAL OUTPUT COMMON/POWER
SPECIAL OUTPUT #1
DIGITAL IN COMMON (RED)
REMOTE STOP (GRN)
3
SPECIAL OUTPUT #2
4
SPECIAL OUTPUT #3
ALARM RESET (BRN)
5
J5
SPECIAL OUTPUT #4
ALARM OUTPUT (BLU)
6
DIGITAL OUTPUT COMMON/POWER
DIGITAL OUTPUT COMMON (ORG)
POT LIFE (YEL)
7
8
FLOW RATE ANALOG IN (PUR)
FLOW RATE ANALOG COMMON (GRAY)
9
10
10
I/O HARNESSES
(+24) YEL
(COM) GRAY
BEACON
ORG
BRN
RED
TERMINAL
BLOCKS
RS485 INTEGRATION A (WHT/BLU)
RS485 INTEGRATION B (BLU/WHT)
RS485 INTEGRATION GROUND (SHIELD)
RS485 NETWORK A (WHT/ORG)
RS485 NETWORK B (ORG/WHT)
1
2
3
4
5
6
1
2
3
4
5
6
J10
RS485 NETWORK GROUND (SHIELD)
CABLE
J7
J8
FO IN (BLK)
FO OUT (BLU)
RJ45
RJ45
3'
P1
RJ45
BULKHEAD
3'
(25'-200' OPTIONS)
WEB SERVER
MODULE
128
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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.
Hazardous Area
HAZARDOUS AREA
3X CABLE
FLUID PANEL CONTROL BOX
FLUID
1
2
3
4
5
6
PWR (RED)
FLOW METER A
COM (BLACK)
SIG (WHITE)
SHIELD/GRN
PWR (RED)
PANEL
J3
CONTROL
BOARD
I.S. METERS
FLOW METER B
COM (BLACK)
SIG (WHITE)
SHIELD/GRN
PWR (RED)
1
2
3
4
5
6
FLOW METER SOLVENT
COM (BLACK)
SIG (WHITE)
SHIELD/GRN
J2
J4
J12
TECNO
V/P
SIG (RED)
1
2
J1
COM (BLK)
1
2
3
4
5
FLOW
CONTROL
BOARD
V/P ANALOG OUT (WHT)
GROUND
TERMINAL
PRESS. (GRN)
+12 V (RED)
GND (BLK)
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
2
3
4
5
6
+ PRESSURE (GRN)
COM (RED)
EX+ (WHT)
- PRESSURE (BLK)
SHIELD (BARE)
FLUID
PRESS.
SENS.
CHASSIS (BARE)
1
2
3
4
5
J10
J13
(10')/
(40')
1
2
3
+12VDC I/S
COM
SHIELD
1
2
3
4
5
6
J5
MH2
J7/J11
1
4
5
2
3
COLOR
BOARD 1
(COLORS
1 THRU 12,
CATALYST
1 THRU 4)
6' STD.
(3'-100' OPTIONS)
3
2
5
4
1
GRD (BLK)
+12VDC (RED)
SHIELD (BARE)
CAN H (WHT)
CAN L (BLU)
J11
J7
MANIFOLD
MANIFOLD
6
5
4
3
2
1
COM
+12VDC
COM
1
2
3
4
5
6
CLR 9
+12VDC
CLR 8
COM
+12VDC
COM
CLR 10
CLR 11
CLR 7
CLR 6
+12VDC
COM
J8
J9
50' STD.
+12VDC
COM
+12VDC
BOOTH
CONTROL
BOARD
3
3
2
5
4
1
GRD (BLK)
2
5
4
1
+12VDC (RED)
SHIELD (BARE)
CAN H (WHT)
CAN L (BLU)
1
2
3
4
5
6
+12VDC
COM
6
5
4
3
2
1
COM
+12VDC
COM
CLR 5
CLR 4
CLR 3
CLR 12
CAT 4
CAT 3
+12VDC
COM
J16
J15
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
6
5
4
3
2
1
1
2
3
4
5
6
+12VDC
COM
CAT 2
CLR 2
+12VDC
COM
CAT 1
MANIFOLD
CLR 1
J14
J10
+12VDC
COM
BLACK
RED
6
+12VDC
COM
SOL CAT
DUMP B
GFB #1
GFB #2
SOL CLR
+12VDC
5
4
3
2
1
BLACK
RED
1
4
5
5
2
2
3
3
J8
J7/J11
J7/J11
BLACK
RED
6' STD.
BLACK
RED
6
5
4
3
2
1
1
4
DUMP A
NOT USED
PURGE C
COLOR
BOARD 2
(COLORS
BLACK
RED
J15
MANIFOLD
13 THRU 30)
BLACK
RED
MANIFOLD
BLACK
RED
6
5
4
3
2
1
MANIFOLD
PURGE B
PURGE A
NOT USED
1
2
3
4
5
6
+12VDC
COM
6
5
4
3
2
1
COM
+12VDC
COM
CLR 21
CLR 20
CLR 19
CLR 22
CLR 23
CLR 24
BLACK
RED
+12VDC
COM
J14
J9
J8
J9
+12VDC
COM
+12VDC
COM
BLACK
RED
+12VDC
1
2
3
4
5
6
+12VDC
COM
CLR 18
CLR 17
CLR 16
6
5
4
3
2
1
COM
+12VDC
COM
6
5
4
3
2
1
BLACK
RED
CLR 25
CLR 26
CLR 27
NOT USED
DOSE B
+12VDC
COM
J15
J14
J16
BLACK
RED
+12VDC
COM
+12VDC
COM
+12VDC
BLACK
RED
DOSE A
1
2
3
4
5
6
+12VDC
COM
COM
+12VDC
COM
6
5
4
3
2
1
CLR 15
CLR 14
CLR 13
CLR 28
CLR 29
CLR 30
+12VDC
COM
1
SIG
J10
+12VDC
COM
AIR FLOW SWITCH 1
2
COM
SIG
+12VDC
COM
+12VDC
3
AIR FLOW SWITCH 2
4
COM
SIG
5
SOLVENT FLOW SWITCH
GFB 1 PRESSURE SWITCH
GFB 2 PRESSURE SWITCH
6
COM
SIG
FO OUT
(BLU)
J1
J4
J6
7
8
COM
SIG
9
FO IN
(BLK)
10
COM
312779E
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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)
Maximum working air pressure . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7 bar)
Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 - 100 psi (0.5 - 0.7 MPa, 5.2 - 7 bar)
Air filter inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 npt(f)
Air filtration for air logic and purge air
(Graco-supplied). . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 range. . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1:1- 50:1*
On-ratio accuracy. . . . . . . . . . . . . . . . . . . . . . . . . . . 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 fluid . . . . . . . . . . . . . . . . . . . . . . . 20- 5000 cps*
Fluid filtration (user-supplied) . . . . . . . . . . . . . . . . . . 100 mesh minimum
Fluid flow rate range*
G3000, G250 Meter . . . . . . . . . . . . . . . . . . . . . . 75 - 3800 cc/min. (0.02-1.00 gal./min.)
G3000HR, G250HR Meter. . . . . . . . . . . . . . . . . 38 - 1900 cc/min. (0.01-0.50 gal./min.)
Coriolis Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . 20 - 3800 cc/min. (0.005-1.00 gal./min.)
S3000 Solvent Meter (accessory) . . . . . . . . . . . 38 - 1900 cc/min. (0.01-0.50 gal./min.)
Fluid inlet sizes
Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 npt(f)
Dose Valve/Color Valve Adapters . . . . . . . . . . . 1/4 npt(f)
Fluid outlet size (static mixer). . . . . . . . . . . . . . . . . . 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 range . . . . . . . . . . . . . . . . . . 41- 122° F (5-50° C)
Environmental Conditions Rating . . . . . . . . . . . . . . . indoor use, pollution degree (2), installation category II
Noise Level
Sound pressure level . . . . . . . . . . . . . . . . . . . . . below 70 dBA
Sound power level . . . . . . . . . . . . . . . . . . . . . . . below 85 dBA
Wetted parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
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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 warranty 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 FITNESS 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 hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
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.
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. 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
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