Instruction/ maintenance manual of the product TI12553a Graco
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312779 E EN Opera tion ProMix ® 2KS Plural Compon ent Proportioner Automatic system for proportional mix ing of pl ural component c oatings, with Wall Mount Fluid Station or RoboMix Fluid Station. For professi onal use only. Approved for use in explosive at mospheres (exc ept th e EasyK ey).
2 312779E Contents Related Ma nuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Equipment Ap provals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 System Confi guration a nd Part Numb ers . . . . . . . . . . . . 4 Wall Mo unt Fluid Station Conf igurato r Key .
Relate d Manual s 312779E 3 Related Ma nuals Component Manuals in English Equipment Approv als Equipm ent appro vals app ear on th e followin g labels which a re attach ed to the F luid Sta tion and E asyKey ™ . See F IG . 1 on page 4 and F IG . 2 on page 6 for label loca- tio ns.
System Configu ration and Part Nu mbers 4 312779E System Configuration a nd Part Numbers Wall Mo unt Fluid St ation Conf igurat or Key The configured part number fo r your equipment is printed on the equipment ide ntification labels. See F IG . 1 for location of the identification labels.
System Con figurat ion and Part Num bers 312779E 5 Standard Featu res Hazardous Lo cation Approval Models u sing a G300 0, G3000H R, or intrin sically safe Coriol is meter for both A a nd B meters are approv ed for install ation in a Hazar dous Locati on - Class I, D iv I, Group D, T3 or Zone I Gr oup IIA T3.
System Configu ration and Part Nu mbers 6 312779E Robo Mix Fl uid St atio n Conf igurator Key The configured part number for your equipment is printed on the equipment identification labels.
System Con figurat ion and Part Num bers 312779E 7 Standard Featu res Hazardous Lo cation Approval Models u sing a G250 or G250H R for both A and B meters ar e approved for install ation in a Hazardous Location - Class I, Div I, Grou p D, T3 or Zon e I Group IIA T3.
Acce ssori es 8 312779E Accessori es Accessor y 15V354 T hird Pur ge Valve Ki t 15V202 T hird Pur ge Valve Ki t 15V536 S olvent F low Switc h Kit 15V213 P ower Cable, 10 0 ft (30.5 m) 15G710 Fi ber Optic Cabl e, 100 ft (30. 5 m) 15G614 F low Control E xtension Cab le, 40 ft (1 2.
Warn ings 312779E 9 Warnings The foll owing warni ngs are for the setup, us e, ground ing, main tenance, a nd repair o f this equipm ent. The exclama- tion p oint symbol alerts yo u to a general warning and the hazar d symb ols refer to p rocedure- specific risks.
Warnings 10 312779E SKIN INJEC TION HAZARD High-pres sure fluid fro m gun, hose leak s, or ruptured com ponents wil l pierc e skin. This may look like just a cut, bu t it is a s erious i njury that c an resu lt in ampu tation. Get immediate surgical treatment.
Importa nt Two-Compon ent Materi al Info rmation 312779E 11 Important Two-Compon ent Material In formation Isocyanate Conditions Material Self-ignition Keep Compo nents A and B Separate Moisture Sensit ivity of Isocyanates Isocyana tes (ISO) are catal ysts used i n two com ponent coatin gs.
Glossary of Terms 12 312779E Glossary of Terms Air Chop - the p rocess of mixing air and solve nt together during the fl ush cycle to help cle an the lines and reduce so lvent usage . Air Chop Time - d urat io n of each act ivat ion of th e air purge va lve during a c hop seque nce.
Glossa ry of Terms 312779E 13 Job Total - a resettab le value that sho ws the amount of material di spensed th rough the system for one job. A job is com plete when a c o lor change or com plete syst em fl ush o ccur s. K-factor - a value that refers to the amou nt of materia l that pass es throug h a meter.
Overvi ew 14 312779E Overview Usage The Graco ProMix 2KS is an elec tronic two-com ponent paint propo rtioner. It can blend most two-comp onent solv ent and wate rborne epo xy, polyur ethane, an d acid-cat alyzed pai nts. It is not for use with “quick -setting” pa ints (tho se with a potl ife of less than 15 mi nutes).
Overview 312779E 15 Flow Meters (MA, MB, MS) The foll owing option al flow meters are av ailable fr om Graco: • G3000 i s a general purpose gea r meter typ ically us ed in flo w ranges of 7 5-3800 cc/min. (0.02–1.0 g al/min.) , pressure s up to 4000 p si (28 MPa, 2 76 bar), and v iscosi- ties of 2 0–3000 cen tipoise.
Overvi ew 16 312779E Wall Mount Sys tem Componen ts F IG . 3. Wall M ount System, shown w ith G3000 Met ers, Color/Cata lyst Change, Access ory Solvent M eter, and Flow Control TI12553 a FO* FC PS* EK ST ACV CCM MS MA MB FM BCV * See t h e Pr oMix 2KS Repair-Pa rts manual for option al cable lengths.
Overview 312779E 17 Key: MA Comp onent A Meter DVA Compone nt A Dose Valve RVA Compo nent A S ampli ng Valve SVA Component A S hutoff Valv e MB Comp onent B Meter DVB Compone nt B Dose Valve RVB Compo.
Overvi ew 18 312779E RoboMix System Components F IG . 5. RoboMix System shown with Color/Catalyst Change and Flow Control TI1255 2a Purge Ai r RoboMix Control Air Air Cont rols FO* FC PS* EK RS ACV CCM BCV * See the Pr oMix 2KS Repair-Pa rts manu al for option al cable le ngths.
Overview 312779E 19 F IG . 6: Details of RoboMix Fluid Station Cover is removed for c larity MA MB A Supply (1/4 npt) B Supply (1/4 npt) Solvent Supply (1/4 n pt) Air P urge Cabl e Pat h Air Logic In .
EasyKey Displa y and Keyboard 20 312779E EasyKey Displ ay and Keyboar d Display Shows gr aphical an d text inform ation relat ed to setup and sp ray opera tions. Ba ck light wi ll turn off a fter 10 minutes without any k ey press. Press any key to turn back on.
EasyKey Displa y and Keyboard 312779E 21 AC Power Switch Turns sy stem AC powe r on or off. I/S Power Power c ircuit to Fluid Station. Potlife Exceeded A udible Alarm Alerts the user when a Potlife Exc eeded alar m occurs. Clear by pressing the Alarm Res et key.
Run Mode Screens 22 312779E Run Mode Screens NOTE: See F IG . 11 for a map of the Ru n screens. Detailed s creen des criptions follow. Splash Screen At power up, the Grac o logo and s oftware revis ion will display for approx imately 5 sec onds, fol lowed by the Status S creen (see page 24).
Run Mode Screens 312779E 23 F IG . 11. Run S creens Map TI1280 2a Press the Setup key to enter Setup mode..
Run Mode Screens 24 312779E Status Screen •U s e t h e U p or Down keys to scroll thr ough the Run sc reens. • Press the Se tup key to ent er the Setup scree ns from the S tatus scr een. • The othe r keys have no functio n in this St atus screen .
Run Mode Screens 312779E 25 Manual Override Screen This scr een will app ear if Manual O verride is s et to “On” in Ad vanced Set up Screen 1 (page 39).
Run Mode Screens 26 312779E Global Flow Control Data Copy This fiel d allows yo u to copy flow contro l data f rom the active re cipe to al l reci pes. Press th e Enter k ey to view the m enu, then s elect Star t or Abort. Se e F IG . 16. Totals Screen This sc reen show s the job totals, gran d totals, and job number.
Run Mode Screens 312779E 27 Alarms Screen Two screen s show the last 10 al arms. Use the Up or Down keys to s croll be tween the two screens. See Tab le 16 on pa ge 115 for a l ist of alarm c odes. Level Control Screen This sc reen sho ws the cur rent volu me for eac h fluid.
Setup Mo de 28 312779E Setup Mode Press the Setup k ey to ente r Setup mode . NOTE: See F IG . 23 for a map of the Setup sc reens. Deta iled sc reen des cript ion s foll ow. F IG . 23. Setup Sc reens Ma p To acce ss Advanced Setup Screens , page 38 and Recipe Setup Screens , page To access System Configuration Screens , pag e 31.
Setup Mod e 312779E 29 Password Screen If a pass word has bee n activa ted (see Configure Scree n 1 , page 32) , the Passw ord screen wi ll appea r. You mu st enter the password to access the Set Up Home Screen . Entering th e wrong pa ssword retur ns the display to the St atus Scr een .
Setup Mo de 30 312779E Table 3: Component Software Versions Component Display (m ay vary from examples shown) Description EK (Eas yKey) 2.00.0 12 EasyK ey software version. FP (Fl uid Plate) 2.00.0 12 Fluid Plate so ftware ve rsion. BC (Bo oth Control) -.
Setup Mod e 312779E 31 System Configuration Screen s NOTE: See F IG . 27 for a map of the System Configura- tion Screens . Detailed screen des criptions follow. NOTE: Each scre en display s the current scr een number and the t otal numbe r of scree ns in the gr oup.
Setup Mo de 32 312779E Configure Screen 1 Language Defines th e languag e of the scr een text. Sel ect Englis h (de faul t), Span ish, Fren ch, German , Itali an, D utc h, Jap - anese (Kanji), Ko rean, and Chinese (S implifie d). Passwo rd The pas sword is on ly used to enter Setup m ode.
Setup Mod e 312779E 33 Configure Screen 3 Run Mode Select t he Run mode applica tion from the pulld own menu: Au tomatic ( default), Semi-Autom atic (u ses a manual s pray gun) , or Manual. NOTE: ProCont rol 1KS is also av ailable as a selec tion. For furth er informat ion, see P roControl 1KS operati on manual 3A 1080.
Setup Mo de 34 312779E DD Setup Mode See F IG . 32 and F IG . 33. Sele cting “D D” makes th e Dynamic Dosing Setup m ode field ap pear. Selec t On to enable DD s etup mode , or Off to di sable. See p age 86 for furth er informa tion. Dose Time Alarm Enter the dose tim e (1 to 99 seconds ).
Setup Mod e 312779E 35 Configure Screen 6 Flow Control This field only appea rs if Run M ode is set to “Auto matic” in Configure Screen 3 , page 33 and Flow Control is se t to “On” i n Configure S creen 5 , page 3 4. Selec t “Dis- crete” or “Network.
Setup Mo de 36 312779E Option Screen s NOTE: See F IG . 27 on pag e 31 for a map of the Option Scree ns . Detailed screen de scription s follow. NOTE: Each screen di splays the cur rent scr een num ber and the tota l number of screens i n the grou p.
Setup Mod e 312779E 37 Option Screen 2 Exte rnal Color Change If set to “O ff”, Color/Catal yst Purge Time and Color/Cat - alyst Fi ll Time ap pear in Adv anced Setu p Screen 1 , page 39 or Recipe Setup S creen 2 , page 44 (depend- ing on whe ther Flus h and Fill Inpu ts are set t o “Global ” or “Rec ipe”).
Setup Mo de 38 312779E Advanced Setup Screens NOTE: See F IG . 39 for a map of the Adv anced Setu p Screens . De tailed s creen desc riptions follow. F IG . 39. Adv anced Setup Screens M ap TI12805 a Advanced Setup s creens 2, 3, 4, and 8 ap pear depending o n selecti ons made in Option screens 1 and 2.
Setup Mod e 312779E 39 NOTE: Each screen di splays the cur rent s creen num ber and the tota l number of screens i n the group. T he total number o f screens in a group a nd the fiel ds display ed on each s creen may vary depe nding on sel ections made in th e System Configur ation Screens and Option Scre ens .
Setup Mo de 40 312779E Advanced Se tup Screen 2 This sc reen appe ars only i f Flush an d Fill Inpu t is set to “Globa l” in Opti on Screen 1 , page 36. First Purge Sour ce Select “Air,” “ Solvent, ” or “3rd Flush Valve” (availab le only if 3 rd Flush Valve is set to “On” in Configure Scree n 3 on page 3 3).
Setup Mod e 312779E 41 Advanced Se tup Screen 4 This scre en appear s only if K -factor Inp ut is set to “Globa l” in Opti on Screen 1 , page 36. K-factor A Meter Enter the k -factor (cc/ pulse) for flow me ter A. This is the amount of m aterial that passes throu gh the flow meter per puls e (electr ical puls e signal).
Setup Mo de 42 312779E Advanced Se tup Screen 6 This sc reen sho ws the sta tus of reci pe analog inputs and digit al outputs . If box is s haded the input recip e is active. Advanced Se tup Screen 7 This sc reen shows the status of digit al input s and digital outputs.
Setup Mod e 312779E 43 Recipe Setup Screens NOTE: See F IG . 49 for a map of the Re cipe scr eens. Detai led screen d escriptio ns follow. F IG . 49: Reci pe Scree ns Ma p TI 12806 a Recipe 0 Screens .
Setup Mo de 44 312779E NOTE: Each screen di splays the cur rent scr een num ber and the tota l numb er of screens i n the grou p. The total number o f screens in a grou p and the fi elds disp layed on each s creen may vary depe nding on sel ections made in th e System Configur ation Screens and Option Scre ens .
Setup Mod e 312779E 45 Recipe Setup S creen 3 This sc reen appe ars only if Flush and F ill Input is set to “Recipe ” in Option Scr een 1 , page 36. First Purge Sour ce Select “Air,” “ Solvent, ” or “3rd Flush Valve” (availab le only if 3 rd Flush Valve is set to “On” in Configure Scree n 3 on page 3 3).
Setup Mo de 46 312779E Recipe Setup Scre en 5 This scre en appear s only if K -factor Inp ut is set to “ Rec- ipe” in Option Scre en 1 , pag e 36. K-factor A Meter Enter the k -factor (cc/ pulse) for flow me ter A. This is the amount of m aterial that passes thr ough the fl ow meter per puls e (electr ical puls e signal).
Setup Mod e 312779E 47 Recipe 0 Screens NOTE: See F IG . 49 on page 43 for a map of the Recipe 0 screens . Detailed screen de scription s follow. Recipe 0 is typ icall y used: • in multi ple colo r systems to purge out material lines without loading a ne w color • at the end o f a shift t o prevent ha rdening of c ata- lyzed m aterial.
Setup Mo de 48 312779E Recipe 0 S creen 3 This sc reen only appears i f Solven t Monitor is set to “Me ter” in Configure Screen 5 , page 34 and Flush Vol- ume Check is set to “On” in Option Scr een 1 , page 36 or 3rd Fl ush Valve is set t o “On” i n Configure S creen 3 on page 33.
Setup Mod e 312779E 49 Calibration Screen Use this sc reen to calibrate a me ter. Set to “Meter A,” “Meter B,” or “Solv ent Meter” (availabl e if Solven t Moni- tor in Configure Screen 5 , page 34, is s et to “Mete r”).
Setup Mo de 50 312779E.
ProMix 2KS I ntegration Specif ics 312779E 51 ProMix 2KS Integration Specif ics Discrete I/O vs Network Comm uni cati ons The ProMi x 2KS Auto matic sys tem does n ot use a Booth Contr ol. Inst ead, it us es Discre te I/O or Netwo rk Commun ications to drive the s ystem.
ProMix 2 KS Integration Spec ifics 52 312779E Digital Inputs See Automation Flow Charts , pages 55-59. Mix Star t: This is a maintained input. W hen High, the ProMix 2KS will a ttempt to en ter Mix mode. This Mi x Start in put shoul d not be atte mpted unle ss the Mix_Read y output i s recogni zed.
ProMix 2KS I ntegration Specif ics 312779E 53 F IG . 64: 255 766 Discrete I/O Board JLS Purge Input Job Complete Input External Color C hange Ready Spare Digital Input Common Special Output #4 Mix Inp.
ProMix 2 KS Integration Spec ifics 54 312779E Digital Outputs See Automation Flow Charts , pages 55-59. Purge_CC_Active : This ou tput will remain High during the manual Purge o r Color Chan ge purge se quence. See the Co lor Chang e Charts (F IG . 109-F IG .
ProMix 2KS I ntegration Specif ics 312779E 55 Auto mat ion Fl ow C har ts Start Mix Mode Proce ss See F IG . 65, Ta ble 5, and Table 6. F IG . 65. St art Mix Mode Process F low Chart Start Mix Mode Pr ocess Is Mi x Read y bit = 1 ? Must b e Alarm Cond i- tion or Ac tive Re cipe 61.
ProMix 2 KS Integration Spec ifics 56 312779E Mixing Mode Proces s See F IG . 66, Ta ble 5, and Table 6. F IG . 66. Mixing Mode Process Flow Chart Mixing Mode Process Is Mix Active bit = 1? Check Al arm Condition : is Alarm_ General b i t = 1? YES NO NO YES Mixing Mode is des ired.
ProMix 2KS I ntegration Specif ics 312779E 57 Purge Mode P rocess See F IG . 67, Ta ble 5, and Table 6. F IG . 67. Purge Mode Process Flow Chart Start Is Mix Read y bit = 1? Must be Alarm Condi tion or Acti ve Recipe 61 . See Alarm Pr ocessing on page 59, or Startup from Recip e 61 (s ee NOTE below).
ProMix 2 KS Integration Spec ifics 58 312779E Color Change Mode Process See F IG . 68, Ta ble 5, and Table 6. F IG . 68. Color Change Mode Process Flow Chart Color Chan ge Proce ss (bas ic) Is Purge_CC_Ac tive bit = 1? Chec k Alarm Conditi on: is Alarm_ Gene ral b it = 1? YES NO NO YES Is Active Rec ipe = to de sired r ecipe ? (Register 400 05).
ProMix 2KS I ntegration Specif ics 312779E 59 Alarm P rocessing See F IG . 69, Ta ble 5, Tabl e 6, and Tabl e 7. F IG . 69. Alarm P rocessing Flow Chart Alarm Proce ssing Is Mi x Read y bit = 1? Check if Potlife Alarm: is Alarm_ Potli fe bit = 1? YES NO NO YES An Alarm Con dition has bee n found previous ly.
ProMix 2 KS Integration Spec ifics 60 312779E NOTE: Shaded cel ls relate to th e flow charts on pages 55 -59. Table 5: ProMix 2KS Digital Inputs (Modbus Register 40040) Bit Digital Input Binary Name Details 0:5 0 0 0 0 0 0 0 0 0 0 X X X X X X Recipe Binary bits for viewing dis crete inpu ts only.
ProMix 2KS I ntegration Specif ics 312779E 61 NOTE: Shaded cel ls relate to th e flow charts on pages 55 -59. Table 6: ProMix 2KS Digital Outputs (Modbus Register 40041) Bit Digital Input Binary Name .
ProMix 2 KS Integration Spec ifics 62 312779E Table 7: P roMix 2KS Activ e Alarms (Modbus Register 40010 ) Bit Digital Input Binary Name Details Low Byte : 0 0000 0 000 0000 00 00 No Bits Set No Acti .
ProMix 2KS I ntegration Specif ics 312779E 63 F IG . 70. Automation 24 Vdc Sourcing Input Diagram 24 Vdc 24 Vdc 24 Vdc Input Outp ut Outp ut Common Common Input Common Outp ut Outp ut Common Output Co.
ProMix 2 KS Integration Spec ifics 64 312779E Table 8: Discrete I/O Terminal Connections Termin al Term inal Locatio n Name Deta ils (also se e pages 60 and 61) Digital Inputs 1 J2, Remo te I/O Boa rd.
ProMix 2KS I ntegration Specif ics 312779E 65 Digital Outputs 1 ★ J4, Remo te I/O Boa rd Digital Output Com mon/Power 2 J4, Remo te I/O Boa rd Purge_CC A ctive “1” Indic ates Purg e or Color Ch .
ProMix 2 KS Integration Spec ifics 66 312779E Table 9: ProMix 2KS Recipe Bits Recipe Bits Number Recipe Bits Number 543210 543210 000000 0 100001 3 3 000001 1 100010 3 4 000010 2 100011 3 5 000011 3 1.
Integrate d Flow Co ntrol 312779E 67 Integrated Flow Control Flow Cont rol Description Flow con trol is an opti onal feature wh ich inco rporates an intrinsic ally safe regulator control mod ule with th e Pro- Mix 2K S automati c system.
Inte grat ed Flo w Cont rol 68 312779E Fluid and Air Pressu re Requirements The fluid i nput press ure to the flu id regulato r must be high enou gh to provid e a 15-20 psi (0.1- 0.14 MPa, 1.0-1.4 b ar) pressure different ial acros s the regul ator at the hig hest flow se tting.
Integrate d Flow Co ntrol 312779E 69 F IG . 73. ProMix 2KS Flow Control Schematic Diagram (249849 Module) TI1711 8a Air-operated Fluid Regulator Met er B Fluid Pressure Sensor Mixed Material Line Pres.
Inte grat ed Flo w Cont rol 70 312779E Flow Control Operating Process Exam ple Operating Ranges Flow Contr ol operating ra nges correlate the desired flo w rate to th e incomi ng flow se t point si gnal (see b elow).
Integrate d Flow Co ntrol 312779E 71 F IG . 75. ProMix 2KS Flow Control Pressure Loop and Flow Loop (249849 Module) TI1711 8a Fluid Pressu re Sensor Step 2: Pressure Input V/P (Voltage/Air Pressure) V alve Analog Signal to V/P Air Line Step 1: ProMix 2KS receives a flow rate setpoint from PLC/robot Step 3: Flow Input F IG .
Inte grat ed Flo w Cont rol 72 312779E Flow Cont rol Setup 1. Install t he intrins ically safe f low regulato r (FC) as explain ed in the Pr oMix 2KS In stallation M anual. 2. Ensu re that the analog s ignal is 0-10 Vdc, or is properly provided t hrough ne twork commu nication.
Integrate d Flow Co ntrol 312779E 73 3. Set Flo w Control Ov erride to % Open. Se e F IG . 79 and Ta ble 10. On the Manual Override Sc reen , the Flow Se t Point fi eld will dis play as a percenta ge open (s ee F IG . 80). NOTE: Set the Flow Contr ol Override to “Pressure” to use the Pressure Flow Control Mode (see page 77 ).
Inte grat ed Flo w Cont rol 74 312779E Flow Cont rol Calibration Flow Cont rol Calibr ation is an automatic routine that establishe s a pres sure vs flo w profile between lo w and high oper ating points . See F IG . 86. The profile may b e unique to each recip e or may be globally c opied to all reci pes.
Integrate d Flow Co ntrol 312779E 75 5. Return to the Status Scr een (s ee F IG . 85). Th e sta- tus bar at the bottom of the screen will indic ate that Mix C alibration is in prog ress. 6. Trigger the gun and mak e sure the gun tr igger input is high.
Inte grat ed Flo w Cont rol 76 312779E Global FC Data Copy Set Glo bal FC Data Copy to Start on th e Manu al Over- ride Sc reen (s ee F IG . 87). G lobal copy provides a start- ing po int for all recipe s, enabling Continuous Learning (see page 7 6) to tak e over.
Integrate d Flow Co ntrol 312779E 77 Pressure Flow Control Mode When the Fl ow Control Overr ide is set to “Press ure”, the system will only d rive to the pressure associate d with the flow rate reques t of the saved cal ibration tabl e. It will not clos e the loop wit h the flow m eters.
Inte grat ed Flo w Cont rol 78 312779E Flow Control Tr oubleshoo ting Problem: Flow Command does not produce fluid output. Test the sy stem as fol lows, to d etermine if the probl em is m echa nic al or elec trical . 1. Install a 0-100 psi ( 0-0.7 MPa, 0- 7.
Integrate d Flow Co ntrol 312779E 79 Result of the Test Cause Solution Gauge r eading in crease s and decreases as % Open v alue is chang ed and fluid f low doe s not change or is not pr esent. The pr oblem is me chanica l: • restric tion/plug ged hose • plugged gun tip • flu id reg ulato r fail ure 1.
System Operation 80 312779E System Oper ation Operation Mo des Mix System mixes a nd dispense s mate rial (apply Mix input) . Standby Stops the system (remove M ix input).
System Operat ion 312779E 81 Typical PLC Inte raction with ProMix 2KS This sec tion describe s a typical in teraction w hen a local PLC is d irectly conn ected to th e Discrete I/O connec - tions of t he ProMix 2KS. See ProMix 2KS Integration Specifics on p age 51 for a detaile d explana tion of in puts and o utputs.
System Operation 82 312779E Alarm Monitoring/Reset (Discrete I/O) Anytime an alarm occurs, the Alarm Re set input will reset th e alarms an d allow for p rocessing o f the next step b y automation, except for the following c ondi- tio ns: • Pot life Al arms cannot be rese t by the Alar m Reset input or through the E asyKey A larm Reset key.
System Operat ion 312779E 83 General Operating Cycle, Sequential Dosing 1. The syst em enters and loads th e desir ed color. 2. The syst em enters Mi x mode to beg in opera tion. 3. The Pr oMix 2 KS cont roller sen ds sig nals to activat e the so lenoid valv es.
System Operation 84 312779E F IG . 91. Wall Mount Fluid Station, Sequential Dosing TI12556 b MA MB DVB MS SPV DVA SM FI SVA SVB RVB RVA Key: MA Component A Meter DVA Component A Dose Valve RVA Compone.
System Operat ion 312779E 85 General Operating Cycle, Dy namic Dosing Over view Dynamic Dosing provi des on-dema nd proportion ing, elimina ting the ne ed for an inte grator and t herefore mi n- imizin g undesir ed materia l contact. T his feat ure is espe- cially useful with shear-se nsitive and waterbor ne materials .
System Operation 86 312779E Select a Component B Restric tor Size Install t he 15U955 In jection Kit in the fluid man ifold as explain ed in the Pr oMix 2KS In stallation m anual. Use the ch arts provide d in that m anual to s elect an appropri- ate rest rictor si ze base d on the des ired flow a nd mix rat io.
System Operat ion 312779E 87 Balancing A/B Pressure If compone nt B pressur e is too high, it will push the c om- ponent A s tream aside d uring B inj ection. The v alve will not open l ong enough , causin g a High Rati o alarm. If compo nent B pressu re is too low, it wil l not be injected in su fficient vo lume.
System Operation 88 312779E Mix Manifold Valve Sett ings To open dose or pur ge valves , turn hex nu t (E) counter - clockw ise . To cl ose, turn cloc kwise.
System Operat ion 312779E 89 Start Up 1. Go throu gh the Pre-Ope ration Che cklist in Ta ble 14. 2. Turn the AC Po wer Swi tch ON (I = O N, 0 = OFF). ➜ Graco l ogo, softwa re revision , and “Estab lishin g Comm unicatio n” will di splay, followed by Stat us screen.
System Operation 90 312779E 10. Purge ai r from the fluid lines . a. Shut off ai r to the g un by clos- ing th e air regulato r or shutof f valve fo r the gun atomizin g air. b. Trigger the gun (man- ual or a utomatic) i nto a ground ed metal pa il. c.
System Operat ion 312779E 91 Shutdown Overnight Shutdown 1. Leave the power on. 2. Run Recip e 0 to purge s olvent through meters and gun. Service Shutdown 1. Follow Pressure Re lief Proce dure on page 9 1. 2. Close ma in air shut off valve on air sup ply line an d on ProMix 2KS.
System Operation 92 312779E Systems with Colo r Change and without Dump Valves NOTE: This procedur e reliev es pressu re through the samp ling valve. 1. Comple te all steps under Sin gle Color Sy stems , page 91. 2. C los e th e A side shutoff valve (SVA) , F IG .
System Operat ion 312779E 93 F IG . 104. Fluid Solenoids TI1265 5a RoboMix Fluid Station Dose Valve A Override Button Dose Valve B Override B utton TI12652 b GFB 1 GFB 2 Dump Valv e A Purge Valve B So.
System Operation 94 312779E F IG . 105: Color Change S olenoids TI1282 6a Solvent Sol enoid Overrides Soleno id Iden tification Label Solen oid Iden tific ati on Label Color Color Catal yst F IG .
System Operat ion 312779E 95 Purging There ar e 4 purging p rocedures in this ma nual: • Purging Mixed Material (below) • Purging Using Recipe 0 (page 96 ) • Purging F luid Supply Sy stem (page 96 ) • Purging Sa mpling Valves a nd Tubes (page 98) Use the c riteria listed in each p rocedure t o determine which proc edure to us e.
System Operation 96 312779E Purging Using Recipe 0 Recipe 0 is typ icall y used: • in multi ple colo r systems to purge out material lines without loading a ne w colo r • at the end o f a shift t o prevent ha rdening of c ata- lyzed m aterial. To setup Rec ipe 0, go to Advanced Setup.
System Operat ion 312779E 97 3. Adjust t he solvent f luid sup ply pressur e. Use the lowest po ssible pressu re to avo id splashi ng. 4. Re move t he Flui d St ation cover t o ac cess th e sole- noid val ves. See F IG . 104 on p age 93. 5. Purge as follows: • Single co lor/single catalyst sy stems: Purge compo nent A side.
System Operation 98 312779E Purging Sampling V alves and Tubes Fol low thi s proc edure af ter met er ca libr ation. 1. Go to Sta ndby mode (remove M ix input). 2. See F IG . 106, pa ge 94. Clos e both fluid s hutoff valves and samp ling valv es. 3. Route th e sampling t ubes into a grounded wa ste containe r.
System Operat ion 312779E 99 Solvent Push Fe ature The Solve nt Push featu re enabl es the user to save some mix ed mater ial by pus hing it ou t to the gun with solvent . The q uantity saved is 50% of th e potlif e volume entered i n Advanced Setup Scre en 1 on page 39.
Meter Cal ibratio n 100 312779E Meter Ca libration Calibrate th e meter: • The first time the sys tem is oper ated. • Wheneve r new mate rials are used in the s ystem, especia lly if the material s have v iscositie s that diffe r signifi cantly. • At least once per mo nth as part o f regular mainte- nance .
Meter Cal ibration 312779E 10 1 8. Dispens e compone nt A or B in to beaker. a. To avoid s plashing, s lowly open sampling valv es. b. For mo re accura te calibra tion, adju st the val ve to dispen se at a flow ra te similar to your prod uc- tion spray flow rate.
Color Ch ange 102 312779E Color Change Color Change Pro cedures Multiple Color System s 1. Shut off ai r to the g un. 2. Place th e gun in the gun flush box if used , and clos e the lid. 3. Go to Sta ndby mode (rem ove Mix input). 4. Select t he new recip e.
Color Change 312779E 10 3 Color Purge/Dump Step P0- P1 • This seq uence flu shes out the color with s olvent, from the col or valve to th e Dump A v alve. • The color change solv ent valve an d the Dump A valve o pen during t he Purge Time. • The color change solv ent valve clos es when the Pur ge Tim e ex pire s.
Color Ch ange 104 312779E NOTES: * F IG . 118 and F IG . 119 show bot h color and catal yst change. If the co lor or cataly st is not changing, di sregard that portion of the chart. ** F IG . 120 and F IG . 121 show color c hange. If th e color is no t changin g, disrega rd that porti on of the c hart.
Color Change 312779E 10 5 F IG . 109: Color Change C hart 1 Valv e Time- Sequ ence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A A Catalyst Change B B P0 P1 P2 P3 P4 Color .
Color Ch ange 106 312779E F IG . 111: Color Change Cha rt 3 Valv e Time -Se quenc e Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A A Catalyst Change B B P0 P1 P2 P3 P4 Color.
Color Change 312779E 10 7 F IG . 113: Color Change C hart 5 Valv e Time -Se quenc e Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A A Catalyst Change B B P0 P1 P2 P3 P4 Catal.
Color Ch ange 108 312779E F IG . 115: Color Change Cha rt 7 Valv e Time- Sequ ence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A A Catalyst Change B B P0 P1 P2 P3 P4 Color .
Color Change 312779E 10 9 F IG . 117: Color Change C hart 9 Valv e Time- Sequ ence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A A A Catalyst Change B Air Chop Time B Solve.
Color Ch ange 110 312779E F IG . 119: Color Change Cha rt 11 Valve Time-Sequen ce Dump A A Dump B B Color Change Solvent Catalyst Change Solvent Color Change A A A Catalyst Change B B B Air Purge Solv.
Color Change 312779E 11 1 F IG . 121: Color Change C hart 13 Valve Time-Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A A A Catalyst Change B Air Purge Solve nt Purg.
Color Ch ange 112 312779E F IG . 123: Color Change Cha rt 15 Valve Ti me-Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A A Catalyst Change B Air Chop Time B Solvent .
Color Change 312779E 11 3 F IG . 125: Color Change C hart 17 Valve Time-Sequen ce Dump A A Dump B B Color Change Solvent Catalyst Change Solvent Color Change A A A Catalyst Change B B B Air Purge Solv.
Color Ch ange 114 312779E.
Alar ms and Warn ings 312779E 11 5 Alarms and Warnings NOTE: Do not us e the fluid in the line t hat was di s- pense d off ratio as it may n ot cure prope rly. System Alarms System alarms ale rt you o f a proble m and hel p prevent off-ratio s praying.
Alarm Tro ubleshoo ting 116 312779E Alarm Troubleshoot ing Table 17. Alarm Troubleshooting E-1: COMM ERROR Cause Solution No power to the Easy Key. Connect power to E asyKey. No power to Fluid Sta tion. The in trinsically s afe power cable be tween the Ea syKey and Fluid S tation is not con- nected.
Alarm Tro ubleshoo ting 312779E 11 7 E-3: RATIO HIGH ALARM Sequ ential Dos ing Syst em The mix r atio is hig her than the s et toleranc e on the pr evious do se cycle. Dynamic Dosing System The mix r atio is hig her than t he set toler ance for an A to B com ponent vo lume com parison.
Alarm Tro ubleshoo ting 118 312779E E-4: RATIO LOW ALARM Sequ ential Dos ing Syst em The mix r atio is lowe r than the se t toleran ce on the previous d ose cycle. Dynamic Dosing System The mix rati o is lower than the se t toleran ce for an A to B compone nt volume comparis on.
Alarm Tro ubleshoo ting 312779E 11 9 E-5: OVERDOSE A/B DOSE TOO SHORT ALARM and E-6: OVERDOSE B/A DOSE TOO SHORT ALARM E-5: the A dose over shoots and, when comb ined with B, is too lar ge for the m ix cham ber capaci ty.
Alarm Tro ubleshoo ting 120 312779E E-7: DOSE TIME A ALARM and E-8: DOSE TIME B ALARM E-7: gun trigger in put is acti ve (AFS or Integration) and no A meter puls es are detec ted during t he dose time sele cted. E-8: gun trigger in put is acti ve (AFS or Integration) and no B meter puls es are detec ted during t he dose time sele cted.
Alarm Tro ubleshoo ting 312779E 12 1 E-9: MIX IN SETUP ALARM Cause Solution Attemp t to operate s ystem wh ile in Setup mode. Syste m must be in Standby to chang e current recipe, and can not be oper ated. E-10: REMOTE STOP ALARM Cause Solution Automatio n has requ ested that the sy stem abort al l oper- ations.
Alarm Tro ubleshoo ting 122 312779E E-12: CAN COMM E RROR ALARM Cause Solution Commun ication betwe en the Colo r Change M odule and the Fluid S tation is interrupt ed. • Verify that all cab les are conne cted secu rely and th at the Color Change po wer LED turns on.
Alarm Tro ubleshoo ting 312779E 12 3 E-15: SYSTE M IDLE WARNING Cause Solution Mix inpu t is high, but the gu n has not been triggered fo r 2 minutes. If not painting, cl ear alarm and resume ope ration. If painti ng, shut d own and ins pect fluid meter.
Alarm Tro ubleshoo ting 124 312779E E-19: I/O ALARM Cause Solution The Mix and Pur ge digital inputs are on at the s ame time. Ensure th at only o ne input i s on at a time . At least 1 sec dela y is requir ed when swi tching from Mix to P urge or vice ve rsa.
Alarm Tro ubleshoo ting 312779E 12 5 E-20: PURGE INITIA TE ALARM Cause Solution System detects atomi zing air to the gun wh en purge is sele cted. Shut off g un air. For sys tems with a gun flush b ox, gun is not in th e box when purg e is selected . Place gun in gun flush bo x.
Alarm Tro ubleshoo ting 126 312779E E-25: AUTO DUMP COMPLETE ALARM Cause Solution A potlife ala rm is active for mor e than 2 minutes , the gun flush bo x is en abled and gun is in the gun fl ush box, an d an auto dum p flush s equence is complet e. Be sur e to spray al l mixed material bef ore potlife ex pires.
Schemati c Diagr ams 312779E 12 7 Schemat ic Diag rams System Pneumatic Schem atic 3/8 AIR FIL TER MANU AL DRAIN 5 MICRON W ALL MOUNT ONL Y FLUSH AIR TO FL UID INLET 1/4 TUBE TO MANIFOLD 1/4 TUBE 4-W .
Schema tic Diag rams 128 312779E System Electrical Schema tic NOTE: The elect rical sc hematic illus trates a ll possib le wiring ex pansion s in a Pro Mix 2KS sy stem.
Schemati c Diagr ams 312779E 12 9 System Electrical Sc hematic NOTE: The elect rical sc hematic illus trates a ll possib le wiring ex pansion s in a Pro Mix 2KS sy stem.
Schema tic Diag rams 130 312779E EasyKey Electrical Schematic J9 4 3 2 1 GREEN/BLACK/WHITE 22 A WG RED/BLACK/WHITE 22 A WG BLACK 18 A WG RED 18 AWG - + ALARM - - + DC OK POWER SUPPL Y COMMON 24 VDC+ B.
Meter Perfo rmanc e Data (G30 00 on A and B) 312779E 13 1 Meter Perf ormance Dat a (G3000 on A and B) 0 500 1000 1500 2000 2500 3000 3500 3800 1:1 2:1 3:1 4:1 5:1 6:1 7:1 8:1 9:1 10:1 11:1 12:1 13:1 1.
Meter Perf ormance Da ta (G3000 on A, Coriolis on B) 132 312779E Meter Perf ormance Data (G300 0 on A, Coriolis on B) 0 500 1000 1500 2000 2500 3000 3500 3800 1:1 2:1 3:1 4:1 5:1 6:1 7:1 8:1 9:1 10:1 .
Technica l Data 312779E 13 3 Technical Data * Dep endent on programmed K-fa ctor and app licatio n. The maximum allowable flow meter pulse freq uency is 4 25 Hz (pulses /sec). F or more deta iled informati on on visco sities, flo w rates, o r mixing rati os, consul t your Gra co dis- tributor .
All written and visual data contained in this document reflects t he latest product i nformation available at the time of publica tion. Graco rese rves the right to make changes at any time without notice. Graco H eadquarte rs: Minneapol is International O ffices: Bel gium, China, J apan, Korea GRACO INC.
An important point after buying a device Graco TI12553a (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Graco TI12553a yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Graco TI12553a - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Graco TI12553a you will learn all the available features of the product, as well as information on its operation. The information that you get Graco TI12553a will certainly help you make a decision on the purchase.
If you already are a holder of Graco TI12553a, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Graco TI12553a.
However, one of the most important roles played by the user manual is to help in solving problems with Graco TI12553a. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Graco TI12553a along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
