Operation
®
ProMix 2KS
312776F
EN
Plural Component Proportioner
Manual system for proportional mixing of plural component coatings.
For professional use only.
Approved for use in explosive atmospheres (except the EasyKey).
components shown are not included with all systems.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
TI12504a
#
53
0359
II 2 G
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Related Manuals
Related Manuals
Equipment Approvals
Equipment approvals appear on the following labels
which are attached to the Fluid Station and EasyKey™.
See FIG. 1 on page 4 for label locations.
Component Manuals in English
Manual Description
312775 ProMix 2KS Manual System Installation
312777 ProMix 2KS Manual System Repair-Parts
312781 Fluid Mix Manifold
EasyKey and Fluid Station Label
ATEX Certificate is listed here
312782 Dispense Valve
312783 Color Change Valve Stacks
312787 Color Change Module Kit
312784 Gun Flush Box Kits
ꢋꢎꢘꢄꢙꢚ&ꢛꢜꢏ
ꢅꢆꢈꢉꢌꢆꢇꢌꢋꢂꢏꢏꢘꢄꢓꢂꢕꢁꢄꢚꢅꢓꢛꢄꢓꢘꢇꢈꢁꢖꢙꢄꢄꢅꢆꢇꢈꢂꢏꢏꢄ
ꢗꢁꢉꢄꢅꢓꢄꢜꢍꢆꢈꢉꢍꢏꢄꢝꢉꢂꢞꢌꢆꢑꢄꢟꢍꢙꢄꢠꢡꢢꢡꢣꢣꢙ
ꢗꢝꢞꢟꢠꢎꢘꢡꢙꢟꢇꢋꢎꢘꢢꢘꢎꢠꢙꢘꢡꢞꢎ
ꢤꢂꢇꢘꢥꢁꢘꢄꢅꢆꢈꢁꢉꢕꢂꢋꢁꢄꢅꢓꢄꢦꢇꢇꢍꢋꢌꢂꢈꢁꢃ
ꢦꢗꢗꢂꢉꢂꢈꢊꢇꢄꢕꢍꢉꢄꢊꢇꢁꢄꢌꢆꢄꢆꢍꢆꢄꢧꢂꢨꢂꢉꢃꢍꢊꢇ
ꢏꢍꢋꢂꢈꢌꢍꢆꢩꢄꢞꢌꢈꢧꢄꢅꢓꢄꢜꢍꢆꢆꢁꢋꢈꢌꢍꢆꢄꢈꢍꢄꢓꢖꢂꢉꢈꢄ
ꢥ
ꢒꢏ
ꢪꢏꢊꢌꢃꢄꢫꢏꢂꢈꢁꢄꢅꢓ
ꢐꢄꢃꢴꢅꢔꢗꢆꢃꢃꢁꢵ
ꢈꢈꢇꢛꢇꢰ
310745 Gun Air Shutoff Kit
ꢈꢡꢠꢎꢙꢡꢨꢙꢟꢌꢝꢝꢩꢇꢨꢌꢪꢞ
ꢞꢫꢬꢙꢢꢭꢞꢡꢠꢇꢪꢘꢎꢇꢥꢝꢌꢨꢨꢇꢈꢮ
ꢓꢙꢯꢇꢂꢮꢇꢰꢎꢘꢬꢢꢇꢓꢮꢇꢔꢱ
ꢔꢌꢇꢲꢇꢳꢛꢃꢤꢥꢇꢠꢘꢇꢣꢃꢤꢥ
ꢦꢗꢗꢂꢉꢂꢈꢊꢇꢄꢕꢍꢉꢄꢊꢇꢁꢄꢌꢆꢒ
ꢜꢏꢂꢇꢇꢄꢅꢩꢄꢝꢌꢬꢌꢇꢌꢍꢆꢄꢭꢩꢄꢮꢉꢍꢊꢗꢄꢝꢄꢯꢣ
ꢰꢂꢨꢂꢉꢃꢍꢊꢇꢄꢱꢍꢋꢂꢈꢌꢍꢆꢇ
ꢗꢚꢇꢙꢌꢇꢈꢈꢅꢇꢔꢱ
312786 Dump Valve and Third Purge Valve Kits
312785 Network Communication Kits
308778 G3000/G3000HR Flow Meter
313599 Coriolis Flow Meter
ꢀꢁꢂꢃꢄꢅꢆꢇꢈꢉꢊꢋꢈꢌꢍꢆꢄꢎꢂꢆꢊꢂꢏ
ꢐꢂꢉꢆꢌꢆꢑꢒꢄꢓꢊꢔꢇꢈꢌꢈꢊꢈꢌꢍꢆꢄꢍꢕꢄꢋꢍꢖꢗꢍꢆꢁꢆꢈꢇ
ꢖꢂꢘꢄꢌꢖꢗꢂꢌꢉꢄꢌꢆꢈꢉꢌꢆꢇꢌꢋꢄꢇꢂꢕꢁꢈꢘꢙ
ꢄꢅꢆꢇꢅꢈꢉꢇꢊꢋꢉ
ꢀꢁ
ꢁ
ꢂꢃꢃ
ꢋꢅꢉꢔꢇꢕꢖꢀ
ꢏꢗꢉꢈꢗꢏ
ꢏꢗꢉꢈꢅꢑ
ꢄꢋꢌ
ꢍꢌꢎ
ꢋꢏꢈ
ꢄꢅꢆꢇꢐꢑꢒꢈꢓꢇꢊꢋꢉ
313290 Floor Stand Kit
ꢄꢐꢰꢀꢇꢷꢉꢀ
ꢰꢉꢅꢥꢖꢇꢈꢕꢥꢀ
ꢋꢀꢖꢀꢇꢶꢘꢚꢇꢂꢵꢵꢂ
ꢄꢙꢡꢡꢞꢌꢢꢘꢝꢙꢨꢮꢇꢄꢕꢇ
ꢣꢣꢵꢵꢃꢇꢒꢀꢏꢀꢅꢀ
313542 Beacon Kit
ꢄꢅꢆꢇꢔꢗꢄꢋꢍꢇꢣꢌꢎꢃꢤꢥꢇꢦꢂꢛꢋꢛꢏꢤꢈꢐꢧ
ꢄꢋꢌ
313386 Basic Web Interface/Advanced Web Inter-
face
406799 15V256 Automatic System Upgrade Kit
406800 15V825 Discrete I/O Board Kit
Fluid Station Label
®
FLUID PANEL
ProMix 2KS
.7MAX AIR WPR
7
100
PSI
PART NO.
SERIES SERIAL MFG. YR.
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
312776F
3
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System Configuration and Part Numbers
System Configuration and Part Numbers
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.
Manual
System Control and Display A and B Meter
Color Valves
Catalyst Valves Applicator Handling
M
D = EasyKey with LCD 0 = No Meters
Display
0 = No Valves
(single color)
0 = No Valves
(single catalyst)
1 = One Air Flow
Switch Kit
1 = G3000 (A and B)
1 = Two Valves
(low pressure)
1 = Two Valves
(low pressure)
2 = Two Air Flow
Switch Kits
2 = G3000HR (A and
B)
2 = Four Valves
(low pressure)
2 = Four Valves
(low pressure)
3 = One Gun Flush Box
Kit
3 = 1/8 in. Coriolis (A)
and G3000 (B)
3 = Seven Valves 3 = Two Valves
4 = Two Gun Flush Box
4 = G3000 (A) and 1/8
in. Coriolis (B)
(low pressure)
(high pressure) Kits
4 = Twelve Valves
(low pressure)
5 = 1/8 in. Coriolis (A)
and G3000HR (B)
5 = Two Valves
(high pressure)
6 = G3000HR (A) and
1/8 in. Coriolis (B)
6 = Four Valves
(high pressure)
7 = 1/8 in. Coriolis (A
and B)
ꢋꢎꢘꢄꢙꢚ&ꢇꢛꢜꢏ
ꢅꢆꢈꢉꢌꢆꢇꢌꢋꢂꢏꢏꢘꢄꢓꢂꢕꢁꢄꢚꢅꢓꢛꢄꢓꢘꢇꢈꢁꢖꢙꢄꢄꢅꢆꢇꢈꢂꢏꢏꢄ
ꢗꢁꢉꢄꢅꢓꢄꢜꢍꢆꢈꢉꢍꢏꢄꢝꢉꢂꢞꢌꢆꢑꢄꢟꢍꢙꢄꢠꢡꢢꢡꢣꢣꢙ
ꢤꢂꢇꢘꢥꢁꢘꢄꢅꢆꢈꢁꢉꢕꢂꢋꢁꢄꢅꢓꢄꢦꢇꢇꢍꢋꢌꢂꢈꢁꢃ
ꢦꢗꢗꢂꢉꢂꢈꢊꢇꢄꢕꢍꢉꢄꢊꢇꢁꢄꢌꢆꢄꢆꢍꢆꢄꢧꢂꢨꢂꢉꢃꢍꢊꢇ
ꢏꢍꢋꢂꢈꢌꢍꢆꢩꢄꢞꢌꢈꢧꢄꢅꢓꢄꢜꢍꢆꢆꢁꢋꢈꢌꢍꢆꢄꢈꢍꢄꢓꢖꢂꢉꢈꢄ
ꢪꢏꢊꢌꢃꢄꢫꢏꢂꢈꢁꢄꢅꢓ
ꢗꢝꢞꢟꢠꢎꢘꢡꢙꢟꢇꢋꢎꢘꢢꢘꢎꢠꢙꢘꢡꢞꢎ
ꢥ
ꢒꢏ
ꢐꢄꢃꢴꢅꢔꢗꢆꢃꢃꢁꢵ
ꢈꢈꢇꢛꢇꢰ
ꢈꢡꢠꢎꢙꢡꢨꢙꢟꢌꢝꢝꢩꢇꢨꢌꢪꢞ
ꢞꢫꢬꢙꢢꢭꢞꢡꢠꢇꢪꢘꢎꢇꢥꢝꢌꢨꢨꢇꢈꢮ
ꢓꢙꢯꢇꢂꢮꢇꢰꢎꢘꢬꢢꢇꢓꢮꢇꢔꢱ
ꢔꢌꢇꢲꢇꢳꢛꢃꢤꢥꢇꢠꢘꢇꢣꢃꢤꢥ
Label Location
on Fluid Station
Label Location
on EasyKey
TI12418a
ꢦꢗꢗꢂꢉꢂꢈꢊꢇꢄꢕꢍꢉꢄꢊꢇꢁꢄꢌꢆꢒ
ꢗꢚꢇꢙꢌꢇꢈꢈꢅꢇꢔꢱ
ꢜꢏꢂꢇꢇꢄꢅꢩꢄꢝꢌꢬꢌꢇꢌꢍꢆꢄꢭꢩꢄꢮꢉꢍꢊꢗꢄꢝꢄꢯꢣ
ꢰꢂꢨꢂꢉꢃꢍꢊꢇꢄꢱꢍꢋꢂꢈꢌꢍꢆꢇ
ꢀꢁꢂꢃꢄꢅꢆꢇꢈꢉꢊꢋꢈꢌꢍꢆꢄꢎꢂꢆꢊꢂꢏ
ꢐꢂꢉꢆꢌꢆꢑꢒꢄꢓꢊꢔꢇꢈꢌꢈꢊꢈꢌꢍꢆꢄꢍꢕꢄꢋꢍꢖꢗꢍꢆꢁꢆꢈꢇ
ꢖꢂꢘꢄꢌꢖꢗꢂꢌꢉꢄꢌꢆꢈꢉꢌꢆꢇꢌꢋꢄꢇꢂꢕꢁꢈꢘꢙ
TI12423a
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. 1: Identification Label
4
312776F
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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 MD2531 has a maximum working pressure of 3000 psi (21 MPa, 210 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]). . . . . . . 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)
Color Change Option 5 and 6 and
Catalyst Change Option 3 (high pressure valves) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 psi (21 MPa, 210 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
B Side Dump Valve, if multiple catalyst valves
Booth Control
Basic Web Interface
312776F
5
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Accessories
Accessories
Accessory
Gun Flush Box Gun Insert Selection
15V354 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)
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
15V337 Advanced Web Interface
15V256 Automatic Mode Upgrade Kit
16D329 S3000 Solvent Flow Meter Kit
15V825 Discrete I/O Integration Board Kit
NOTE: This is not a complete list of available accesso-
ries and kits. Refer to the Graco website for more infor-
mation about accessories available for use with this
product.
6
312776F
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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.
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.
312776F
7
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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
8
312776F
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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.
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Glossary of Terms
Glossary of Terms
Advanced Web Interface (AWI) - This allows remote
ProMix backup and restore, configuration, logging, and
software update options.
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.
Air Chop - the process of mixing air and solvent
together during the flush cycle to help clean the lines
and reduce solvent usage.
Custom Language - A method to load a translation file
into the ProMix to display languages other than those
built into the system. Only Unicode characters through
codespace 0x00FF are supported.
Air Chop Time- duration of each activation of the air
purge valve during a chop sequence. User settable from
0.0-99.9 seconds.
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.
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.
Discrete I/O - refers to data that constitutes a separate
entity and has direct communication to another control.
B Purge After Chop - Optional 2-second B solvent
valve activation after the Chop sequence. This is used
to separate the chop material and the Final Purge mate-
rial to prevent unwanted mixing.
Dose Size - the amount of resin (A) and catalyst (B) that
is dispensed into an integrator.
Dose Time Alarm - the amount of time that is allowed
for a dose to occur before an alarm occurs. More than
30 pulses from the flow meter of the active dose valve
are needed while the Gun Trigger is on to prevent the
alarm.
Basic Web Interface (BWI) - This allows remote Pro-
Mix backup and restore, logging, and software update
options.
Bootloader - The utility program that handles initial sys-
tem startup re-programming of the main ProMix applica-
tion.
Dynamic Dosing - Component A dispenses constantly.
Component B dispenses intermittently in the necessary
volume to attain the mix ratio.
Chop Time- refers to the total length of the chop
sequence during a purge. User settable from 0-999 sec-
onds.
Ethernet - a method for directly connecting a computer
to a network or equipment in the same physical location.
Closed Loop Flow Control - refers to the process
when the flow rate is adjusted automatically to maintain
a constant flow.
ExtSP - External Set Point selection for PLC input of the
flow rate set point while operating in Flow Control Over-
ride mode.
Color/Catalyst Purge - 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.
Fiber Optic Communication - the use of light to trans-
mit communication signals. Blue is the transmitter, and
black is the receiver. This must be cross-connected
between the EasyKey and the Fluid Panel for communi-
cation to work. The Fiber Optic cable has a blue band to
indicate the proper connection.
Color/Catalyst Fill - refers to the time required to fill the
lines from the color or catalyst change module to the mix
manifold.
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.
Command Holdoff - The amount of time that flow rate
learning is not allowed after the set point is changed to
allow the flow rate to stabilize.
Final Purge Time- duration of the final purge cycle.
User settable from 0-999 seconds.
10
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Glossary of Terms
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
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.
First Purge Time- duration of the first purge cycle. User
Kd - refers to the amount the fluid flow system attempts
settable from 0-999 seconds.
to not overshoot the target set point.
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.
Ki - refers to the degree fluid flow over shoots its set
point.
Kp - refers to the speed in which the fluid flow reaches
Flow Rate Analog Signal - the type of communication
its set point.
signal that can be used on the ProControl module.
Learn Strength - How much and how quickly to apply
the difference in the flow rate set point compared to the
measured flow rate when updating the flow control data
table.
Flow Rate Tolerance - the settable percent of accept-
able variance that the system will allow before a flow
rate warning occurs.
Flow Set Point - a predefined flow rate target.
Manual Mode - when the proportioning or flow control
system is controlling the inputs without any input from
an outside control.
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).
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).
Global - indicates that values on the screen apply to all
recipes, 1 through 60.
Grand Total - a non-resettable value that shows the
Mix - when cross-linking of the resin (A) and catalyst (B)
total amount of material dispensed through the system.
occurs.
GT-Off Drive Time - The amount of time to regulate the
fluid pressure based on the flow rate set point after the
gun trigger is closed.
Mix Fill Push - An option for the Autodump selection to
automatically clear the Potlife alarm if the gun is in the
Gun Flush Box by running new mixed material through
the gun.
GT-Off Target Rise - The additional time to regulate the
fluid pressure based on the flow rate set point after the
gun trigger is closed.
Mix Input Signal- refers to system mode status where
system begins a dose sequence each time the mix sig-
nal is made “High”.
Gun Trigger Holdoff - The amount of time that flow rate
learning is not allowed after the gun trigger is opened to
allow the flow rate to stabilize.
Mixed Material Fill Time - the amount of time that is
required to load mixed material from the dose valves to
the applicator/gun.
Gun Trigger Input Signal - used to manage ratio
assurance dose times and flow control processes.
Modbus/TCP - a type of communication protocol used
to communicate Digital I/O signals over an ethernet.
Intrinsically Safe (IS) - refers to the ability to locate cer-
tain components in a hazardous location.
Network Station - a means to identify a particular indi-
vidual proportioning or flow control system.
Idle - if the gun is not triggered for 2 minutes the system
enters Idle mode. Trigger the gun to resume operation.
One-Point Learning - Flow Control table calibration
method using learned points above a specified flow rate
to interpolate the table at low flow rates with short gun
trigger times.
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.
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Glossary of Terms
Overdose (A, B, C) Alarm - when either the resin (A),
or catalyst (B), or reducer (C) component dispenses too
much material and the system cannot compensate for
the additional material.
Third Purge Valve - refers to the use of three purge
valves used to flush some waterborne materials. The
valves are used to flush with water, air and solvent.
V/P - refers to the voltage to pressure device in the flow
Potlife Time - the amount of time before a material
control module.
becomes unsprayable.
Valve Holdoff Maximum - The maximum amount of
time that flow rate learning is not allowed after a dose
valve cycles. The system may internally use a time less
than is based on the stability of the fluid meter pulse
stream.
Potlife Volume - the amount of material that is required
to move through the mix manifold, hose and applicator
before the potlife timer is reset.
Purge - when all mixed material is flushed from the sys-
tem.
Purge Drive - The voltage drive during the Purge
sequence, maximum of 3300 mV. The response curve
of the V/P regulator is not linear, so it may be necessary
to test the response using Manual Override mode.
Purge Time - the amount of time required to flush all
mixed material from the system.
Purge Volume Alarm - E-11 Alarm occurs if minimum
flush volume is not achieved.
Ratio Tolerance - the settable percent of acceptable
variance that the system will allow before a ratio alarm
occurs.
Sequential Color Change - the process when a color
change is initiated and the system automatically flushes
the old color and loads a new color.
Sequential Dosing - Components A and B dispense
sequentially in the necessary volumes to attain the mix
ratio.
Solvent/3rd Purge Valve Chop Time- duration of each
activation of the solvent or 3rd purge valve during a
chop sequence. User settable from 0.0-99.9 seconds.
Solvent Fill - the time required to fill the mixed material
line with solvent.
Solvent Push - enables the user to save some mixed
material by pushing it out to the gun with solvent.
Requires an accessory solvent meter.
Standby - refers to the status of the system.
System Idle - This warning occurs if the ProMix is set to
Mix, and 2 minutes have elapsed since the system
received a flow meter pulse.
12
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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 with the wall mount fluid station.
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
See Table 1, FIG. 2, and FIG. 3 for the 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)
Used by the operator for daily painting functions including: choosing recipes, initiating job
complete, reading/clearing alarms, and placing the system in Standby, Mix, or Purge
mode. It is typically mounted inside the booth or near the painter.
Booth Control (BC)
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.
Fluid Station (ST)
•
•
•
•
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
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
Fluid Manifold (FM)
•
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.
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Overview
Table 1: Component Descriptions
Component
Description
Three 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.
•
•
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.
Dual Fiber Optic
Cable (FO)
Used to provide power to the Wall Mount Fluid Station.
Fluid Station Power
Supply Cable (PS)
Air Flow Switch: The air flow switch detects air flow to the gun and signals the ProMix
controller when the gun is being triggered. The switch functions with the flow meters to
information.
Applicator
Handling: use Air
Flow Switch (AFS)
or Gun Flush Box
(GFB)
Gun Flush Box: The gun flush box kit provides an automated flushing system for manual
spray guns, and includes an air flow switch.
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Overview
EK
CCM
PS
BC
BCV
FO
ACV
MS
ST
MA
MB
FM
GFB
TI12504a
FIG. 2. Manual System, shown with G3000 Meters, Color/Catalyst Change, One Gun Flush Box, and
Accessory Solvent Flow Meter
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Overview
DVA
FI
DVB
MB
MS
MA
RVB
AT
APV
RVA
SVA
SM
SVB
SPV
TI12556b
FIG. 3. 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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Booth Control
Booth Control
Used by the operator for daily painting functions includ-
ing: changing recipes, signalling job complete, read-
ing/clearing alarms, and placing the system in Standby,
Mix, or Purge mode. It is typically mounted inside the
booth or near the painter.
Table 2: Booth Control Key and Indicator Functions
(see FIG. 4)
Key/Indicator Definition and Function
Up Key
Scrolls recipe numbers up.
Table 2: Booth Control Key and Indicator Functions
(see FIG. 4)
Down Key
Scrolls recipe numbers down.
Key/Indicator Definition and Function
Display
•
Displays recipe number in Run
mode.
Mix Mode Key • Starts Mix mode.
•
If an alarm occurs, displays the
alarm code (E1 to E28) and red
Alarm indicator blinks.
Recipe number displays after
alarm is reset.
If Solvent Push is on, display alter-
nately shows dashes and the per-
•
Green LED remains lit while in Mix
mode or in Idle mode.
•
Press and hold for 5 seconds to
turn on the Solvent Push feature.
•
•
Standby
Mode Key
•
•
Starts Standby mode.
Green LED remains lit while in
Standby mode.
Recipe
Indicator
•
•
Green LED stays lit while a recipe
is in use.
Purge Mode
Key
•
•
Starts Purge mode.
Green LED remains lit while in
Purge mode.
LED shuts off when Up
or
Down keys are pressed or if an
alarm occurs.
•
LED blinks while a new recipe is
loading and turns solid after load-
ing is complete.
Alarm Indicator (red)
Display
•
•
LED blinks when purging.
Select a new recipe by pressing
Up
or Down
keys, then
.
pressing Enter
Alarm Reset
Key and
Indicator
•
•
Red LED blinks when an alarm
occurs.
Press key to reset alarm. LED
shuts off after alarm is reset.
Job Complete • Signals that job is complete, and
Key and
Indicator
resets A and B totalizers.
Green LED blinks once after key is
pressed.
•
Recipe Indicator (green)
TI11614A
Enter Key
Enters selected recipe and starts color
change sequence.
FIG. 4. Booth Control (see Table 2)
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EasyKey Display and Keypad
EasyKey Display and Keypad
Keypad
LCD Display
TI11630A
Navigation Keys
Alarm Reset Key
FIG. 5. EasyKey Display and Keypad
Display
Table 3: EasyKey Keypad Functions (see FIG. 5)
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.
NOTE: Pressing a key to turn on the display back light
will also perform the function of that key. If you are
unsure whether that key will impact your current opera-
tion, use the setup or navigation keys to turn on the dis-
play back light.
Up Arrow: move to previous field or menu
item, or to previous screen within a group.
Down Arrow: move to next field or menu
item, or to next screen within a group.
Keypad
Used to input numerical data, enter setup screens, scroll
through screens, and select setup values.
Left Arrow: move to previous screen group.
Right Arrow: move to next screen 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,
Alarm Reset: resets all active alarms.
If the display becomes unresponsive,
pressing this key 4 times in succession will
re-initialize the display.
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EasyKey Display and Keypad
AC
Fiber Optic Strain
Relief Port
Audible Alarm
Power
Main Power
Access Port
Ground Screw
I/S Power
Graco Web
Interface
Discrete I/O Cable
Connector Ports
TI12638a
TI12657a
FIG. 6. EasyKey Connections and AC Power Switch
AC Power Switch
Graco Web Interface Port
Turns system AC power on or off.
Used to communicate 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
Restore factory defaults
Restore setup password
Audible Alarm
Alerts the user when an alarm occurs. Available settings
for selecting which alarms will cause an audible alarm
Clear the audible alarm by pressing the Alarm Reset
key.
See manual 313386 for more information.
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.
Even after the Alarm Reset key is pressed, the Potlife
Exceeded alarm message will remain displayed until a
sufficient amount of mixed material has been dispensed
to ensure that the expired material has been ejected.
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Run Mode Screens
Run Mode 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. 7. 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. 8. Fluid Plate Programming Screen
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Run Mode Screens
4
5
Status Screen
Potlife Timer: shows remaining potlife time in min-
utes. Two times are shown if there are two guns.
•
Use the Up
or Down
keys to scroll through the
Run screens.
Status Bar: shows current alarm or operation mode
(standby, mix, purge, recipe change, or the current
alarm).
•
•
Press the Setup
key to enter the Setup screens
from the Status screen.
6
7
Current Flow Rate: in cc/min.
The other keys have no function in this Status
screen.
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.
1
10
8
9
8
2
3
4
Current Date and Time
7
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.
9
6
5
10
Lock Symbol: indicates that Setup screens are
FIG. 10. Status Screen
Key to FIG. 10:
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
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.
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Run Mode Screens
Totals Screen
Reset Total Screen
FIG. 11. Totals Screen
FIG. 12. Reset Total Screen
This screen shows the job totals, fill totals, grand totals,
and job number. Use the tabs to reset job totals (Job
Complete), reset solvent totals (Rst Solvent), or go to
If job is reset, job number will increment by one for
default.
Reset Solvent Screen
The job totals generally refer to material dispensed
while in Mix mode. This is likely atomized and sprayed
material with the gun trigger “On”.
The fill totals generally refer to material dispensed while
in Mix-fill mode after a color change or a purge opera-
tion. This is likely not sprayed or atomized, and is dis-
pensed to a purge container.
Solvent Totals and the Rst Solvent tab only appear if
“Meter” is selected under Solvent Monitor in Configure
FIG. 13. Reset Solvent Total Screen
NOTE: Grand totals are not resettable.
The screen will ask if you want to reset solvent total.
Select Yes or No.
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Run Mode Screens
occur after 25% of the remaining volume is mixed.
Refill tank volume to clear the alarm.
Alarms Screens
FIG. 14. Alarms Screen
FIG. 16. Tank Level Low Screen (Tank A Shown)
Two screens show the last 10 alarms. Use the Up
or
Down
keys to scroll between the two screens.
See Table 10 on page 80 for a list of alarm codes.
Level Control Screen
FIG. 15. 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.
See FIG. 16. If the tank volume reaches the low-level
threshold, the EasyKey screen will display the Tank
Level Low alarm and prompt the user to do one of the
following:
1. Refill tank volume to clear the alarm.
2. Resume mixing by selecting “Spray 25% of Remain-
der.” If this selection is chosen, a second alarm will
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Setup Mode
Setup Mode
NOTE: See FIG. 17 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.
TI12784a
FIG. 17. Setup Screens Map
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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 2KS Web Interface
(see manual 313386).
FIG. 20. 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
FIG. 18. Password Screen
NOTE: If a password is activated, Setup Locked dis-
plays momentarily after exiting Setup mode and return-
symbol appears
FIG. 19. Setup Locked Screen
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Setup Mode
Table 4: Component Software Versions
Display (may
vary from
Component
examples shown) Description
EK (EasyKey)
3.01.001
3.01.001
-.-
EasyKey software version.
Fluid Plate software version.
FP (Fluid Plate)
BC (Booth Control)
Booth Control not installed, not detected, or not operational.
Booth Control software version 1.00 or 1.01.
Booth Control software version 2.XX.
1.XX
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)
No Key
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 Manual,
Semi-automatic, or Automatic Mode.
3K AutoKey detected. System can operate in 3K Manual,
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.
Axx By Cz
A30 B4 Cx
Color Change board valve configuration. This shows the num-
ber of valves available for each of the components. This is set
by the configuration switches on the color change boards
connected to the system.
Code Description
-
Component not available with this machine configura-
tion.
x
Component not used with this machine configuration.
Component available but no change stack.
1
4-30 Component available with change stack.
Number of valves flushed with a solvent valve.
IP (Internet Address)
MAC (MAC address)
192.168.178.3
Example of the address EasyKey is set to for basic and
advanced web interface reporting.
00204AAD1810
Example of internet MAC address. Each EasyKey will have a
different value in this format.
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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.
TI12785a
FIG. 21. System Configuration and Option Screens Map
28
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Setup Mode
Screen Timeout
Configure Screen 1
Select the desired screen timeout in minutes (0-99). 5 is
the default.
Configure Screen 2
FIG. 22. Configure Screen 1
Language
Defines the language of the screen text. Select English
(default), Spanish, French, German, Italian, Dutch, Jap-
anese (Kanji), Korean, Chinese (Simplified), and Cus-
tom.
FIG. 23. Configure Screen 2
Month
Enter current month.
NOTE: Refer to document 313386 for instructions on
using the Custom Language feature to modify the
screens to support undefined languages.
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), minutes, and
seconds. 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-YYYY, DD-MM-YYYY, or
YYYY-MM-DD.
Select the desired display units:
•
•
cc/liter (default)
cc/gallon
Buzzer Alarms
As the default, the alarm buzzer is set to “Potlife Only”
and will sound only for the Potlife Alarm (E-2).
Set to “All Alarms” to have the buzzer sound for any
alarm.
Set to “All Except Potlife” to have the buzzer sound for
any alarm except a Potlife Alarm (E2). This option is not
recommended unless another active method of handling
the Potlife Alarm is implemented.
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Setup Mode
Configure Screen 3
Configure Screen 4
FIG. 24. Configure Screen 3
1K/2K/3K
FIG. 25. Configure Screen 4
Dose Time Alarm
Set this value to indicate the system performance level
designation. Selecting a value other than the installed
system level will result in restricted functionality.
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.
Run Mode
Dose Size
NOTE: If an Autokey is installed, additional selections of
Semi-Automatic and Automatic are available.
Select the total dose size (cc) from the pulldown menu:
100, 50, 25, 10, or select DD to turn on dynamic dosing
Indicates that this is a Manual system.
Example:
Dump Valve A
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.
This field only appears if the color change option is
detected from the cc board. Select “On” if an optional
Dump Valve A is installed and desired to be used.
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.
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.
Number of Guns
Enter the number of spray guns (1 or 2).
3rd Flush Valve
Gun Flush Box
Off is default. If the system includes an optional 3rd
flush valve, set to On.
Enter the number of gun flush boxes (Off, 1, or 2).
NOTE: For color change and flushing purposes, it is rec-
ommended that two GFBs are installed when using a
2-gun system.
DD Setup Mode
30
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Setup Mode
Special Outputs
Use of Special Outputs on Manual systems requires
installation of a Discrete I/O Integration Board. Order
Graco Part No. 15V825 Discrete I/O Integration Board
Kit. See manual 406800.
NOTE: At system power up, the Special Outputs may
activate for up to 1/4 second.
Select special outputs (0-4, or 3 + GFB on #4). A selec-
tion of “0” will disable use of the Special Outputs. If the
“3 + GFB on #4” selection is chosen, the other 3 special
outputs (1-3) can be used for user-defined functions and
the special output #4 settings will duplicate those set-
tings established for the Gun Flush Box.
FIG. 26. Configure Screen 4, dynamic dosing
selected
Each output has two different start times and durations
defined on the Recipe Setup screen (Flush and Fill Input
the Advanced Setup screen (Flush and Fill Input is set
Solvent Monitor
Select solvent monitor (Off, Flow Switch, or Meter).
A selection of “Meter” will cause the system to track the
for more information about solvent totals.
FIG. 27. Configure Screen 4, dynamic dosing setup
mode enabled
Web Browser IP
DD Setup Mode
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.
Selecting “DD” in the Dose Size field makes the
Dynamic Dosing setup mode field appear. Select On to
enable DD setup mode, or Off to disable. See page 49
for further information.
Control Network ID
Used for the Graco Gateway network system. See
Graco Gateway manual 312785 for further information.
Configure Screen 5
FIG. 28. Configure Screen 5
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Setup Mode
Option Screens
Screens. Detailed screen descriptions follow.
Minimum Material Fill Volume
Enter 0-9999 cc.
NOTE: Each screen displays the current screen number
and the total number of screens in the group.
Verification Screen
Option Screen 1
FIG. 30. Verification Screen
Verification
FIG. 29. Option Screen 1
Flush Volume Check
This screen appears if Flush and Fill Input or K-factor
Input are changed from “Recipe” to “Global” in Option
This field only appears if Solvent Monitor is set to
If set to “On”, Minimum Flush Volume will appear in
Recipe Setup Screen 2, page 39.
Flush and Fill Input
If set to “Global”, Color/Catalyst Purge and Color/Cata-
If set to “Recipe”, Color/Catalyst Purge and Color/Cata-
lyst Fill are added to Recipe Setup Screen 2, page 39.
K-factor Input
Global mode is useful when the material properties,
flush and fill characteristics, or K-factors are the same
for all materials used by the system.
is added.
added.
32
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Setup Mode
B Purge After Chop
Option Screen 2
NOTE: This is used to isolate the Chop cycle from the
Final Purge cycle with solvent to prevent reaction issues
with some types of materials.
Optional 2-second burst (2 s B) operation of the B Purge
valve on the integrator after the Chop cycle.
change charts and timing information.
FIG. 31. Option Screen 2
Auto Dump
If the auto dump feature is being used, set to “Solvent
Push” or “Mix Fill Push”. Once the auto dump is
enabled, the gun flush box is enabled and the potlife
alarm is active for 2 minutes, the system will automati-
cally flush or push out the old material based on the
selected option.
“Solvent Push” will flush out expired material using the
for more information.
“Mix Fill Push” will push out expired material with new
mixed material. When sufficient material has been
pushed, the potlife alarm will reset. See Mix Fill Push
Flow Rate Monitor
added, enabling setting of high and low flow limits.
If set to “Off,” flow rate monitoring is disabled and Rec-
Solvent Push Enable
information.
To enable the Solvent Push feature, select “Solvent” or
“3rd Valve” (available if 3rd Flush Valve in Configure
Screen 3, page 30, is set to “On”).
To disable the Solvent Push feature, set to “Off.”
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Setup Mode
Advanced Setup Screens
Screens. Detailed screen descriptions follow.
Advanced Setup screens 2, 3,
4, and 5 appear depending on
selections made in Option
screens 1 and 2.
TI12786a
FIG. 32. Advanced Setup Screens Map
34
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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
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.
Advanced Setup Screen 1
Advanced Setup Screen 2
FIG. 33. Advanced Setup Screen 1
Gun 1/Gun2 Potlife Volume
FIG. 34. Advanced Setup Screen 2
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.
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
Screen 3 on page 30).
Use the following information to determine approximate
pot life volume (PLV) in cc:
Hose ID (inches) Volume (cc/foot)*
Chop Type
3/16
1/4
5.43
9.648
21.71
Select “Air/Solvent” or “Air/3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
Screen 3 on page 30). This refers to the process of mix-
ing air and solvent (or air and 3rd flush fluid) together
during the flush cycle, to help clean the lines and reduce
solvent usage.
3/8
Integrator manifold and mixer volume = 75 cc
Spray Gun Volume = 20 cc
(Hose Volume* x Feet of Hose) + 75 + 20 = PLV
Final Purge Source
Color/Catalyst Purge
Select “Air,” “Solvent,” or “3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
Screen 3 on page 30).
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.
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
Advanced Setup Screen 3
Advanced Setup Screen 4
FIG. 35. Advanced Setup Screen 3
FIG. 36. Advanced Setup Screen 4
This screen appears only if Flush and Fill Input is set to
This screen appears only if K-factor Input is set to
K-factor A Meter
Enter the k-factor (cc/pulse) for flow meter A. This is the
amount of material that passes through the flow meter
per pulse (electrical pulse signal).
First Purge Time
Enter the first purge time (0 to 999 seconds).
K-factor B Meter
Total Chop Time
Enter the k-factor (cc/pulse) for flow meter B.
Enter the total chop time (0 to 999 seconds).
K-factor Solvent Meter
Final Purge Time
This field only appears if Solvent Monitor in Configure
(cc/pulse) for the solvent flow meter.
Enter the final purge time (0 to 999 seconds).
Mixed Material Fill Time
Enter the mixed material fill time (0 to 999 seconds). It
refers to the amount of time that is required to load
mixed material from the dose valves to the applica-
tor/gun.
36
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Setup Mode
Advanced Setup Screen 5
FIG. 37. Advanced Setup Screen 5
This screen appears only if Flush and Fill Input is set to
31. The I/O board has four programmable outputs.
On-Purge
Delay time at the start of the purge cycle before the Spe-
cial Output turns on.
Length
Duration for the Special Output to be active during the
purge cycle.
On-Fill
Delay time at the start of the fill cycle before the Special
Output turns on.
Length
Duration for the Special Output to be active during the
fill cycle.
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Setup Mode
Recipe Setup Screens
NOTE: See FIG. 38 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
TI12787a
FIG. 38: Recipe 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
Recipe Setup Screen 2
Recipe Setup Screen 1
FIG. 40. Recipe Setup Screen 2
Minimum Flush Volume
This field only appears if Flush Volume Check is set to
mum flush volume (0 to 9999 cc). Entering 0 disables
this function.
FIG. 39. 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).
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Setup Mode
Recipe Setup Screen 3
Recipe Setup Screen 4
FIG. 42. Recipe Setup Screen 4
FIG. 41. 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
Screen 3 on page 30).
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
Screen 3 on page 30). This refers to the process of mix-
ing air and solvent (or air and 3rd flush fluid) together
during the flush cycle, to help clean the lines and reduce
solvent usage.
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
Screen 3 on page 30.)
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
Recipe Setup Screen 5
Recipe Setup Screen 6
FIG. 43. Recipe Setup Screen 5
FIG. 44. Recipe Setup Screen 6
This screen appears only if K-factor Input is set to “Rec-
This screen appears only if Flow Rate Monitor is set to
K-factor A Meter
Flow Rate Monitor
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).
Select the desired flow rate monitoring (Off, Warning, or
Alarm).
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 in Configure
(cc/pulse) for the solvent flow meter.
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Setup Mode
Recipe Setup Screen 7
FIG. 45. Recipe Screen 7
This screen appears only if Flush and Fill Input is set to
puts is set to 1, 2, 3, 4, or “3 + GFB on #4” in Configure
ble outputs.
NOTE: If the Special Outputs is set to “3 + GFB on #4”,
the Recipe 0 Screen 4 does not display the column of
information for Special 4. That Output assumes the val-
ues assigned to GFB #1.
On-Purge
Delay time at the start of the purge cycle before the Spe-
cial Output turns on.
Length
Duration for the Special Output to be active during the
purge cycle.
On-Fill
Delay time at the start of the fill cycle before the Special
Output turns on.
Length
Duration for the Special Output to be active during the
fill cycle.
42
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Setup Mode
Air Chop Time
Recipe 0 Screens
NOTE: See FIG. 38 on page 38 for a map of the Recipe
Enter the air chop time (0.0 to 99.9 seconds).
0 screens. Detailed screen descriptions follow.
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 is typically used:
•
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.
Recipe 0 Screen 2
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 0 Screen 1
FIG. 47. Recipe 0 Screen 2
Color/Catalyst Purge Time
This field only appears if the system includes a color
change module. It refers to the amount of time required
to flush the lines from the color or catalyst module to the
dose valve or dump valve. Enter the purge time (0 to
999 seconds).
FIG. 46. Recipe 0 Screen 1
First Purge Source
First Purge Time
Enter the first purge time (0 to 999 seconds).
Select “Air,” “Solvent,” or “3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
Screen 3 on page 30).
Total Chop Time
Enter the total chop time (0 to 999 seconds).
Chop Type
Final Purge Time
Select “Air/Solvent” or “Air/3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
Screen 3 on page 30). This refers to the process of mix-
ing air and solvent (or air and 3rd flush fluid) together
during the flush cycle, to help clean the lines and reduce
solvent usage.
Enter the final purge time (0 to 999 seconds).
Final Purge Source
Select “Air,” “Solvent,” or “3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
Screen 3 on page 30.)
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Setup Mode
Recipe 0 Screen 3
Recipe 0 Screen 4
FIG. 48. Recipe 0 Screen 3
FIG. 49. Recipe 0 Screen 4
This screen only appears if Solvent Monitor is set to
or 3rd Flush Valve is set to “On” in Configure Screen 3
on page 30.
This screen appears only if Flush and Fill Input is set to
puts is set to 1, 2, 3, 4, or “3 + GFB on #4” in Configure
ble outputs.
Minimum Flush Volume
NOTE: If the Special Outputs is set to “3 + GFB on #4”,
the Recipe 0 Screen 4 does not display the column of
information for Special 4. That Output assumes the val-
ues assigned to GFB #1.
This field only appears if Flush Volume Check is set to
mum flush volume (0 to 9999 cc).
Exiting Fill Source
On-Purge
This field only appears if 3rd Flush Valve is set to “On” in
Configure Screen 3 on page 30. Select “Off,” “Air,”
“Solvent,” or “3rd Valve.”
Delay time at the start of the purge cycle before the Spe-
cial Output turns on.
Length
Duration for the Special Output to be active during the
purge cycle.
On-Fill
Delay time at the start of the fill cycle before the Special
Output turns on.
Length
Duration for the Special Output to be active during the
fill cycle.
44
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Setup Mode
Calibration Screen
FIG. 50. Calibration Screen
Use this screen to calibrate a meter. Set to “A Meter,” “B
Meter,” or “Solvent Meter” (available if Solvent Monitor
•
•
•
Start - start calibration
Abort - stop calibration
Purge - purge sampling valves after calibration
calibrate a meter.
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System Operation
System Operation
Operation Modes
General Operating Cycle,
Sequential Dosing
Mix
1. The spray gun operator enters and loads the
desired recipe. The color change LED blinks while
recipe is loading, then turns solid when complete.
System mixes and dispenses material.
2. The operator presses the Mix
operation.
key to begin
Standby
Stops the system.
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 is triggered.
Purge
Purges the system, using air and solvent.
4. Components A and B are introduced into the fluid
integrator (FI) one at a time as follows.
Sequential Dosing
Components A and B dispense sequentially in the nec-
essary volumes to attain the mix ratio.
a. Dose Valve A (DVA) opens, and fluid flows into
the integrator.
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.
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.
c. When the target volume dispenses, Dose Valve
A closes.
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.
Recipe (Color) Change
The process when the system automatically flushes out
the old color and loads a new color.
d. Dose Valve B (DVB) opens, and fluid flows into
the integrator and is aligned proportionately with
component A.
Solvent Push
e. Flow Meter B (MB) monitors the fluid volume
dispensed and sends electrical pulses to the
ProMix 2KS controller.
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
f. When the target volume is dispensed, Dose
Valve B closes.
Mix Fill Push
The Mix Fill Push feature enables the user to prevent
potlife expiration of material by mixing and flowing new
complete information.
46
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System Operation
5. The components are pre-mixed in the integrator,
then uniformly blended in the static mixer (SM).
7. If the gun is not triggered for two minutes, the sys-
tem switches to Idle mode, which closes off the mix
manifold dose valves.
NOTE: To control output from the static mixer to the
gun, install an optional fluid pressure regulator.
8. When the gun is triggered again, the ProMix 2KS
continues the process where it left off.
6. Components A and B are alternately fed into the
integrator as long as the gun is triggered.
NOTE: Operation can be stopped at any time by
pressing the Standby
main power switch.
key or shutting off the
Table 5: Sequential Dosing Operation
Dose 2
Ratio = 2.0:1
A = 2
Dose 1
Dose 3
B = 1
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. 51. Wall Mount Fluid Station, Sequential Dosing
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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-
tion and frequency of each injection. See FIG. 52 for a
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. 52. Schematic Diagram of Dynamic Dosing Operation
48
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System Operation
3. Selecting “DD” in System Configure Screen 4
Select a Component B Restrictor Size
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.
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-
ration” to access the configuration screens. FIG. 53.
FIG. 53. Set Up Home Screen
FIG. 55. 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. 54.
FIG. 54. Configure Screen 4, dynamic dosing
selected
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System Operation
Balancing A/B Pressure
If component B pressure is too high, it will push the com-
ponent A stream aside during B injection. The valve will
not open long enough, causing a High Ratio alarm.
B Pressure
Too Low
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. 57. 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.
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. 58. 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-
FIG. 56. B Pressure Too Low, displayed on EasyKey
50
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System Operation
Table 6: 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 Low (see FIG. 56)
•
•
•
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-
FIG. 59.
E
TI11581a
FIG. 59. Valve Adjustment
Table 7: Mix Manifold Valve Settings
Function
Valve
Setting
Dose
(FIG. 59)
Hex nut (E) 1-1/4 turns out
from fully closed
Limits maximum fluid flow rate into integrator
and minimizes valve response time.
Purge
(FIG. 59)
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 and
Fully open during Run/Mix
operation
Closes component A and B ports to integrator
during ratio check or meter calibration. Open
ports during Run/Mix operation.
Sampling
(RVA and
67)
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
Operating Without Air Flow Switch
Air Flow Switch (AFS) Function
It is not recommended to run without an air flow switch.
If a switch fails, replace it as soon as possible.
Air or Air-assisted Guns
The air flow switch (AFS) detects air flow to the gun and
signals the ProMix controller when the gun is triggered.
The AFS functions with the flow meters to ensure that
system components are functioning correctly.
Airless Gun
It is not recommended to use an airless gun with the
ProMix 2KS. Two issues can arise from operating with-
out an air flow switch:
For example, if a flow meter fails or clogs, pure resin or
catalyst could spray indefinitely if the ProMix does not
detect the condition and intervene, which is why the
AFS is so important.
•
Without a gun trigger/air flow switch input the Pro-
Mix 2KS does not know it is spraying and will not
generate a Dose Time Alarm (E-7 or E-8). This
means there is no way to detect a failed meter. You
could spray pure resin or catalyst for 2 minutes with-
out knowing.
If the ProMix detects through the AFS signal that the
gun is triggered, yet there is no fluid flow through the
meter, a Dose Time Alarm (E-7 or E-8) occurs after 40
seconds and the system shuts down.
•
Since the ProMix 2KS does not know it is spraying
because there is no gun trigger/air flow switch input,
it will go into System Idle (E-15) every 2 minutes
when in Mix mode.
System Idle Warning (E-15)
This warning occurs if the ProMix is set to Mix
and 2 minutes have elapsed since the system received
a flow meter pulse.
,
AFS
TI13350a
In applications using the AFS, triggering the gun clears
the warning and you can start spraying again.
FIG. 60: Air Flow Switches
Without the AFS, triggering the gun does not clear the
alarm. To start spraying again, you must press Standby
, then Mix
, then trigger the gun.
52
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System Operation
Start Up
1. Go through the Pre-Operation Checklist in Table 8.
Graco logo, software revision, and “Establishing
Communication” will display, followed by Status
Table 8: Pre-Operation Checklist
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).
In bottom left corner, the system status dis-
plays, which can be Standby, Mix, Purge, or an
alarm notification
Checklist
System grounded
Verify all grounding connections were made. See
the Installation manual.
All connections tight and correct
Verify all electrical, fluid, air, and system connec-
tions are tight and installed according to the
Installation manual.
Check air purge valve tubing
Check the air purge valve supply tube daily for
any visible solvent accumulation. Notify your
supervisor if solvent is present.
Fluid supply containers filled
Check component A and B and solvent supply
containers.
Mix manifold valves set
Check that mix manifold valves are set correctly.
Start with the settings recommended in Mix Mani-
needed.
FIG. 62. Status Screen
3. Make sure that the Booth Control is working. The
active recipe number should display and the
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.
Standby LED
should be lit.
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.
Solenoid pressure set
75-100 psi inlet air supply (0.5-0.7 MPa, 5.2-7
bar)
2. Turn the AC Power Switch ON (I = ON, 0 = OFF).
5. Make sure that the Booth Control is in Standby
mode.
I = ON
TI12656a
FIG. 61. Power Switch
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System Operation
6. Adjust component A and B fluid supplies
as needed for your application. Use low-
est pressure possible.
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.
7. Do not exceed the maximum rated work-
ing pressure shown on the system identification
label or the lowest rated component in the system.
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.
8. Open the fluid supply valves to the
system.
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.
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).
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.
10. If using a gun flush box, place the gun into the box
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.
and close the lid. Press the Purge
key on the
Booth Control. The purge sequence automatically
starts.
12. Turn on atomizing air to the gun. Check the spray
pattern as instructed in your spray gun manual.
If the gun flush box is not used, trig-
ger the gun into a grounded metal
pail until the purge sequence is com-
plete.
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.
When done purging, the Booth Control automati-
cally switches to Standby mode.
11. Adjust the flow rate.
The fluid flow rate shown on the EasyKey Status
screen is for either component A or B, depending on
which dose valve is open. The fluid supply lines on
the screen highlight to show which dose valve is
open.
FIG. 63. Status Screen Flow Rate Display
54
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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.
Single Color Systems
3. Shut off ProMix 2KS power (0 position). FIG. 64.
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. 65.
0 = OFF
NOTE: If a Dose Time alarm (E-7, E-8) occurs,
clear the alarm.
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
TI12657a
FIG. 64. Power Switch
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. 65. Verify that solvent
pressure is reduced to 0.
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.
1. Complete all steps under Single Color Systems,
1. Complete all steps under Single Color Systems,
page 55.
page 55.
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. 65.
4. See FIG. 66. 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. 66. 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. 65.
6. See FIG. 66. Using the solenoid identification labels
as a guide, press and hold the override button 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. 65.
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. 65.
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.
56
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System Operation
Power
F2
F1
J1
Fiber
Optic
CAN
J13
CAN
J12
J3
1
Dose A
Dose B
Valve
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
Purge Valve A
Solenoid
Purge Valve B
Solenoid
Solenoid
TI12652b
FIG. 65. Fluid Solenoids
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System Operation
Solenoid
Identification
Label
Solenoid
Identification
Label
TI12826a
Solvent Solenoid
Overrides
FIG. 66: 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
SPV Solvent Purge Valve
APV Air Purge Valve
SM Static Mixer
AT
FI
AT
Fluid Integrator
Air Purge Valve Air
Supply Tube
TI12556b
APV
RVA
SVA
SM
SVB
SPV
FIG. 67. Wall Mount Fluid Station
58
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System Operation
Purging
If using an electrostatic gun shut off the electrostatics
before flushing the gun.
instructions in your system Installation manual.
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.
To avoid splashing fluid in the eyes, wear eye protec-
tion.
There are 4 purging procedures in this manual:
•
•
•
•
Purging Mixed Material (below)
3. If using a gun flush box, place the gun into the box
and close the lid. Press the Purge
key on the
Booth Control. The purge sequence automatically
starts.
Use the criteria listed in each procedure to determine
which procedure to use.
If the gun flush box is not used, trig-
ger the gun into a grounded metal
pail until the purge sequence is com-
plete.
Purging Mixed Material
There are times when you only want to purge the fluid
manifold, such as:
•
•
•
•
end of potlife
breaks in spraying that exceed the potlife
overnight shutdown
before servicing the fluid manifold assembly, hose
or gun.
When done purging, the Booth Control automati-
cally switches to Standby mode.
NOTE: If necessary, adjust purge sequence so only
one cycle is required.
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.
Trigger the gun to relieve pressure. Engage trigger
lock.
1. Press the Standby
key on the Booth Control.
5. If spray tip was removed, reinstall it.
6. Adjust the solvent supply regulator back to its nor-
mal operating 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.
312776F
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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 flushing,
as no material has been loaded into the system
yet.
1. Press the Standby
key on the Booth Control.
1. Press the Standby
key on the Booth Control.
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 into a grounded metal pail
until the purge sequence is com-
plete.
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
.
60
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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. 65.
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.
312776F
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System Operation
8. Close sampling valves.
Purging Sampling Valves and Tubes
Follow this procedure after meter calibration.
NOTE: Select Abort on Calibration screen to cancel
current calibration and close dose or purge valves.
1. Press the Standby
key on the Booth Control.
9. Fully open both fluid shutoff valves.
sampling valves.
10. On a single color system, reconnect component A
fluid supply line to flow meter A.
3. Route the sampling tubes into a grounded waste
container.
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.
4. On a single color system, attach a solvent supply
line to Flow Meter A inlet.
5. On the EasyKey, press the Setup
access the Advanced Setup screens.
key and
6. Press the Right Arrow
key to select the Calibra-
key and
tion screen. Press the Down Arrow
select Purge from the menu. Press the Enter
key.
Dose A, solvent purge valve (B side), and color
change solvent valves (if used) will open.
FIG. 68. Calibration Screen
7. To avoid splashing, slowly open the sampling
valves and dispense solvent until the valves and
tubes are clean.
NOTE: When performing a calibration purge, the
solvent valve(s) close automatically after 2 minutes
or when Abort is selected on the screen.
62
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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.
close the Dose Valves (DVA, DVB) and open the
Solvent Purge Valve (SPV).
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.
Solvent Push requires an accessory solvent meter (MS).
Order Graco Part No. 16D329 S3000 Solvent Meter Kit.
See manual 308778.
NOTE: To manually interrupt Solvent Push, press the
Standby
3rd purge valve will close. To re-enter Solvent Push,
press the Mix key.
key. The Solvent Purge Valve (SPV) or
side of the fluid station, as explained in the ProMix
2KS Installation Manual.
2. To enable Solvent Push, select “Solvent” or “3rd
5. When the total solvent dispensed exceeds 50% of
the potlife volume, the system will go into Standby
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.
mode.
6. Perform a manual purge or recipe change to purge
the remaining mixed material. This will clear the sys-
tem out of Solvent Push, allowing you to resume
Mix mode.
NOTE: The system must be in Mix to initiate Solvent
Push.
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
DVA is closed
DVB is closed
Key:
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. 69. Solvent Push Setup
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System Operation
Mix Fill Push Feature
The Mix Fill Push feature enables the user to prevent
potlife expiration of material by mixing and flowing new
material through the Gun Flush Box.
1. The system gets a Potlife alarm.
2. The buzzer will do a double "chirp" every 4 seconds
to indicate an impending Mix Fill Push.
Mix Fill Push requires an accessory Gun Flush Box for
each gun that will use this feature. Order Graco Part No.
15V826 Fun Flush Box Kit. See manual 312784.
3. After waiting for the 2-minute Auto Dump time the
system will run the Mix Fill Push.
NOTE: On a one-gun system the gun must be in the
GFB. On a 2-gun system both guns must be in the
GFBs.
NOTE: If the gun is not in the box the Mix Fill Push fea-
ture will not operate.
NOTE: The Mix Fill Push operation will run every time
the Potlife alarm occurs with the gun in the box. Unat-
tended systems can therefore repeatedly perform this
operation as the potlife keeps happening.
4. If one of the guns in not in the GFB, the system will
not perform any of the Mix Fill Push or Auto Dump
operations. The system will retry every 30 seconds
in case the gun is then installed in the GFB.
Mix Fill Push requires a Gun Flush Box for the gun. If
two guns are used, each requires a Fun Flush Box for
this feature to operate. The second Gun Flush Box must
be configured as a Special Output. See Configure
5. With the guns in the GFBs, the system will propor-
tion mixed material through the guns in order to
reset the potlife volume.
6. The alarm is cleared.
To enable Mix Fill Push, select “Mix Fill Push” in the
7. The event is logged in the Alarm Log as two alarms:
E-5 Overdose A and E-6 Overdose B.
FIG. 70. Mix Fill Push Timing Chart
64
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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.
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
tion Screen. Press the Enter
either A Meter, B Meter, or Solvent. Press the Down
Arrow key and select Start from the menu. Start
only one at a time.
key to select the Calibra-
key to select
•
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.
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Meter Calibration
12. After the volume for A, B, or Solvent is entered, the
ProMix 2KS controller calculates the new flow meter
8. Dispense component A, B, or Solvent into beaker.
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.
66
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Color Change
Color Change
Color Change Procedures
Color Change Sequences
sequences. See Table 9 to determine which figure to
reference, based on the recipe change and system con-
figuration. The time sequences are detailed in the fol-
lowing paragraphs.
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. Switch to Standby
mode at the Booth Control.
sources and set desired purge, chop, and fill times.
4. Use the scroll keys,
or
, to select the new
color. Press Enter
sequence.
to begin the color change
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.
5. If a gun flush box is not used, trigger
the gun into a grounded metal pail
until the color change sequence is
complete.
•
•
The system uses the new recipe data for the fill
cycle.
6. When the color change indicator light stops flashing
on the Booth Control, the color change sequence is
complete.
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.
NOTE: The color change timer does not start until
the gun is triggered and fluid flow is detected. If no
flow is detected within 2 minutes, the color change
operation aborts. The Booth Control enters Standby
•
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.
mode at the previous color.
7. When you are ready to spray, remove the gun from
the gun flush box if used, and close its door.
•
•
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.
NOTE: The gun flush box door must be closed for
the atomizing air valve to open.
For systems without dump valves, the First Purge
begins after the Color/Catalyst Change steps are
completed.
8. Press the Mix
key to start spraying.
Single Color Systems
•
•
•
Dump Valve B is required for a Catalyst Change
system.
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 Y, only the fill
cycle data from Recipe Y is used.
3. Press the Mix
key to start spraying.
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Color Change
Color Purge/Dump
First Purge
•
•
•
This sequence flushes out the color with solvent,
from the color valve to the Dump A valve.
Select the First Purge Source (air, solvent, or 3rd valve)
and First Purge Time. For most applications, air is
selected.
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.
Color Fill
Chop Cycle
•
•
•
This sequence fills the line with the new color all the
way to the Dump A valve.
Select the Chop Type (air/solvent or air/3rd valve) and
Chop Times.
The new color valve and the Dump A valve open
during the Fill Time.
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 close
when the Fill Time expires.
Catalyst Purge/Dump
Final Purge
•
•
•
This sequence flushes out the catalyst with solvent,
from the catalyst valve to the Dump B valve.
Select the Final Purge Source (air, solvent, or 3rd valve)
and Final Purge Time. For most applications, solvent is
selected.
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
during the Final Purge Time and closes when the time
expires.
The catalyst change solvent valve closes when the
Purge Time expires.
Catalyst Fill
Fill
•
•
•
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.
The new catalyst valve and the Dump B valve close
when the Fill Time expires.
68
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Color Change
Table 9: Color Change Chart Reference
Starting
Recipe
Ending
Recipe
Change
Type
Dump A
Exiting Fill Refer to Fig.
X
X
0
0
0
0
X
X
0
0
Y
Y
Y
Y
Y
Y
0
Change
Change
Fill
Yes
No
NA
NA
Yes
No
Yes
Yes
No
Fill
Fill
Yes
No
Fill
No
Purge
Purge
Purge
Purge
Yes
No
NA
NA
NA
NA
0
0
Yes
No
0
NOTE: For manual systems, the Digital I/O signals iden-
tified in the color charts on the following pages represent
internal states.
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ProMix 2KS Recipe Change Chart #1 X to Y
Stack Valves A1 to A2, B1 to B2
Dump A Enabled, 3rd Flush Valve Enabled
Color/Catalyst/(Reducer)
Purge from X, Fill from Y -->
Color Change Stack Purge and Fill Operations by Time
B Purge B Fill Waiting
Color Change Stack Flush Sequence
A Purge
A Fill
Stack Valves
Color Change Stack Components
If a component is not changing, that time segment is skipped
Flush out old color and fill with new color
Solvent A
Dump A
Component A
Solvent B
Dump B
Flush out old catalyst and fill with new catalyst
Component B
Separate Gun 1 and Gun 2
Dose Valve and Integrator Flush Purge and Chop Operations by Time
Total Chop 2 s B Final Purge
Dose Valve and Integrator Flush Sequence
Purge from X -->
First Purge
Purge Valves
Purge Operation Details
First Purge Selection
Purge A (Air)
Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Fixed for Purge A (Air)
Purge B (Solvent)
3rd Purge Valve on A
If Chop Type is "Air/Solvent"
If Chop Type is "Air/3rd Purge"
2 s B Purge after Chop
Final Purge Selection
Fixed Purge B. Enabled in Options Screen 2
Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Separate Gun 1 and Gun 2
Dose Valve and Integrator Mix Fill Operations by Time
Fill from Y -->
Dose Valves
Mixed Fill Time using Sequential Dosing
Mixed Fill Time using Dynamic Dosing
Dose A
Dose B
GFB Outputs
Gun and Hose Flush Operations by Time
Gun and Hose Mix Material Fill Operations by Time
If No Gun Flush Boxes
Gun Trigger(s) by Operator
1 Gun
This happens on the same time scale as the Dose Valve and Integrator Flush Sequence
Each Integrator Flush Purge, Chop, and Mix Material Fill operation runs sequentially for Gun 1 then for Gun 2
Discrete I/O Signals by Time
Gun Flush Box Output 1
Gun Flush Box Output 2
2 Guns
Gun Flush Box Output 1
Gun Flush Box Output 2
Digital I/O
Color Change Input
Purge Active Output
Fill Active Output
<- Start of Color Change
End of Color Change ->
Mix Ready Output
Special Outputs
<- Start of On-Purge
<- Length ->
<- Start of On-Fill
<- Length ->
Special Output #1
Special Output #2
Special Output #3
Special Output #4
3 + GFB on #4
<- Length ->
<- Length ->
<- Length ->
<- Length ->
<- Length ->
<- Length ->
2KS X to Y K15
FIG. 71: ProMix 2KS Recipe Change Chart #1 X to Y
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ProMix 2KS Recipe Change Chart #2 X to Y
Stack Valves A1 to A2, B1 to B2
No Dump A, 3rd Flush Valve Enabled
Color/Catalyst/(Reducer)
Purge from X, Fill from Y -->
Stack Valves
Color Change Stack Purge and Fill Operations by Time
B Fill Waiting
Color Change Stack Flush Sequence
A Purge
A Fill
B Purge
Color Change Stack Components
If a component is not changing, that time segment is skipped
Flush out old color and fill with new color
Solvent A
Dump A
No Dump A
Component A
Solvent B
Dump B
Flush out old catalyst and fill with new catalyst
Component B
Separate Gun 1 and Gun 2
Purge from X -->
Purge Valves
First Purge Selection
Dose Valve and Integrator Flush Purge and Chop Operations by Time
First Purge Total Chop 2 s B Final Purge
Dose Valve and Integrator Flush Sequence
Waiting
Purge Operation Details
Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Fixed for Purge A (Air)
Purge A (Air)
Purge B (Solvent)
3rd Purge Valve on A
2 s B Purge after Chop
Final Purge Selection
If Chop Type is "Air/Solvent"
If Chop Type is "Air/3rd Purge"
Fixed Purge B. Enabled in Options Screen 2
Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Separate Gun 1 and Gun 2
Fill from Y -->
Dose Valve and Integrator Mix Fill Operations by Time
Dose Valves
Mixed Fill Time using Sequential Dosing
Mixed Fill Time using Dynamic Dosing
Dose A
Dose B
<- A Purge and A Fill through Dose A with no Dump A
GFB Outputs
Gun and Hose Flush Operations by Time
Gun and Hose Mix Material Fill Operations by Time
If No Gun Flush Boxes
Gun Trigger(s) by Operator
1 Gun
This happens on the same time scale as the Dose Valve and Integrator Flush Sequence
Gun Flush Box Output 1
Gun Flush Box Output 2
2 Guns
Gun Flush Box Output 1
Gun Flush Box Output 2
Each Integrator Flush Purge, Chop, and Mix Material Fill operation runs sequentially for Gun 1 then for Gun 2
Discrete I/O Signals by Time
GFB 1 Only
Digital I/O
Color Change Input
Purge Active Output
Fill Active Output
Mix Ready Output
Special Outputs
Special Output #1
Special Output #2
Special Output #3
Special Output #4
3 + GFB on #4
<- Start of Color Change
End of Color Change ->
<- Start of On-Purge
<- Length ->
<- Start of On-Fill
<- Length ->
<- Length ->
<- Length ->
<- Length ->
<- Length ->
<- Length ->
<- Length ->
2KS X to Y K13
FIG. 72: ProMix 2KS Recipe Change Chart #2 X to Y
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ProMix 2KS Recipe Fill Chart #3 0 to Y
Stack Valves A1, B1
Dump A Enabled, 3rd Flush Valve Enabled
Exiting Fill Enabled
Color/Catalyst/(Reducer)
No Purge, Fill from Y -->
Stack Valves
Color Change Stack Purge and Fill Operations by Time
B Fill
Color Change Stack Fill Sequence
Waiting
A Fill
Color Change Stack Components
Solvent A
Dump A
Only active components are filled
Push out solvent and fill with new color
Push out solvent and fill with new catalyst
Component A
Solvent B
Dump B
Component B
Separate Gun 1 and Gun 2
No Purge -->
Dose Valve and Integrator Flush Purge and Chop Operations by Time
Waiting
Exit. Fill
Purge Valves
Dose Valve and Integrator Flush Sequence
Purge Operation Details
Exiting Fill Selection
First Purge Selection
Purge A (Air)
From Recipe 0
Recipe 0: Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Fixed for Purge A (Air)
Purge B (Solvent)
3rd Purge Valve on A
2 s B Purge after Chop
Final Purge Selection
If Chop Type is "Air/Solvent"
If Chop Type is "Air/3rd Purge"
Fixed Purge B. Enabled in Options Screen 2
Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Separate Gun 1 and Gun 2
Fill from Y -->
Dose Valve and Integrator Mix Fill Operations by Time
Dose Valves
Mixed Fill Time using Sequential Dosing
Mixed Fill Time using Dynamic Dosing
Dose A
Dose B
GFB Outputs
Gun and Hose Flush Operations by Time
Gun and Hose Mix Material Fill Operations by Time
If No Gun Flush Boxes
Gun Trigger(s) by Operator
1 Gun
This happens on the same time scale as the Dose Valve and Integrator Flush Sequence
Gun Flush Box Output 1
Gun Flush Box Output 2
2 Guns
Gun Flush Box Output 1
Gun Flush Box Output 2
Each Integrator Flush Purge, Chop, and Mix Material Fill operation runs sequentially for Gun 1 then for Gun 2
Discrete I/O Signals by Time
Digital I/O
Color Change Input
Purge Active Output
Fill Active Output
Mix Ready Output
Special Outputs
Special Output #1
Special Output #2
Special Output #3
Special Output #4
3 + GFB on #4
<- Start of Color Change
End of Color Change ->
<- Start of On-Purge
<- Length ->
<- Start of On-Fill
<- Length ->
<- Length ->
<- Length ->
<- Length ->
<- Length ->
<- Length ->
<- Length ->
2KS 0 to Y K15
FIG. 73: ProMix 2KS Recipe Fill Chart #3 0 to Y
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ProMix 2KS Recipe Fill Chart #4 0 to Y
Stack Valves A1, B1
Dump A Enabled, 3rd Flush Valve Enabled
No Exiting Fill
Color/Catalyst/(Reducer)
No Purge, Fill from Y -->
Stack Valves
Color Change Stack Purge and Fill Operations by Time
B Fill
Color Change Stack Flush Sequence
A Fill
Color Change Stack Components
Only active components are filled
Solvent A
Dump A
Push out solvent and fill with new color
Component A
Solvent B
Dump B
Push out solvent and fill with new catalyst
Component B
Separate Gun 1 and Gun 2
No Purge -->
Dose Valve and Integrator Flush Purge and Chop Operations by Time
Waiting
Purge Valves
Dose Valve and Integrator Flush Sequence
Purge Operation Details
First Purge Selection
Purge A (Air)
Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Fixed for Purge A (Air)
Purge B (Solvent)
3rd Purge Valve on A
2 s B Purge after Chop
Final Purge Selection
If Chop Type is "Air/Solvent"
If Chop Type is "Air/3rd Purge"
Fixed Purge B. Enabled in Options Screen 2
Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Separate Gun 1 and Gun 2
Fill from Y -->
Dose Valve and Integrator Mix Fill Operations by Time
Dose Valves
Mixed Fill Time using Sequential Dosing
Mixed Fill Time using Dynamic Dosing
Dose A
Dose B
GFB Outputs
Gun and Hose Flush Operations by Time
Gun and Hose Mix Material Fill Operations by Time
If No Gun Flush Boxes
Gun Trigger(s) by Operator
1 Gun
Gun Flush Box Output 1
Gun Flush Box Output 2
This happens on the same time scale as the Dose Valve and Integrator Flush Sequence
Each Integrator Flush Purge, Chop, and Mix Material Fill operation runs sequentially for Gun 1 then for Gun 2
Discrete I/O Signals by Time
2 Guns
Gun Flush Box Output 1
Gun Flush Box Output 2
Digital I/O
Color Change Input
Purge Active Output
Fill Active Output
Mix Ready Output
Special Outputs
Special Output #1
Special Output #2
Special Output #3
Special Output #4
3 + GFB on #4
<- Start of Color Change
End of Color Change ->
<- Start of On-Purge
<- Length ->
<- Start of On-Fill
<- Length ->
<- Length ->
<- Length ->
<- Length ->
<- Length ->
<- Length ->
<- Length ->
2KS 0 to Y K14
FIG. 74: ProMix 2KS Recipe Fill Chart #4 0 to Y
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ProMix 2KS Recipe Fill Chart #5 0 to Y
Stack Valves A1, B1
No Dump A, 3rd Flush Valve Enabled
Exiting Fill Enabled
Color/Catalyst/(Reducer)
No Purge, Fill from Y -->
Stack Valves
Color Change Stack Purge and Fill Operations by Time
B Fill
Color Change Stack Fill Sequence
Waiting
A Fill
Color Change Stack Components
Solvent A
Dump A
Only active components are filled
No Dump A
Push out solvent and fill with new color
Push out solvent and fill with new catalyst
Component A
Solvent B
Dump B
Component B
Separate Gun 1 and Gun 2
No Purge -->
Dose Valve and Integrator Flush Purge and Chop Operations by Time
Waiting
Exit. Fill
Purge Valves
Dose Valve and Integrator Flush Sequence
Purge Operation Details
Exiting Fill Selection
First Purge Selection
Purge A (Air)
From Recipe 0
Recipe 0: Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Fixed for Purge A (Air)
Purge B (Solvent)
3rd Purge Valve on A
2 s B Purge after Chop
Final Purge Selection
If Chop Type is "Air/Solvent"
If Chop Type is "Air/3rd Purge"
Fixed Purge B. Enabled in Options Screen 2
Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Separate Gun 1 and Gun 2
Fill from Y -->
Dose Valve and Integrator Mix Fill Operations by Time
Dose Valves
Mixed Fill Time using Sequential Dosing
Mixed Fill Time using Dynamic Dosing
Dose A
Dose B
<- A Fill through Dose A with no Dump A
GFB Outputs
Gun and Hose Flush Operations by Time
Gun and Hose Mix Material Fill Operations by Time
If No Gun Flush Boxes
Gun Trigger(s) by Operator
1 Gun
This happens on the same time scale as the Dose Valve and Integrator Flush Sequence
Gun Flush Box Output 1
Gun Flush Box Output 2
2 Guns
Gun Flush Box Output 1
Gun Flush Box Output 2
Each Integrator Flush Purge, Chop, and Mix Material Fill operation runs sequentially for Gun 1 then for Gun 2
GFB 1 Only
Digital I/O
Discrete I/O Signals by Time
Color Change Input
Purge Active Output
Fill Active Output
Mix Ready Output
Special Outputs
Special Output #1
Special Output #2
Special Output #3
Special Output #4
3 + GFB on #4
<- Start of Color Change
End of Color Change ->
<- Start of On-Purge
<- Length ->
<- Start of On-Fill
<- Length ->
<- Length ->
<- Length ->
<- Length ->
<- Length ->
<- Length ->
<- Length ->
2KS 0 to Y K13
FIG. 75: ProMix 2KS Recipe Fill Chart #5 0 to Y
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ProMix 2KS Recipe Fill Chart #6 0 to Y
Stack Valves A1, B1
No Dump A, 3rd Flush Valve Enabled
No Exiting Fill
Color/Catalyst/(Reducer)
No Purge, Fill from Y -->
Stack Valves
Color Change Stack Purge and Fill Operations by Time
B Fill
Color Change Stack Flush Sequence
A Fill
Color Change Stack Components
Only active components are filled
Solvent A
Dump A
No Dump A
Push out solvent and fill with new color
Component A
Solvent B
Dump B
Push out solvent and fill with new catalyst
Component B
Separate Gun 1 and Gun 2
No Purge -->
Dose Valve and Integrator Flush Purge and Chop Operations by Time
Waiting
Dose Valve and Integrator Flush Sequence
Purge Valves
Purge Operation Details
First Purge Selection
Purge A (Air)
Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Fixed for Purge A (Air)
Purge B (Solvent)
3rd Purge Valve on A
2 s B Purge after Chop
Final Purge Selection
If Chop Type is "Air/Solvent"
If Chop Type is "Air/3rd Purge"
Fixed Purge B. Enabled in Options Screen 2
Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Separate Gun 1 and Gun 2
Fill from Y -->
Dose Valve and Integrator Mix Fill Operations by Time
Dose Valves
Mixed Fill Time using Sequential Dosing
Mixed Fill Time using Dynamic Dosing
Dose A
Dose B
<- A Fill through Dose A with no Dump A
GFB Outputs
Gun and Hose Flush Operations by Time
Gun and Hose Mix Material Fill Operations by Time
If No Gun Flush Boxes
Gun Trigger(s) by Operator
1 Gun
This happens on the same time scale as the Dose Valve and Integrator Flush Sequence
Gun Flush Box Output 1
Gun Flush Box Output 2
2 Guns
Gun Flush Box Output 1
Gun Flush Box Output 2
Each Integrator Flush Purge, Chop, and Mix Material Fill operation runs sequentially for Gun 1 then for Gun 2
Discrete I/O Signals by Time
GFB 1 Only
Digital I/O
Color Change Input
Purge Active Output
Fill Active Output
Mix Ready Output
Special Outputs
Special Output #1
Special Output #2
Special Output #3
Special Output #4
3 + GFB on #4
<- Start of Color Change
End of Color Change ->
<- Start of On-Purge
<- Length ->
<- Start of On-Fill
<- Length ->
<- Length ->
<- Length ->
<- Length ->
<- Length ->
<- Length ->
<- Length ->
2KS 0 to X K12
FIG. 76: ProMix 2KS Recipe Fill Chart #6 0 to Y
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ProMix 2KS Recipe Purge Chart #7 X to 0
Stack Valves Off
Dump A Enabled, 3rd Flush Valve Enabled
Color/Catalyst/(Reducer)
Purge from 0, No Fill -->
Stack Valves
Color Change Stack Purge and Fill Operations by Time
B Purge
Color Change Stack Flush Sequence
A Purge
Color Change Stack Components
Every recipe 0 entry will flush all components
Solvent A
Dump A
Flush out old color
Component A
Solvent B
Dump B
Flush out old catalyst
Component B
Separate Gun 1 and Gun 2
Purge from 0 -->
Purge Valves
First Purge Selection
Dose Valve and Integrator Flush Purge and Chop Operations by Time
2 s B Final Purge
Dose Valve and Integrator Flush Sequence
First Purge
Total Chop
Purge Operation Details
Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Fixed for Purge A (Air)
Purge A (Air)
Purge B (Solvent)
3rd Purge Valve on A
2 s B Purge after Chop
Final Purge Selection
If Chop Type is "Air/Solvent"
If Chop Type is "Air/3rd Purge"
Fixed Purge B. Enabled in Options Screen 2
Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Separate Gun 1 and Gun 2
No Fill -->
Dose Valve and Integrator Mix Fill Operations by Time
Dose Valves
Mixed Fill Time using Sequential Dosing
Mixed Fill Time using Dynamic Dosing
Dose A
Dose B
GFB Outputs
Gun and Hose Flush Operations by Time
Gun and Hose Mix Material Fill Operations by Time
If No Gun Flush Boxes
Gun Trigger(s) by Operator
1 Gun
This happens on the same time scale as the Dose Valve and Integrator Flush Sequence
Gun Flush Box Output 1
Gun Flush Box Output 2
2 Guns
Each Integrator Flush Purge, Chop, and Mix Material Fill operation runs sequentially for Gun 1 then for Gun 2
Gun Flush Box Output 1
Gun Flush Box Output 2
Digital I/O
Discrete I/O Signals by Time
End of Color Change ->
Color Change Input
Purge Active Output
Fill Active Output
Mix Ready Output
Special Outputs
Special Output #1
Special Output #2
Special Output #3
Special Output #4
3 + GFB on #4
<- Start of Color Change
<- Start of On-Purge
<- Length ->
<- Length ->
<- Length ->
<- Length ->
This activates for Autodump operations only
2KS X to 0 K15
FIG. 77: ProMix 2KS Recipe Purge Chart #7 X to 0
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ProMix 2KS Recipe Purge Chart #8 X to 0
Stack Valves Off
No Dump A, 3rd Flush Valve Enabled
Color/Catalyst/(Reducer)
Purge from X, Fill from Y -->
Stack Valves
Color Change Stack Purge and Fill Operations by Time
Waiting
Color Change Stack Flush Sequence
A Purge
B Purge
Color Change Stack Components
Solvent A
Dump A
Every recipe 0 entry will flush all components
Flush out old color
No Dump A
Component A
Solvent B
Dump B
Flush out old catalyst
Component B
Separate Gun 1 and Gun 2
Purge from 0 -->
Dose Valve and Integrator Flush Purge and Chop Operations by Time
Total Chop 2 s B Final Purge
Dose Valve and Integrator Flush Sequence
Waiting
First Purge
Purge Valves
Purge Operation Details
First Purge Selection
Purge A (Air)
Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Fixed for Purge A (Air)
Purge B (Solvent)
3rd Purge Valve on A
2 s B Purge after Chop
Final Purge Selection
If Chop Type is "Air/Solvent"
If Chop Type is "Air/3rd Purge"
Fixed Purge B. Enabled in Options Screen 2
Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Separate Gun 1 and Gun 2
Dose Valve and Integrator Mix Fill Operations by Time
No Fill -->
Dose Valves
Mixed Fill Time using Sequential Dosing
Mixed Fill Time using Dynamic Dosing
<- A Purge through Dose A with no Dump A
Dose A
Dose B
GFB Outputs
Gun and Hose Flush Operations by Time
Gun and Hose Mix Material Fill Operations by Time
If No Gun Flush Boxes
Gun Trigger(s) by Operator
1 Gun
This happens on the same time scale as the Dose Valve and Integrator Flush Sequence
Gun Flush Box Output 1
Gun Flush Box Output 2
2 Guns
Each Integrator Flush Purge, Chop, and Mix Material Fill operation runs sequentially for Gun 1 then for Gun 2
Gun Flush Box Output 1
Gun Flush Box Output 2
GFB 1 Only
Digital I/O
Discrete I/O Signals by Time
End of Color Change ->
Color Change Input
Purge Active Output
Fill Active Output
Mix Ready Output
Special Outputs
<- Start of Color Change
<- Start of On-Purge
<- Length ->
Special Output #1
Special Output #2
Special Output #3
Special Output #4
3 + GFB on #4
<- Length ->
<- Length ->
<- Length ->
This activates for Autodump operations only
2KS X to 0 K13
FIG. 78: ProMix 2KS Recipe Purge Chart #8 X to 0
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ProMix 2KS Recipe Purge Chart #9 0 to 0
Stack Valves Off
Dump A Enabled, 3rd Flush Valve Enabled
Exiting Fill Enabled
Color/Catalyst/(Reducer)
Purge from 0, No Fill -->
Stack Valves
Color Change Stack Purge and Fill Operations by Time - From Recipe 0
Waiting
A Purge
B Purge
Waiting
Color Change Stack Flush Sequence
Color Change Stack Components
Every recipe 0 entry will flush all components
Solvent A
Dump A
Flush out old color
Component A
Solvent B
Dump B
Flush out old catalyst
Component B
Separate Gun 1 and Gun 2
Purge from 0 -->
Purge Valves
Exiting Fill Selection
First Purge Selection
Purge A (Air)
Dose Valve and Integrator Flush Purge and Chop Operations by Time - From Recipe 0
Total Chop 2 s B Final Purge
Dose Valve and Integrator Flush Sequence
Exit. Fill
First Purge
Purge Operation Details
From Recipe 0
Recipe 0: Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Fixed for Purge A (Air)
Purge B (Solvent)
3rd Purge Valve on A
2 s B Purge after Chop
Final Purge Selection
If Chop Type is "Air/Solvent"
If Chop Type is "Air/3rd Purge"
Fixed Purge B. Enabled in Options Screen 2
Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Separate Gun 1 and Gun 2
No Fill -->
Dose Valve and Integrator Mix Fill Operations by Time
Dose Valves
Mixed Fill Time using Sequential Dosing
Mixed Fill Time using Dynamic Dosing
Dose A
Dose B
GFB Outputs
Gun and Hose Flush Operations by Time
Gun and Hose Mix Material Fill Operations by Time
If No Gun Flush Boxes
Gun Trigger(s) by Operator
1 Gun
This happens on the same time scale as the Dose Valve and Integrator Flush Sequence
Gun Flush Box Output 1
Gun Flush Box Output 2
2 Guns
Each Integrator Flush Purge, Chop, and Mix Material Fill operation runs sequentially for Gun 1 then for Gun 2
Gun Flush Box Output 1
Gun Flush Box Output 2
Digital I/O
Discrete I/O Signals by Time
End of Color Change ->
Color Change Input
Purge Active Output
Fill Active Output
Mix Ready Output
Special Outputs
Special Output #1
Special Output #2
Special Output #3
Special Output #4
3 + GFB on #4
<- Start of Color Change
<- Start of On-Purge
<- Length ->
<- Length ->
<- Length ->
<- Length ->
2KS 0 to 0 K3
FIG. 79: ProMix 2KS Recipe Purge Chart #9 0 to 0
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ProMix 2KS Recipe Purge Chart #10 0 to 0
Stack Valves Off
No Dump A, 3rd Flush Valve Enabled
Exiting Fill Enabled
Color/Catalyst/(Reducer)
Purge from 0, No Fill -->
Stack Valves
Color Change Stack Purge and Fill Operations by Time - From Recipe 0
Waiting
A Purge
B Purge
Waiting
Color Change Stack Flush Sequence
Color Change Stack Components
Every recipe 0 entry will flush all components
Solvent A
Dump A
No Dump A
Flush out old color
Component A
Solvent B
Dump B
Flush out old catalyst
Component B
Separate Gun 1 and Gun 2
Purge from 0 -->
Purge Valves
Exiting Fill Selection
First Purge Selection
Purge A (Air)
Dose Valve and Integrator Flush Purge and Chop Operations by Time - From Recipe 0
First Purge Total Chop 2 s B Final Purge
Dose Valve and Integrator Flush Sequence
Exit. Fill
Waiting
Purge Operation Details
From Recipe 0
Recipe 0: Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Fixed for Purge A (Air)
Purge B (Solvent)
3rd Purge Valve on A
2 s B Purge after Chop
Final Purge Selection
If Chop Type is "Air/Solvent"
If Chop Type is "Air/3rd Purge"
Fixed Purge B. Enabled in Options Screen 2
Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Separate Gun 1 and Gun 2
No Fill -->
Dose Valve and Integrator Mix Fill Operations by Time
Dose Valves
Mixed Fill Time using Sequential Dosing
Mixed Fill Time using Dynamic Dosing
Dose A
Dose B
<- A Purge through Dose A with no Dump A
GFB Outputs
Gun and Hose Flush Operations by Time
Gun and Hose Mix Material Fill Operations by Time
If No Gun Flush Boxes
Gun Trigger(s) by Operator
1 Gun
This happens on the same time scale as the Dose Valve and Integrator Flush Sequence
Gun Flush Box Output 1
Gun Flush Box Output 2
2 Guns
Each Integrator Flush Purge, Chop, and Mix Material Fill operation runs sequentially for Gun 1 then for Gun 2
Gun Flush Box Output 1
Gun Flush Box Output 2
Digital I/O
Discrete I/O Signals by Time
End of Color Change ->
Color Change Input
Purge Active Output
Fill Active Output
Mix Ready Output
Special Outputs
Special Output #1
Special Output #2
Special Output #3
Special Output #4
3 + GFB on #4
<- Start of Color Change
<- Start of On-Purge
<- Length ->
<- Length ->
<- Length ->
<- Length ->
2KS 0 to 0 K1
FIG. 80: ProMix 2KS Recipe Purge Chart #10 0 to 0
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Alarms and Warnings
Alarms and Warnings
NOTE: Do not use the fluid in the line that was dis-
pensed off ratio as it may not cure properly.
To Reset Alarm and Restart
NOTE: When an alarm occurs be sure to determine the
E-Code before resetting it. See Table 10. If you forget
24) to view the last 10 alarms, with date and time
stamps.
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:
•
•
•
•
A red LED illuminates steadily or blinks on the
Booth Control.
Booth Control displays an alarm E-Code, E-1 to
E-28. See FIG. 81.
all alarms).
Status bar on the EasyKey Display shows the alarm
cleared by simply pressing the Alarm Reset
key.
Table 10: System Alarm/Warning Codes
Code Description
Details
Page 81
E-1
E-2
E-3
E-4
E-5
E-6
E-7
E-8
E-9
Communication Error Alarm
E-Code with a description (see Table 10).
Potlife Alarm
Page 81
Page 82
Page 83
Page 84
Page 84
Page 85
Page 85
NA
Ratio High Alarm
Alarm Indicator (red)
Display
Ratio Low Alarm
Overdose A/B Dose Too Short Alarm
Overdose B/A Dose Too Short Alarm
Dose Time A Alarm
Dose Time B Alarm
Not used
E-10 Remote Stop Alarm
E-11 Purge Volume Alarm
Page 86
Page 86
Page 87
E-12 CAN Network Communication Error
Alarm
E-13 High Flow Alarm
Page 88
Page 88
Page 88
Page 88
Page 88
Page 88
Page 89
Page 90
Page 90
Page 90
Page 90
Page 90
Page 91
Page 91
Page 91
Page 91
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
Recipe Indicator (green)
FIG. 81. Booth Control
TI11614A
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
E-28 Mix Fill Push Complete
System Warnings
Table 10 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).
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Alarm Troubleshooting
Alarm Troubleshooting
Table 11. 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.
•
Solvent Purge - See Purging Mixed Material on
page 59. The system purges until the preset purge
time is complete.
•
•
New Mixed Material Purge - Go to Mix mode and
spray the required volume to restart the timer.
312776F
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Alarm Troubleshooting
Table 11. 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.
page 53, 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 11. 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.
page 53, 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 11. 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).
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Alarm Troubleshooting
Table 11. 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 fewer than 31 A meter pulses were detected during the
dose time selected.
E-8: gun trigger input is active (AFS or Integration) and fewer than 31 B meter pulses were detected during the
dose time selected.
Cause
Solution
Fully trigger the gun.
Increase flow rate.
System is in Mix
triggered, allowing air but no fluid to pass through gun.
mode and gun is only partially
Fluid flow rate is too low.
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.
There is an air leak downstream from the air flow switch. Check the air lines for leaks and repair.
The air flow switch is stuck open.
Clean or replace air flow switch.
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.
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Alarm Troubleshooting
Table 11. Alarm Troubleshooting
E-9: Not used
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 11. 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 and Booth Control power LEDs
turn on. If the power LED does not turn on, the prob-
lem is probably caused by a bad connection. The nut
on the connector 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.
•
•
•
Appears on the EasyKey display if the unit is pro-
grammed for Manual Mode, and a booth control is
not connected.
The dip switch settings on the Color Change Module
were changed (see manual 312787) while the power
was on. Cycle the power to clear the alarm.
The dip switch configuration on the Color Change
Control Module (see manual 312787) is setup incor-
rectly.
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.
Communication between the Booth Control and the Fluid Verify that the cable is correctly connected.
Station is interrupted.
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Alarm Troubleshooting
Table 11. Alarm Troubleshooting
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.
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 and air flow
switch.
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/POWER OFF 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.
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Alarm Troubleshooting
Table 11. 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.
Fluid Plate Reboot (FP 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.
Level Control (LC) Error: Occurs if level control data is Verify that the Autokey is set properly.
received by the EasyKey, and the current Autokey set-
ting (2K or 3K) has changed since the level control data
was originally initialized.
Level Control (LC) Range Error: Occurs if level control Set level control data correctly.
data includes a valve range exceeding the capability of
the machine.
Modbus (MB) Overflow: Occurs if the Modbus connec- Verify the Modbus protocol to the EasyKey.
tion to a PLC experiences data overflow.
312776F
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Alarm Troubleshooting
Table 11. 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.
90
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Alarm Troubleshooting
Table 11. 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.
E-28: MIX FILL PUSH COMPLETE
Cause
Solution
Mix fill push has been completed.
Potlife expired material has been purged.
312776F
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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
5/32 TUBE
4-WAY SOLENOID
A
A
B
B
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
5/32 TUBE
OPEN
4-WAY SOLENOID
A
A
B
B
AIR INPUT
12 VDC
PURGE C
VALVE
OSE
CL
5/32 TUBE
(OPTIONAL)
4-WAY SOLENOID
AIR EXHAUST MUFFLER
12 VDC
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
92
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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
312776F
93
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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
94
312776F
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Technical Data
Technical Data
Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . Base system: 4000 psi (28 MPa, 280 bar)
Low pressure color change: 300 psi (2.1 MPa, 21 bar)
High pressure color change: 3000 psi (21 MPa, 210 bar)
Coriolis meter: 2300 psi (16.1 MPa, 161 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.
98
312776F
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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
For the latest information about Graco products, visit www.graco.com.
For patent information, see www.graco.com/patents.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2008, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Revision F, April 2015
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