Graco 313885F, ProMix 3KS Owner's Manual

Operation
®
ProMix
3KS
313885F
EN
Plural Component Proportioner
Automatic system for proportional mixing of plural component coatings.
For professional use only.
Approved for use in explosive atmospheres (except the EasyKey and 3KS Power Supply
Module).
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
See page 4 for model information, including maximum working
pressure. Equipment approval labels are on page 3. Some
components shown are not included with all systems.
TI14826a
2575
#
53
II 2 G
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Equipment Approvals . . . . . . . . . . . . . . . . . . . . . . . 3
System Configuration and Part Numbers . . . . . . . 4
Configurator Key . . . . . . . . . . . . . . . . . . . . . . . . . 4
Standard Features . . . . . . . . . . . . . . . . . . . . . . . 5
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Important Two-Component Material Information . 9
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 9
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 9
Keep Components A and B Separate . . . . . . . . . 9
Moisture Sensitivity of Isocyanates . . . . . . . . . . . 9
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 9
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . 10
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Component Identification and Definition . . . . . . 13
EasyKey Display and Keypad . . . . . . . . . . . . . . . 17
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
EasyKey and 3KS Power Supply Module Connection
Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
EasyKey AC Power Switch . . . . . . . . . . . . . . . . 19
3KS Power Supply Module AC Power Switch . 19
EasyKey I/S Power . . . . . . . . . . . . . . . . . . . . . . 19
3KS Power Supply Module I/S Power . . . . . . . . 19
Audible Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Graco Web Interface Port . . . . . . . . . . . . . . . . . 19
Ethernet Connection . . . . . . . . . . . . . . . . . . . . . 19
Run Mode Screens . . . . . . . . . . . . . . . . . . . . . . . . 20
Splash Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Manual Override Screen . . . . . . . . . . . . . . . . . . 23
Totals Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Reset Total Screen . . . . . . . . . . . . . . . . . . . . . . 24
Reset Solvent Screen . . . . . . . . . . . . . . . . . . . . 24
Alarms Screens . . . . . . . . . . . . . . . . . . . . . . . . . 25
Level Control Screen . . . . . . . . . . . . . . . . . . . . 25
Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Password Screen . . . . . . . . . . . . . . . . . . . . . . . 27
Set Up Home Screen . . . . . . . . . . . . . . . . . . . . 27
System Configuration Screens . . . . . . . . . . . . . 29
Option Screens . . . . . . . . . . . . . . . . . . . . . . . . . 34
Advanced Setup Screens . . . . . . . . . . . . . . . . . 36
Recipe Setup Screens . . . . . . . . . . . . . . . . . . . 42
2
Recipe 0 Screens . . . . . . . . . . . . . . . . . . . . . . . 47
Calibration Screen . . . . . . . . . . . . . . . . . . . . . . . 49
ProMix Integration Specifics . . . . . . . . . . . . . . . . . 50
System Setup for Automatic Operation . . . . . . . 50
Status Verification of Automatic Operation . . . . 51
Discrete I/O vs Network Communications . . . . . 51
Discrete I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Automation Flow Charts . . . . . . . . . . . . . . . . . . 56
Modbus and I/O Data . . . . . . . . . . . . . . . . . . . . . . . 67
Start Mix Process . . . . . . . . . . . . . . . . . . . . . . . 67
Stop Mix Process . . . . . . . . . . . . . . . . . . . . . . . . 67
Color Change Process . . . . . . . . . . . . . . . . . . . 67
Purge Process . . . . . . . . . . . . . . . . . . . . . . . . . . 67
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Typical PLC Interaction with ProMix . . . . . . . . . 70
System Operation . . . . . . . . . . . . . . . . . . . . . . . . . 79
Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . 79
Sequential Dosing . . . . . . . . . . . . . . . . . . . . . . . 79
Recipe (Color) Change . . . . . . . . . . . . . . . . . . . 79
Solvent Push . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
General Operating Cycle, Sequential Dosing . . 79
General Operating Cycle, Dynamic Dosing . . . . 82
Mix Manifold Valve Settings . . . . . . . . . . . . . . . 85
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Pressure Relief Procedure . . . . . . . . . . . . . . . . 88
Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Solvent Push Feature . . . . . . . . . . . . . . . . . . . . 98
Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Color Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Color Change Procedures . . . . . . . . . . . . . . . . 101
Color Change Sequences . . . . . . . . . . . . . . . . 101
Alarms and Warnings . . . . . . . . . . . . . . . . . . . . . 114
System Alarms . . . . . . . . . . . . . . . . . . . . . . . . 114
System Warnings . . . . . . . . . . . . . . . . . . . . . . 114
Alarm Troubleshooting . . . . . . . . . . . . . . . . . . . . 115
Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . 126
System Pneumatic Schematic . . . . . . . . . . . . . 126
System Electrical Schematic . . . . . . . . . . . . . . 128
Power Supply Module Electrical Schematic . . 132
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Graco Standard Warranty . . . . . . . . . . . . . . . . . . 134
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 134
313885F
Related Manuals
Related Manuals
Equipment Approvals
Component Manuals in English
Equipment approvals appear on the following labels
which are attached to the Fluid Station and Power Supply Module. See FIG. 1 on page 4 for label locations.
Manual
Description
313881
313883
312778
312779
312780
ProMix 3KS Kit Installation
ProMix 3KS Kit Repair-Parts
ProMix 2KS Automatic System Installation
ProMix 2KS Automatic System Operation
ProMix 2KS Automatic System
Repair-Parts
Fluid Mix Manifold
Dispense Valve
Color Change Valve Stacks
Color Change Module Kit
Gun Flush Box Kits
Gun Air Shutoff Kit
Dump Valve and Third Purge Valve Kits
Network Communication Kits
G3000/G3000HR Flow Meter
Coriolis Flow Meter
Floor Stand Kit
Beacon Kit
Basic Web Interface/Advanced Web Interface
15V825 Discrete I/O Board Kit
312781
312782
312783
312787
312784
310745
312786
312785
308778
313599
313290
313542
313386
406800
Power Supply Module and Fluid Station Label
ATEX Certificate is listed here
®
ProMix 3KS
Electronic Proportioner
C
FM08ATEX0074
II 2 G
Ex ia IIA T3
US
Intrinsically safe
equipment for Class I,
Div 1, Group D, T3
Ta = -20°C to 50°C
Intrinsically Safe (IS) System. Install
per IS Control Drawing No. 258682.
EasyKey Interface IS Associated
Apparatus for use in non hazardous
location, with IS Connection to Smart
Fluid Plate IS
Apparatus for use in:
Class I, Division 1, Group D T3 C
Hazardous Locations
Read Instruction Manual
MAX AIR WPR
.7
MPa
7
100
bar
PSI
Warning: Substitution of components
may impair intrinsic safety.
PART NO.
SERIES
SERIAL
MAX FLUID WPR
MFG. YR.
MPa
bar
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
PSI
MAX TEMP 50°C (122°F)
TI14376a
Fluid Station Label
ProMix® 3KS
PART NO.
C
SERIES
FLUID PANEL
MAX AIR WPR
SERIAL MFG. YR.
Intrinsically safe equipment
for Class I, Div 1, Group D, T3
US Ta = -20°C to 50°C
Install per 289833
.7
7
MPa
bar
100
PSI
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
FM08ATEX0073
II 2 G
Ex ia IIA T3
TI14374a
ATEX Certificate is listed here
Power Supply Module Label
POWER REQUIREMENTS
ProMix® 3KS
PART NO. SERIES NO. MFG. YR.
VOLTS
85-250 ~
AMPS 2 AMPS MAX
GRACO INC.
C
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
50/60 Hz
Intrinsically safe connections
for Class I, Div 1, Group D
US Ta = -20°C to 50°C
Install per 258682
II (2) G
[Ex ia] IIA
FM08ATEX0072
Um: 250 V
TI14375a
ATEX Certificate is listed here
313885F
3
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 digits from
each of the following categories, depending on the configuration of your system.
3K
System
Component C
Fluid Meter
Component C Change
TK
0 = No Meter
0 = No Valves (single component C)
1 = G3000
1 = Two Valves (low pressure)
2 = G3000HR
2 = Four Valves (low pressure)
3 = 1/8 in. Coriolis
3= Two Valves (high pressure)
4 = Solvent Meter
4= Four Valves (high pressure)
®
ProMix 3KS
Electronic Proportioner
C
Label Location
on Fluid Station
FM08ATEX0074
II 2 G
Ex ia IIA T3
US
Intrinsically safe
equipment for Class I,
Div 1, Group D, T3
Ta = -20°C to 50°C
TI14361a
Not
Designated
0
Intrinsically Safe (IS) System. Install
per IS Control Drawing No. 258682.
EasyKey Interface IS Associated
Apparatus for use in non hazardous
location, with IS Connection to Smart
Fluid Plate IS
Apparatus for use in:
Class I, Division 1, Group D T3 C
Hazardous Locations
0
Label Location on
Power Supply Module
TI14370a
Read Instruction Manual
MAX AIR WPR
Maximum Fluid
Working Pressure
is listed here
Not
Designated
.7
7
100
MPa
bar
PSI
Warning: Substitution of components
may impair intrinsic safety.
PART NO.
SERIES
SERIAL
MAX FLUID WPR
MFG. YR.
MPa
bar
PSI
MAX TEMP 50°C (122°F)
Configured Part Number
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
TI14376a
FIG. 1: Identification Label
4
313885F
System Configuration and Part Numbers
Hazardous Location Approval
Models using a G3000, G3000HR, or intrinsically safe Coriolis meter for A, B, and C 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: A Model with Flow Control has a maximum working pressure of 190 psi (1.31 MPa, 13.1 bar).
Check the identification label on the EasyKey, power supply module, 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/component C change [option 0],
and no flow control [Optional with ProMix 2KS Base Unit]) . . . . . . . . . . . . . . . . . . . .3000 psi (21.0 MPa, 210 bar)
Meter Option 1, 2, and 4 (G3000 or G3000HR, Solvent Meter) . . . . . . . . . . . . . . . . .3000 psi (21.0 MPa, 210 bar)
Meter Option 3 (Coriolis Meter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2300 psi (15.86 MPa, 158.6 bar)
Color Change Option 1 and 2 (low pressure valves) . . . . . . . . . . . . . . . . . . . . . . . . . 300 psi (2.07 MPa, 20.6 bar)
Color Change Option 3 and 4 (high pressure valves) . . . . . . . . . . . . . . . . . . . . . . . . . 3000 psi (21 MPa, 210 bar)
Flow Control (Optional with ProMix 2KS Automatic Base Unit) . . . . . . . . . . . . . . . . . 190 psi (1.31 MPa, 13.1 bar)
Flow Meter Fluid Flow Rate Range
G3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-3800 cc/min. (0.02-1.0 gal./min.)
G3000HR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-1900 cc/min. (0.01-0.50 gal./min.)
Coriolis Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3800 cc/min. (0.005-1.00 gal./min.)
S3000 Solvent Meter (accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-1900 cc/min. (0.01-0.50 gal./min.)
Standard Features
Feature
ProMix 3KS Power Supply Module
Wall Mount Fluid Station, 50 cc Integrator and Static Mixer
IS Power Cable, red color coded, 50 ft (15.25 m)
CAN Communication Cable, green color coded, 10 ft (3.05 m)
Meter and Solenoid Cable, 10 ft (3.05 m)
Third Component Network Cable, yellow color coded, 6 ft (1.83 m)
C Side Dump Valve, if color valve(s) selected
313885F
5
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)
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
NOTE: This is not a complete list of available
accessories and kits. Refer to the Graco website for more information about accessories
available for use with this product.
6
313885F
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found 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
Only models with a G3000, G250, G3000HR, G250HR, or intrinsically safe Coriolis meter for A, B, and C
meters are approved for installation in a Hazardous Location - Class I, Div I, Group D, T3 or Zone I
Group IIA T3. To help prevent fire and explosion:
• 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.
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.
313885F
7
Warnings
WARNING
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 manufacturer’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 impervious 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
313885F
Important Two-Component Material Information
Important Two-Component Material Information
Isocyanate Conditions
Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and
atomized particulates.
Read material manufacturer’s warnings and material SDS to know specific hazards and precautions
related to isocyanates.
Prevent inhalation of isocyanate mists, vapors, and
atomized particulates by providing sufficient ventilation in the work area. If sufficient ventilation is not
available, a supplied-air respirator is required for
everyone in the work area.
To prevent contact with isocyanates, appropriate
personal protective equipment, including chemically
impermeable gloves, boots, aprons, and goggles, is
also required for everyone in the work area.
Material Self-ignition
Some materials may become self-igniting if applied
too thickly. Read material manufacturer’s warnings
and material SDS.
Keep Components A and B
Separate
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 viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts.
NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the
humidity, and the temperature.
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.
•
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.
•
Never use solvent on one side if it has been contaminated from the other side.
•
Always lubricate threaded parts with ISO pump oil
or grease when reassembling.
Changing Materials
•
When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.
•
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 damage equipment. To prevent cross-contamination of
the equipment’s wetted parts, never interchange
component A (isocyanate) and component B (resin)
parts.
313885F
9
Glossary of Terms
Glossary of Terms
Advanced Web Interface (AWI) - This allows remote
ProMix backup and restore, configuration, logging, and
software update options.
Air Chop - the process of mixing air and solvent
together during the flush cycle to help clean the lines
and reduce solvent usage.
Air Chop Time- duration of each activation of the air
purge valve during a chop sequence. User settable from
0.0-99.9 seconds.
Analog - relating to, or being a device in which data are
represented by continuously variable, measurable,
physical quantities, such as length, width, voltage, or
pressure.
Coriolis Meter - a non-intrusive flow meter often used in
low flow applications or with light viscosity, shear sensitive, or acid catalyzed materials. This meter uses vibration to measure flow.
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.
Digital Input and Output - a description of data which
is transmitted as a sequence of discrete symbols, most
commonly this means binary data represented using
electronic or electromagnetic signals.
Discrete 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 material
to prevent unwanted mixing.
Dose Size - the amount of resin (A) and catalyst (B) that
is dispensed into an integrator.
Basic Web Interface (BWI) - This allows remote ProMix
backup and restore, logging, and software update
options.
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.
Bootloader - The utility program that handles initial system startup re-programming of the main ProMix application.
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 seconds.
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 Override 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 transmit communication signals. Blue is the transmitter, and
black is the receiver. This must be cross-connected
between the EasyKey and the Fluid Panel for communication 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.
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 Source- source of the media used in the
final purge cycle. User settable to air purge valve, solvent purge valve, or 3rd purge valve.
Final Purge Time- duration of the final purge cycle.
User settable from 0-999 seconds.
10
313885F
Glossary of Terms
First Purge Source- source of the media used in the
first purge cycle. User settable to air purge valve, solvent
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
settable from 0-999 seconds.
Kd - refers to the amount the fluid flow system attempts
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.
Flow Rate Analog Signal - the type of communication
signal that can be used on the ProControl module.
Flow Rate Tolerance - the settable percent of acceptable variance that the system will allow before a flow
rate warning occurs.
Flow Set Point - a predefined flow rate target.
Flush Volume Check - system monitors flush volume.
E-11 Alarm occurs if minimum volume is not achieved.
Minimum flush volume is user settable (0-999 cc).
Kp - refers to the speed in which the fluid flow reaches
its set point.
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.
Manual Mode - when the proportioning or flow control
system is controlling the inputs without any input from
an outside control.
Global - indicates that values on the screen apply to all
recipes, 1 through 60.
Minimum Material Fill Volume - system monitors material fill volume. E-21 Alarm occurs if minimum volume is
not achieved. Minimum material fill volume is user settable (0-9999 cc).
Grand Total - a non-resettable value that shows the
total amount of material dispensed through the system.
Mix - when cross-linking of the resin (A) and catalyst (B)
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.
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.
Gun Trigger Input Signal - used to manage ratio assurance dose times and flow control processes.
Intrinsically Safe (IS) - refers to the ability to locate certain components in a hazardous location.
Idle - if the gun is not triggered for 2 minutes the system
enters Idle mode. Trigger the gun to resume operation.
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.
313885F
Mix Input Signal- refers to system mode status where
system begins a dose sequence each time the mix signal is made “High”.
Mixed Material Fill Time - the amount of time that is
required to load mixed material from the dose valves to
the applicator/gun.
Modbus/TCP - a type of communication protocol used
to communicate Digital I/O signals over an ethernet.
Network Station - a means to identify a particular individual proportioning or flow control system.
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.
11
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.
Potlife Time - the amount of time before a material
becomes unsprayable.
Potlife Volume - the amount of material that is required
to move through the mix manifold, hose and applicator
before the potlife timer is reset.
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
control module.
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.
Purge - when all mixed material is flushed from the system.
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
313885F
Overview
Overview
Usage
The Graco ProMix 3KS Kit adapts a ProMix 2KS system to be an electronic 3-component paint proportioner. It can
blend most 3-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 maintain up to +/-1% accuracy, depending on materials
and operating conditions.
Models are available to operate air spray or
air-assisted systems with a capacity of up to 3800
cc/min.
•
Color change options are available for low pressure
(300 psi [2.1 MPa, 21 bar]) air spray and high pressure (3000 psi [21 MPa, 210 bar]) systems with up
to 25 color change valves and up to 4 catalyst and 4
component C change valves.
NOTE: Optional accessories are available for in field
installation to achieve 25 colors or for component C
change.
Component Identification and Definition
See FIG. 2 and Table 1for the system components. Components marked with a star () are available as part of the
ProMix 3KS Kit. All other components are part of the ProMix 2KS System or are available as accessories.
EK
PSM
CCM
PS
PS
BCV
FO
3KS
CCV
ACV
MB
MC
2KS
MA
3KM
2KM
 See the ProMix 3KS Repair-Parts manual
for optional cable lengths.
TI14826a
6 ft (1.83 m) fluid
hose (supplied)
FIG. 2. ProMix 3KS System, shown with G3000 Meters and Color/Catalyst/Component C Change
313885F
13
Overview
Table 1: Component Descriptions
Component
Description
EasyKey (EK)
Used to set up, display, operate, and monitor the system. The EasyKey accepts 85-250
VAC, 50/60 Hz line power and converts that power to acceptable low voltage and optical
signals used by other system components.
 3KS Power
Supply Module
(PSM)
Accepts 85-250 VAC, 50/60 Hz line power and converts that power to acceptable low
voltage signals used by other system components.
2KS Fluid Station
(2KS)
Includes air control solenoids, flow switches, and mountings for the A, B, and solvent flow
meters and the 2K fluid manifold assembly. Its control board manages all proportioning
functions.
 3KS Fluid Station
(3KS)
Includes air control solenoids, flow switches, and mountings for the C and solvent flow
meters and the 3K fluid manifold assembly. Its control board manages all proportioning
functions.
2K Fluid Manifold
(2KM)
•
•
•
•
•
 3K Fluid Manifold
(3KM)
•
•
•
•
•
14
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 manifold, to allow for accurate calibration and ratio checks
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.
Pneumatically Operated Dose Valve for component C
Purge Valve for solvent
Sampling Valve for calibrating the flow meter and performing ratio check
Shutoff Valve for component C to close the fluid passage to the mix manifold, to
allow for accurate calibration and ratio check
Mix Manifold, which includes the fluid integrator and static mixer.
 Fluid Integrator is the chamber where component C aligns with blended
components A/B at the selected ratio and begins to mix.
 Static Mixer has 24 elements to uniformly blend the materials downstream
of the fluid integrator.
313885F
Overview
Table 1: Component Descriptions
Component
Flow Meters (MA,
MB, MC, MS)
Description
Four optional flow meters are available from Graco:
•
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 viscosities 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 centipoise. The K-factor is approximately 0.021 cc/pulse.
•
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.
Color Change
Valves (ACV) and
Color Change
Module (CCM)
An optional component. It is available as a color change valve stack for either low or high
pressure with up to 25 color change valves. Each stack includes one additional valve for
solvent to clean the fluid line between color changes.
Catalyst Change
Valves (BCV)
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.
 Component C
Change Valves
(CCV)
An optional component. It is available as a component C change valve stack for either
low or high pressure with up to 4 component C change valves. Each stack includes one
additional valve for solvent to clean the fluid line between component C changes.
Dual Fiber Optic
Cable (FO)
Used to communicate between the EasyKey and Wall Mount Fluid Station.
 Fluid Station
Power Supply Cable
(PS)
Used to provide power to the Wall Mount Fluid Station.
Flow Control
Regulator
Assembly (FC)
Not shown. See ProMix 2KS manuals for details.
Applicator
Handling: use Air
Flow Switch (AFS)
or Gun Flush Box
(GFB)
Not shown. See ProMix 2KS manuals for details.
313885F
15
Overview
DVA
DVB
FI
MB
MS
MA
RVB
RVA
TI12556a
APV
AT
SVA
SM
SVB
SPV
Key: ProMix 2KS Fluid Station
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
DVC
FI
SVB Component B Shutoff
Valve
MS Solvent Meter
SPV Solvent Purge Valve
APV Air Purge Valve
SM Static Mixer
FI
Fluid Integrator
AT
Air Purge Valve Air Supply
Tube
Key: ProMix 3KS Fluid Station
MC
CPV
MC
DVC
RVC
SVC
CPV
SM
FI
RVC
1
Component C Meter
Component C Dose Valve
Component C Sampling Valve
Component C Shutoff Valve
Component C Purge Valve
Static Mixer
Fluid Integrator
1
3KS fluid inlet. Connect fluid supply line from
2KS fluid manifold outlet here.
2
Connect fluid supply line to gun.
SVC
SM
2
TI14382b
FIG. 3. ProMix 2KS and ProMix 3KS Wall Mount Fluid Stations
16
313885F
EasyKey Display and Keypad
EasyKey Display and Keypad
Keypad
LCD Display
TI11630b
Navigation Keys
Alarm Reset Key
FIG. 4. EasyKey Display and Keypad
Display
Shows graphical and text information related to setup
and spray operations. Back light will turn off after 10
minutes without any key press. Press any key to turn
back on.
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 operation, use the setup or navigation keys to turn on the display back light.
Table 2: EasyKey Keypad Functions (see FIG. 4)
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.
Up Arrow: move to previous field or menu
item, or to previous screen within a group.
Keypad
Down Arrow: move to next field or menu
item, or to next screen within a group.
Used to input numerical data, enter setup screens, scroll
through screens, and select setup values.
Left Arrow: move to previous screen group.
In addition to the numbered keys on the EasyKey keypad, which are used to enter values in setup, there are
keys to navigate within a screen and between screens,
and to save entered values. See Table 2.
Right Arrow: move to next screen group.
313885F
Alarm Reset: resets all active alarms.
If the display becomes unresponsive,
pressing this key 4 times in succession will
re-initialize the display.
17
EasyKey and 3KS Power Supply Module Connection Ports
EasyKey and 3KS Power Supply Module Connection
Ports
EasyKey
Fiber Optic Strain
Relief Port
Audible Alarm
AC
Power
Main Power
Access Port
Ground Screw
I/S Power
to 2KS
Panel
Graco Web
Interface
Discrete I/O Cable
Connector Ports
TI12638a
TI12657a
3KS Power Supply Module
AC
Power
Ground Screw
Main Power
Access Port
I/S Power
to 3KS
Panel
TI14366a
TI14372a
FIG. 5. Connections and AC Power Switches
18
313885F
EasyKey and 3KS Power Supply Module Connection Ports
EasyKey AC Power Switch
Graco Web Interface Port
Turns system AC power on or off.
Used to communicate from a PC to:
3KS Power Supply Module AC
Power Switch
Turns 3KS AC power on or off.
EasyKey I/S Power
Power circuit to 2KS Fluid Station.
3KS Power Supply Module I/S
Power
See manual 313386 for more information.
NOTE: If using the Graco Gateway in your system, disconnect its cable from the EasyKey before updating the
ProMix 3KS software.
Power circuit to 3KS Fluid Station.
Audible Alarm
Alerts the user when an alarm occurs. Available settings
for selecting which alarms will cause an audible alarm
are explained in Configure Screen 1, page 30.
Clear by pressing the Alarm Reset
 Upgrade software
 View software version
 Download
• 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
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.
key.
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.
313885F
19
Run Mode Screens
Run Mode Screens
NOTE: See FIG. 8 for a map of the Run screens.
Detailed screen descriptions follow.
Splash Screen
At power up, the Graco logo and software revision will
display for approximately 5 seconds, followed by the
Status Screen (see page 22).
FIG. 6. Splash Screen
The Splash screen will also momentarily display “Establishing 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. 7. Fluid Plate Programming Screen
20
313885F
Run Mode Screens
1
/
4
Press the Setup
key to
enter Setup mode.
3
/
4
TI12802a
FIG. 8. Run Screens Map
313885F
21
Run Mode Screens
Status Screen
•
6 Potlife Timer: shows remaining potlife time in min-
Use the Up
or Down
Run screens.
keys to scroll through the
utes. Two times are shown if there are two guns
(manual or semi-automatic mode only).
7 Status Bar: shows current alarm or operation mode
•
Press the Setup
key to enter the Setup screens
(standby, mix, purge, recipe change, or the current
alarm).
from the Status screen.
•
The other keys have no function in this Status
screen.
13
1
2
3
4
5
8 Target Flow Rate and Current Flow Rate: in
10
cc/min.
1
12 11 /
4
9
6
NOTE: If the auto key board is removed from the
EasyKey display board, the Status Bar will read
“Auto key not found.” This indicates that the automatic mode is not operable.
8
9 Animation: when the gun is triggered, the gun
appears to spray and the component A, B. or C
hose lights up, showing which component dose
valve is open.
10 Current Date and Time
7
11 Screen Number and Scroll Arrows: displays the
FIG. 9. Status Screen
Key to FIG. 9:
current screen number and the total number of
screens in a group. The Up and Down arrows on the
right edge of the screen indicate the scroll feature.
The total number of screens in some groups may
vary depending on system configuration selections.
1 Active Recipe: shows the active recipe.
NOTE: At power up the system defaults to Recipe
61, which is not a valid recipe number.
2 Stage 1 Target Ratio (A:B): for the active recipe.
The ratio can be from 0.0:1–50.0:1, in 0.1 increments.
12 Current Flow Control Data: fluid output pressure
and voltage of analog signal used for driving the
fluid regulator V/P.
The fluid target pressure is shown if Flow Control is
set to “On: Setup” in Configure Screen 5, page 32.
13 Lock Symbol: indicates that Setup screens are
3 Stage 1 Actual Ratio (A:B): in hundredths, calcu-
password protected. See page 27.
lated after each dose of A and B.
4 Stage 2 Target Ratio (A+B):C: for the active recipe.
The ratio can be from 0.0:1–50.0:1, in 0.1 increments.
5 Stage 2 Actual Ratio (A+B):C: in hundredths, cal-
culated after each dose of C.
22
313885F
Run Mode Screens
Manual Override Screen
Flow Rate Range
This screen displays the flow rate range selected on
Advanced Setup Screen 5 (see page 39).
Flow Set Point
The Flow Set Point is user settable. If Flow Control
Override is set to “Off” or “Pressure” in Advanced
Setup Screen 1 on page 37, the Flow Set Point will display as cc/min. Enter the desired flow set point within
the range.
FIG. 10. Manual Override Screen
If Flow Control Override is set to “% Open,” the Flow Set
Point will display as % Open. This percentage relates to
the flow control V/P ratio which translates to a fluid flow
rate. Set the initial percentage at 35% and increase as
necessary to reach the desired flow rate.
This screen will appear if Manual Override is set to “On”
in Advanced Setup Screen 1 (page 37). It shows the
active recipe, new/go to recipe, and manual override
mode.
Flow Control Calibration
If Flow Control is set to “On” in Configure Screen 5 on
page 32, this screen will also display Flow Rate Range,
Flow Set Point, Flow Control Calibration (Start/Abort),
and Global Flow Control Data Copy (Start/Abort).
Manual Override Menu
This field allows you to set the operating mode from the
EasyKey. Press the Enter
key to view the menu,
then select the desired operating mode (Standby, Mix,
Purge, or Recipe Change). See FIG. 11.
This field allows you to calibrate flow control for each
recipe. The system must be in Mix mode and receiving a
Gun Trigger signal. Press the Enter
key to view the
menu, then select Start or Abort. See FIG. 12.
The flow rate will drop to 0, then incrementally increase
until it reaches the maximum flow rate. To view the progress, go to the Status Screen, page 22. The system will
populate the data for the current recipe. To copy this
data to all recipes, see Global Flow Control Data
Copy, page 24.
FIG. 12. Flow Control Calibration
FIG. 11. Manual Override Menu
313885F
23
Run Mode Screens
Global Flow Control Data Copy
This field allows you to copy flow control data from the
Solvent Totals and the Rst Solvent tab only appear if
“Meter” is selected under Solvent Monitor in Configure
Screen 5 on page 32.
active recipe to all recipes. Press the Enter
key to
view the menu, then select Start or Abort. See FIG. 13.
NOTE: Grand totals are not resettable.
Reset Total Screen
FIG. 13. Global FC Data Copy
FIG. 15. Reset Total Screen
Totals Screen
If job is reset, job number will increment by one for
default.
3
/
4
Reset Solvent Screen
FIG. 14. Totals 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
Level Control Screen, page 25.
The job totals generally refer to material dispensed while
in Mix mode. This is likely atomized and sprayed material with the gun trigger “On”.
FIG. 16. Reset Solvent Total Screen
The screen will ask if you want to reset solvent total.
Select Yes or No.
The fill totals generally refer to material dispensed while
in Mix-fill mode after a color change or a purge operation. This is likely not sprayed or atomized, and is dispensed to a purge container.
24
313885F
Run Mode Screens
Alarms Screens
See FIG. 19. 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 Remainder.” If this selection is chosen, a second alarm will
occur after 25% of the remaining volume is mixed.
Refill tank volume to clear the alarm.
FIG. 17. Alarms Screen
Two screens show the last 10 alarms. Use the Up
Down
or
keys to scroll between the two screens.
See Table 17 on page 114 for a list of alarm codes.
Level Control Screen
FIG. 19. Tank Level Low Screen (Tank A Shown)
FIG. 18. Level Control Screen
This screen shows the current volume for each fluid.
Adjust the actual volumes on this screen, or use the tab
to go to Usage (Totals Screen, page 24).
313885F
25
Setup Mode
Setup Mode
Press the Setup
key to enter Setup mode.
NOTE: See FIG. 20 for a map of the Setup screens.
Detailed screen descriptions follow.
Press the Setup
key to
enter Setup mode.
This screen appears only if a
password is activated.
To access Advanced Setup Screens, page
36 and Recipe Setup Screens, page 42.
To access System Configuration Screens,
page 29.
Press the Setup
key to exit
Setup mode and return to the Status
screen.
This screen appears momentarily
if a password is activated.
3
1
/
4
TI12803a
FIG. 20. Setup Screens Map
26
313885F
Setup Mode
Password Screen
Set Up Home Screen
If a password has been activated (see Configure
Screen 1, page 30), the Password screen will appear.
You must enter the password to access the Set Up
Home Screen. Entering the wrong password returns the
display to the Status Screen.
NOTE: If you forget the password, you can reset the
password (to 0), using the ProMix Web Interface (see
manual 313386).
FIG. 23. Set Up Home Screen
This screen displays when you enter Setup mode. From
it you can go to Recipe and Advanced Setup Screens
(pages 36-46) or System Configuration Screens
(pages 29-33). Press the Enter
selected screen set.
FIG. 21. Password Screen
NOTE: If a password is activated, Setup Locked displays momentarily after exiting Setup mode and returning to the Status Screen. A lock
key to go to the
The screen also displays software versions and internet
addresses of various components. The values shown in
FIG. 23 are only examples and may vary on your screen.
See Table 3 for further information.
symbol appears
on the Status Screen.
Setup Locked
FIG. 22. Setup Locked Screen
313885F
27
Setup Mode
Table 3: Component Software Versions
Component
Display (may
vary from
examples shown) Description
EK (EasyKey)
3.01.001
EasyKey software version.
FP (Fluid Plate)
3.01.001
Fluid Plate software version.
BC (Booth Control)
-.-
Booth Control not installed, not detected, or not operational.
1.XX
Booth Control software version 1.00 or 1.01.
2.XX
Booth Control software version 2.XX.
-.-
Color Change Module 1/2 not installed, not detected, or not operational.
1.XX
Color Change Module software version 1.00 or 1.01.
2.XX
Color Change Module software version 2.XX.
No Key
No AutoKey installed or detected. System operates in 2K Manual
Mode only
2K-Auto
2K AutoKey detected. System can operate in 2K Manual,
Semi-automatic, or Automatic Mode.
3K-Auto
3K AutoKey detected. System can operate in 3K Manual,
Semi-automatic, or Automatic Mode.
XP (XPORT)
V6.6.0.2
Example of XPORT network module software version. Other versions are acceptable.
MC (Micro Controller)
1042.0198
Example of fluid plate micro controller version. Other versions are
acceptable.
Axx By Cz
A30 B4 C4
Color Change board valve configuration. This shows the number of
valves available for each of the components. This is set by the configuration switches on the color change boards connected to the
system.
C1/C2 (Color Change
Modules 1 and 2)
AK (Autokey)
28
Code
Description
-
Component not available with this machine configuration.
x
Component not used with this machine configuration.
1
Component available but no change stack.
4-30
Component available with change stack.
Number of valves flushed with a solvent valve.
IP (Internet Address)
192.168.178.5
Example of the address EasyKey is set to for basic and advanced
web interface reporting.
MAC (MAC address)
00204AAD1810
Example of internet MAC address. Each EasyKey will have a different value in this format.
313885F
Setup Mode
System Configuration Screens
NOTE: See FIG. 24 for a map of the System Configuration Screens. Detailed screen descriptions follow.
NOTE: Each screen displays the current screen number
and the total number of screens in the group.
Automatic
3
/
6
4
/
6
TI12804a
FIG. 24. System Configuration and Option Screens Map
313885F
29
Setup Mode
Configure Screen 1
Screen Timeout
Select the desired screen timeout in minutes (0-99). 5 is
the default.
Configure Screen 2
FIG. 25. Configure Screen 1
Language
Defines the language of the screen text. Select English
(default), Spanish, French, German, Italian, Dutch, Japanese (Kanji), Korean, Chinese (Simplified), and Custom.
NOTE: Refer to document 313386 for instructions on
using the Custom Language feature to modify the
screens to support undefined languages.
Password
FIG. 26. Configure Screen 2
Month
Enter current month.
Day
Enter current day.
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.
Year
NOTE: Be sure to write down the password and keep it
in a secure location.
Enter current time in hours (24 hour clock) and minutes.
Seconds are not adjustable.
Display Units
Date Format
Select the desired display units:
Select MM-DD-YYYY, DD-MM-YYYY, or YYYY-MM-DD.
•
•
Enter current year (four digits).
Time
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.
30
313885F
Setup Mode
Configure Screen 3
3rd Flush Valve
Off is default. If optional 3rd flush valve is used, set to
On.
Configure Screen 4
FIG. 27. Configure Screen 3
1K/2K/3K
FIG. 28. Configure Screen 4
Indicates the configuration that the system will function
as.Selecting a value other than the installed system
level will result in restricted functionality.
Dose Time Alarm
NOTE: This field is only changeable if the system has
recipe 61 selected. Once another recipe is selected, the
selection in this field is locked.
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
(see page 79).
Select the Run mode application from the pulldown
menu: Automatic (default), Semi-Automatic (uses a
manual spray gun), or Manual.
NOTE: ProControl 1KS is also available as a selection.
For further information, see ProControl 1KS operation
manual 3A1080.
Dump Valve A
Example:
For a total dose size of 50 cc and a ratio of 4.0:1, the
component A dose size is 40 cc and component B dose
size is 10 cc.
NOTE: Increase the dose size in applications with
higher flow rates or wider ratios. Decrease the dose size
for a better mix under low flow conditions.
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.
Number of Guns
Dump Valve B
In Automatic mode, only 1 gun is allowed. In Semi-Automatic mode, two guns are allowed. Number of Guns is
for information only on this screen in Automatic mode.
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.
Dump Valve C
This field only appears if the component C change
option is detected from the cc board, meaning that dump
valve C is present. On is the only setting.
313885F
Enter the number of spray guns (1 or 2).
Gun Flush Box
NOTE: This field is only shown if the system is being
operated in either Manual or Semi-Automatic mode.
Enter the number of gun flush boxes (Off, 1 or 2). For
color change and flushing purposes, it is recommended
that two GFBs are installed when using a 2-gun system.
31
Setup Mode
System Idle Timeout
Configure Screen 5
The number of minutes for the system to wait before
entering System Idle when it is in Mix with no Gun Trigger input. The range is 2 to 99 minutes.
DD Setup Mode
See FIG. 29 and FIG. 30.
FIG. 31. Configure Screen 5
Flow Control
FIG. 29. Configure Screen 4, dynamic dosing
selected
This field only appears if Run Mode is set to “Automatic”
in Configure Screen 3, page 31. Select “On”, “Off”, or
“On: Setup”.
If set to “On” Advanced Setup Screen 5, page 39,
Advanced Setup Screen 6, page 40, and Advanced
Setup Screen 7, page 40 are added.
If set to “On: Setup” Advanced Setup Screen 5, page
39 and Advanced Setup Screen 6, page 40 are added.
Special Outputs
Select special outputs (0-4, or 3 + GFB on #4). Each
output has two different start times and durations.
FIG. 30. Configure Screen 4, dynamic dosing setup
mode enabled
DD Setup Mode
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 79
for further information.
Gun Flush Box (manual or semi-automatic mode)
This field is only appears if the Run Mode is set to “Manual” or “Semi-Automatic” in Configure Screen 3, page
31. Enter the number of gun flush boxes (Off, 1 or 2).
If “3 + GFB on #4” is selected, the other 3 special outputs (1-3) are available, with special output #4 being a
copy of the Gun Flush Box output.
Each output has two different start times and durations
defined on the Recipe Setup screen (Flush and Fill Input
is set to “Recipe” in Option Screen 1,page 34), or on
the Advanced Setup screen (Flush and Fill Input is set
to “Global” in Option Screen 1, page 34).
NOTE: At system power up, the Special Outputs may
activate for up to 1/4 second.
Solvent Monitor
Select solvent monitor (Off, Flow Switch, or Meter).
Web Browser IP
The default web browser IP address prefix is
192.168.178.__ Assign a unique number for each
EasyKey in your system (1-99) and enter it here.
32
313885F
Setup Mode
Configure Screen 6
FIG. 32. Configure Screen 6 (Automatic mode shown)
Flow Set Source
This field only appears if Run Mode is set to “Automatic”
in Configure Screen 3, page 31. Select “Discrete” or
“Network.”
Proportioning
Select “Discrete” or “Network.”
Gun 1 Trigger
Displays AFS if Run Mode is set to “Semi-automatic” in
Configure Screen 3, page 31.
Select “Discrete”, “Network”, or AFS 1” if Run Mode is
set to “Automatic” in Configure Screen 3, page 31. In
automatic systems, the Air Flow Switch can be selected
to operate from AFS 1. This allows the robot controller to
drive this signal directly to the fluid panel, avoiding the
communications delay.
Gun 2 Trigger
Displays AFS if Number of Guns is set to “2” in Configure Screen 4, page 31.
Control Network ID
Used for the Graco Gateway network system. See
Graco Gateway manual 312785 for further information.
313885F
33
Setup Mode
Option Screens
NOTE: See FIG. 24 on page 29 for a map of the Option
Screens. Detailed screen descriptions follow.
NOTE: Each screen displays the current screen number
and the total number of screens in the group.
Option Screen 1
Minimum Material Fill Volume
Enter 0-9999 cc.
Stage Fill Volume
This field refers to the amount of material that is
required to fill the mixed material line from the A/B fluid
panel to the C fluid panel, before adding component C.
This value must be the same as the selected dose size.
Default is 50 cc.
Verification Screen
FIG. 33. Option Screen 1
Flush Volume Check
This field only appears if Solvent Monitor is set to
“Meter” in Configure Screen 5, page 32.
FIG. 34. Verification Screen
If set to “On”, Minimum Flush Volume will appear in Recipe Setup Screen 2, page 43.
Verification
Flush and Fill Input
This screen appears if Flush and Fill Input or K-Factor
Input are changed from “Recipe” to “Global” in Option
Screen 1.
If set to “Global”, Color/Catalyst Purge and Color/Catalyst Fill are added to Advanced Setup Screen 1, page
37. Advanced Setup Screen 2, 3, and 5 are added.
See pages 38-41.
If set to “Recipe”, Color/Catalyst Purge and Color/Catalyst Fill are added to Recipe Setup Screen 2, page 43.
Recipe Setup Screen 3, 4, and 7 are added. See
pages 44-46.
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.
If set to “Global,” Advanced Setup Screen 4, page 39 is
added.
If set to “Recipe,” Recipe Setup Screen 5, page 45, is
added.
34
313885F
Setup Mode
Option Screen 2
B Purge After Chop
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.
See Color Change Sequences, page 101 for color
change charts and timing information.
FIG. 35. Option Screen 2
External Color Change
If set to “Off”, Color/Catalyst Purge Time and Color/Catalyst Fill Time appear in Advanced Setup Screen 1,
page 37 or Recipe Setup Screen 2, page 43 (depending on whether Flush and Fill Inputs are set to “Global”
or “Recipe”).
If set to “On”, these fields are removed from the screens.
Auto Dump
If the auto dump feature is being used, set to ”On”. Once
the auto dump is enabled, the gun flush box is enabled
and the potlife alarm is active for 2 minutes, the system
will automatically flush out the old material.
Flow Rate Monitor
This field only appears if Flow Control is set to “Off” in
Configure Screen 5, page 32.
If set to “On,” Recipe Setup Screen 6 on page 45 is
added, enabling setting of high and low flow limits.
If set to “Off,” flow rate monitoring is disabled and Recipe Setup Screen 6 on page 45 will not appear.
Solvent Push Enable
NOTE: See Solvent Push Feature on page 98 for more
information.
To enable the Solvent Push feature, select “Solvent” or
“3rd Valve” (availableif 3rd Flush Valve in Configure
Screen 3, page 31, is set to “On”).
To disable the Solvent Push feature, set to “Off”.
313885F
35
Setup Mode
Advanced Setup Screens
NOTE: See FIG. 36 for a map of the Advanced Setup Screens. Detailed screen descriptions follow.
Advanced Setup screens 2, 3, 4, and 10
appear depending on selections made in
Option screens 1 and 2. Screen 5 and 6
appear if Flow Control is set to “On” in
Configure screen 5. Screens 5, 6, and 7
appear if Flow Control is set to “On:Setup”
in Configure screen 5.
TI12805b
FIG. 36. Advanced Setup Screens Map
36
313885F
Setup Mode
NOTE: Each screen displays the current screen number
and the total number of screens in the group. The total
number of screens in a group and the fields displayed
on each screen may vary depending on selections
made in the System Configuration Screens and
Option Screens. The title at the top of the Advanced
Setup screens will display “Global” when Flush and Fill
on Option Screen 1, page 34 is set to “Global”.
Advanced Setup Screen 1
Manual Override
This field only appears if Run Mode is set to “Automatic”
or “Semi-automatic” in Configure Screen 3, page 31.
Set to “On: EK” to override all outside control using the
Manual Override “Flow Set Point” control to set the flow
rate. Set it to “On: EXT” to use the Flow Set Source on
Configure Screen 6, page 33 to determine if the flow
rate is set from the Discrete or the Network input. If
selected, the Manual Override Screen (page 23) will
be added.
Gun 1/Gun2 Potlife Volume
Enter the potlife volume (1 to 1999 cc) for each gun.
This is the amount of material required to move through
the mix manifold, hose and applicator/gun before the
potlife timer is reset.
Use the following information to determine approximate
pot life volume (PLV) in cc:
FIG. 37. Advanced Setup Screen 1
Hose ID (inches)
Volume (cc/foot)*
3/16
1/4
3/8
5.43
9.648
21.71
Flow Control Override
This field only appears if Flow Control is set to “On” in
Configure Screen 5 on page 32. The selections made
will affect the display in Manual Override Screen on
page 23. Choose the desired selection as defined
below:
Selection
Description
Off
% Open
Normal operation
Flow control regulator is opened to a
desired percentage.
Flow control regulator is opened to a
calibrated pressure.
External Setpoint. The regulation output voltage is set to a percentage of
full scale. The range is 0 to 10000
which correlates to 0 to 100.00%. The
register used for this is setup
RegManualPercent, at address
40120.
Pressure
ExtSP
313885F
Integrator manifold and mixer volume = 75 cc
Spray Gun Volume = 20 cc
(Hose Volume* x Feet of Hose) + 75 + 20 = PLV
Color/Catalyst Purge
This field only appears if the system includes a color
change module and Flush and Fill Input is set to
“Global” in Option Screen 1, page 34. Enter the purge
time (0 to 99 seconds). It refers to the amount of time
required to flush the lines from the color/catalyst/component C module to the dose valve or dump valve.
Color/Catalyst Fill
This field only appears if the system includes a color
change module and Flush and Fill Input is set to
“Global” in Option Screen 1, page 34. Enter the fill time
(0 to 99 seconds). It refers to the time required to fill the
lines from the color/catalyst/component C module to the
dose valve or dump valve.
37
Setup Mode
Advanced Setup Screen 2
FIG. 38. Advanced Setup Screen 2
This screen appears only if Flush and Fill Input is set to
“Global” in Option Screen 1, page 34. The word
“Global” appears after the “Recipe” title to indicate that
Global Flush and Fill Input is enabled.
Advanced Setup Screen 3
FIG. 39. Advanced Setup Screen 3
This screen appears only if Flush and Fill Input is set to
“Global” in Option Screen 1, page 34. The word
“Global” appears after the “Recipe” title to indicate that
Global Flush and Fill Input is enabled.
First Purge Source
If Number of Guns is set to “2” in Configure Screen 4,
page 31, a Gun 2 column will appear in this screen.
Select “Air,” “Solvent,” or “3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
Screen 3 on page 31).
First Purge Time (Stage 1)
Chop Type
Select “Air/Solvent” or “Air/3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
Screen 3 on page 31). This refers to the process of mixing air and solvent (or air and 3rd flush fluid) together
during the flush cycle, to help clean the lines and reduce
solvent usage.
Final Purge Source
Select “Air,” “Solvent,” or “3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
Screen 3 on page 31).
Enter the first purge time (0 to 999 seconds) for components A and B.
C First Purge Time (Stage 2)
Enter the component C first purge time (0 to 999 seconds).
Total Chop Time
Enter the total chop time (0 to 999 seconds) for components A and B.
Final Purge Time (Stage 1)
Enter the final purge time (0 to 999 seconds) for components A and B.
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).
C Final Purge Time (Stage 2)
Enter the component C final purge time (0 to 999 seconds).
Mixed Fill Time
Enter the mixed fill time (0 to 999 seconds). It refers to
the amount of material that is required to fill from the
dose valves to the applicator/gun.
38
313885F
Setup Mode
Advanced Setup Screen 4
Advanced Setup Screen 5
FIG. 40. Advanced Setup Screen 4
FIG. 41. Advanced Setup Screen 5 (Automatic Mode
with Flow Control Only)
This screen appears only if K-Factor Input is set to
“Global” in Option Screen 1, page 34. The word
“Global” appears after the “Recipe” title to indicate that
K-Factor Input is enabled.
This screen appears only if Flow Control is set to “On” in
Configure Screen 5, page 32.
Range
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).
Enter the flow rate range (0-300, 0-600, or 0-1200). This
determines the flow control PID loop resolution.
Tolerance
Enter the k-factor (cc/pulse) for flow meter B.
Enter the flow rate tolerance (1 to 99%). This is the percentage of variance that the system will allow before a
flow rate warning/alarm occurs.
K-factor C Meter
Alarm Time
Enter the k-factor (cc/pulse) for flow meter C.
Enter the flow rate alarm time (1 to 99 seconds).
K-factor Solvent Meter
Ki
This field only appears if Solvent Monitor in Configure
Screen 5, page 32, is set to “Meter.” Enter the k-factor
(cc/pulse) for the solvent flow meter.
Enter the flow rate Ki (flow control PID loop integral
value). Output drive amount based on the accumulation
of error between the command and measured pressures
scaled to the output transducer.
K-factor B Meter
Kp
Enter the flow rate Kp (flow control PID loop gain value).
Output drive amount based on the instantaneous error
between the command and measured pressures scaled
to the output transducer.
Kd
Enter the flow rate Kd (flow control PID loop derivative
value). Output drive amount based on the change of
error between the command and measured pressures
scaled to the output transducer.
313885F
39
Setup Mode
Advanced Setup Screen 6
FIG. 42. Advanced Setup Screen 6
This screen appears only if Flow Control is set to either
“On” or “On: Setup” in Configure Screen 5, page 32.
One-Point threshold
Flow Control runs in Pressure mode for flow setpoints
below this value. If the setpoint is at or above this value,
a linear calibration is made from (0,0) to the point.
Learn Strength
This controls how much of the flow error signal is
applied when adjusting the Pressure-Flow curve. It will
always target the same flow. Because the flow control
drives to pressure, the reported flow rate may jump
around. However, if the material is consistent and the
pressure is constant, then the actual flow is correct.
Pressure zero offset
Zero-pressure calibration adjustment for pressure sensor. Used primarily for accurate flow rate calculation in
Pressure mode. This is added to the pressure reading,
so a negative value zeros out a positive offset.
Pressure intercept
Pressure-axis intercept of Pressure-Flow curve to match
the slope with the actual response.
Advanced Setup Screen 7
FIG. 43. Advanced Setup Screen 7
This screen appears only if Flow Control is set to “On” in
Configure Screen 5, page 32.
Command holdoff
Learn blanking time after setpoint command change.
Flow learning is turned off during this interval. May be
reduced for systems that have less than around x2 from
minimum to maximum pressure setpoints. May need to
be increased for systems with wide pressure swings.
Gun trigger holdoff
Learn blanking time after gun trigger is opened. Flow
learning is turned off during this interval. May be
reduced for high-pressure systems. May need to be
increased for low-pressure systems.
GT-Off drive time
Time to drive to pressure while the gun trigger is off.
GT-Off target rise
The additional pressure to control to based on flow rate
setpoint when the gun is closed. This allows the system
to be close to the pressure target when the gun is
opened.
Purge drive
Output drive during the Purge sequence. Maximum of
3300 mV.
Valve holdoff maximum
The maximum learn blanking time after dose valve
change. This is adjusted based on how much learning
was needed per dose changeover up to this maximum
value.
40
313885F
Setup Mode
Advanced Setup Screen 8
Advanced Setup Screen 10
FIG. 44. Advanced Setup Screen 8
FIG. 46. Advanced Setup Screen 10
This screen shows the status of recipe analog inputs
and digital outputs. If box is shaded the input recipe is
active. See pages 53-55 for details on the inputs and
outputs.
This screen appears only if Flush and Fill Input is set to
“Global” in Option Screen 1, page 34 and Special Outputs is set to 1, 2, 3, 4, or 3 + GFB on #4 in Configure
Screen 5, page 32. The I/O board has four programmable outputs. The word “Global” appears after “Recipe” in
the title to indicate that Global Flush and Fill Input is
enabled.
Advanced Setup Screen 9
NOTE: If 3 + GFB on #4 is selected, this screen will only
display columns for Special 1, 2, and 3. Column Special
4 is not displayed because this output has assumed the
same settings as those assigned to the Gun Flush Box
#1.
On-Purge
Delay time at the start of the purge cycle before the Special Output turns on.
FIG. 45. Advanced Setup Screen 8
This screen shows the status of digital inputs and digital
outputs. If box is shaded the input is active. If not, input
is off. See pages 53-55 for details on the inputs and outputs.
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
purge cycle.
313885F
41
Setup Mode
Recipe Setup Screens
NOTE: See FIG. 47 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. 47: Recipe Screens Map
42
313885F
Setup Mode
NOTE: Each screen displays the current screen number
and the total number of screens in the group. The total
number of screens in a group and the fields displayed
on each screen may vary depending on selections
made in the System Configuration Screens and
Option Screens.
Recipe Setup Screen 2
Recipe Setup Screen 1
FIG. 49. Recipe Setup Screen 2
Minimum Flush Volume
This field only appears if Flush Volume Check is set to
“On” in Option Screen 1 on page 34. Enter the minimum flush volume (0 to 9999 cc). Entering 0 disables
this function.
FIG. 48. Recipe Setup Screen 1
Ratio
Enter the mix ratio of component A over component B
(0.0:1 to 50:1) and the ratio of A+B over C (0.0:1 to
50:1). An A:B ratio of 0.0:1 deactivates component B.
An (A+B):C ratio of 0.0:1 deactivates component C.
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.
Potlife Time
Enter the potlife time (0 to 999 minutes). Entering 0 disables this function.
Color/Catalyst Purge
This field only appears if the system includes a color
change module and Flush and Fill Input is set to “Recipe” in Option Screen 1, page 34. Enter the purge time
(0 to 99 seconds). It refers to the amount of time
required to flush the lines from the color, catalyst, or
component C module to the dose valve or dump valve.
Color/Catalyst Fill
Component A (Color) Valve (if present)
This field only appears if the system includes a color
change module. Enter the component A valve number
(1 to 25).
Component B (Catalyst) Valve (if present)
This field only appears if the system includes a color
change module and Flush and Fill Input is set to “Recipe” in Option Screen 1, page 34. Enter the fill time (0
to 99 seconds). It refers to the time required to fill the
lines from the color, catalyst, or component C module to
the dose valve or dump valve.
This field only appears if the system includes a color
change module. Enter the component B valve number
(1 to 4).
Component C (Reducer) Valve (if present)
This field only appears if the system includes a color
change module. Enter the component C valve number
(1 to 4).
313885F
43
Setup Mode
Recipe Setup Screen 3
Recipe Setup Screen 4
FIG. 50. Recipe Setup Screen 3
FIG. 51. Recipe Setup Screen 4
This screen appears only if Flush and Fill Input is set to
“Recipe” in Option Screen 1, page 34.
This screen appears only if Flush and Fill Input is set to
“Recipe” in Option Screen 1, page 34.
First Purge Source
In Automatic mode, only one jun is allowed. In
Semi-automatic mode, two guns are allowed. If Number
of Guns is set to “2” in Configure Screen 4, page 31, a
Gun 2 column will appear in this screen.
Select “Air,” “Solvent,” or “3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
Screen 3 on page 31).
Chop Type
Select “Air/Solvent” or “Air/3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
Screen 3 on page 31). This refers to the process of mixing air and solvent (or air and 3rd flush fluid) together
during the flush cycle, to help clean the lines and reduce
solvent usage.
First Purge Time (Stage 1)
Enter the first purge time (0 to 999 seconds) for components A and B.
C First Purge Time (Stage 2)
Enter the component C first purge time (0 to 999 seconds).
Final Purge Source
Total Chop Time
Select “Air,” “Solvent,” or “3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
Screen 3 on page 31.)
Enter the total chop time (0 to 999 seconds) for components A and B.
Final Purge Time (Stage 1)
Air Chop Time
Enter the air chop time (0.0 to 99.9 seconds).
Enter the final purge time (0 to 999 seconds) for components A and B.
Solvent Chop Time/3rd Flush Valve Chop Time
C Final Purge Time (Stage 2)
Enter the solvent or 3rd flush valve chop time (0.0 to
99.9 seconds).
Enter the component C 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 material that is required to fill
from the dose valves to the applicator/gun.
44
313885F
Setup Mode
Recipe Setup Screen 5
FIG. 52. Recipe Setup Screen 5
This screen appears only if K-Factor Input is set to “Recipe” in Option Screen 1, page 34.
K-factor A Meter
Enter the k-factor (cc/pulse) for flow meter A. This is the
amount of material that passes through the flow meter
per pulse (electrical pulse signal).
K-factor B Meter
Enter the k-factor (cc/pulse) for flow meter B.
K-factor C Meter
Enter the k-factor (cc/pulse) for flow meter C.
Recipe Setup Screen 6
FIG. 53. Recipe Setup Screen 6
This screen appears only if Flow Rate Monitor is set to
“On” in Option Screen 2 on page 35.
Flow Rate Monitor
Select the desired flow rate monitoring (Off, Warning, or
Alarm).
Low Flow Limit
Enter the low flow rate limit (1 to 3999 cc/min).
High Flow Limit
Enter the high flow rate limit (1 to 3999 cc/min).
K-factor Solvent Meter
This field only appears if Solvent Monitor in Configure
Screen 5, page 32, is set to “Meter.” Enter the k-factor
(cc/pulse) for the solvent flow meter.
313885F
45
Setup Mode
Recipe Setup Screen 7
FIG. 54. Recipe Screen 7
This screen appears only if Flush and Fill Input is set to
“Recipe” in Option Screen 1, page 34 and Special Outputs is set to 1, 2, 3, or 4 in Configure Screen 5, page
32. The I/O board has four programmable outputs.
On-Purge
Delay time at the start of the purge cycle before the Special 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
purge cycle.
46
313885F
Setup Mode
Recipe 0 Screens
NOTE: See FIG. 47 on page 42 for a map of the Recipe
0 screens. Detailed screen descriptions follow.
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 catalyzed material.
NOTE: Each screen displays the current screen number
and the total number of screens in the group. The total
number of screens in a group and the fields displayed
on each screen may vary depending on selections
made in the System Configuration Screens and
Option Screens.
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).
Recipe 0 Screen 2
Recipe 0 Screen 1
FIG. 56. Recipe 0 Screen 2
If Number of Guns is set to “2” in Configure Screen 4,
page 31, a Gun 2 column will appear in this screen.
FIG. 55. Recipe 0 Screen 1
First Purge Source
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).
Select “Air,” “Solvent,” or “3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
Screen 3 on page 31).
First Purge Time
Enter the first purge time (0 to 999 seconds) for components A and B in stage 1.
Chop Type
C First Purge Time
Enter the component C first purge time (0 to 999 seconds).
Select “Air/Solvent” or “Air/3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
Screen 3 on page 31). This refers to the process of mixing air and solvent (or air and 3rd flush fluid) together
during the flush cycle, to help clean the lines and reduce
solvent usage.
Final Purge Source
Select “Air,” “Solvent,” or “3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure
Screen 3 on page 31.)
313885F
Total Chop Time
Enter the total chop time (0 to 999 seconds) for components A and B in stage 1.
Final Purge Time
Enter the final purge time (0 to 999 seconds) for components A and B in stage 1.
C Final Purge Time
Enter the component C final purge time (0 to 999 seconds).
47
Setup Mode
Recipe 0 Screen 3
Recipe 0 Screen 4
FIG. 57. Recipe 0 Screen 3
FIG. 58. Recipe 0 Screen 4
This screen only appears if Solvent Monitor is set to
“Meter” in Configure Screen 5, page 32 and Flush Volume Check is set to “On” in Option Screen 1, page 34
or 3rd Flush Valve is set to “On” in Configure Screen 3
on page 31.
This screen appears only if Flush and Fill Input is set to
“Recipe” in Option Screen 1, page 34 and Special Outputs is set to 1, 2, 3, or 4 in Configure Screen 5, page
32. The I/O board has four programmable outputs.
Minimum Flush Volume
This field only appears if Flush Volume Check is set to
“On” in Option Screen 1 on page 34. Enter the minimum flush volume (0 to 9999 cc).
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 values assigned to GFB #1.
On-Purge
Exiting Fill Source
This field only appears if 3rd Flush Valve is set to “On” in
Configure Screen 3 on page 31. Select “Off,” “Air,” “Solvent,” or “3rd Valve.”
Exiting Fill Time
This field only appears if Exiting Fill Source is set to
“Air,” “Solvent,” or “3rd Valve.” Enter the time in seconds.
Delay time at the start of the purge cycle before the Special 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
purge cycle.
48
313885F
Setup Mode
Calibration Screen
FIG. 59. Calibration Screen
Use this screen to calibrate a meter. Set to “Meter A,”
“Meter B,” “Meter C,” or “Solvent Meter” (available if Solvent Monitor in Configure Screen 5, page 32, is set to
“Meter”).
•
Start - start calibration
•
Abort - stop calibration
•
Purge - purge sampling valves after calibration
See Meter Calibration, page 99, for when and how to
calibrate a meter.
313885F
49
ProMix Integration Specifics
ProMix Integration Specifics
System Setup for Automatic
Operation
Configuration of the options for ProMix Automatic operation is done through a few setup screens. Several utility
screens are also available for debug and verification.
First, set the ProMix to Automatic mode.
FIG. 62. Configure Screen 6
Flow Set Source
This appears only if Flow Control is turned on. Select
“Discrete” or “Network”.
In Discrete mode control is driven through the analog
voltage input. In Network mode control is driven through
a Modbus register.
FIG. 60. Configure Screen 3
Proportioning
Select “Discrete” or “Network”.
If Flow Control is used, then turn it on. There are two
activation options: “On”, and “On: Setup”. The only difference is that “On: Setup” allows the display of the
“Flow Control Tuning” screen.
In Discrete mode control is driven through the Discrete
I/O board. In Network mode control is driven through a
Modbus register.
NOTE: It is not possible to read back the active recipe
number using the Discrete I/O interface.
Gun 1 Trigger
Select “Discrete”, “Network”, or “AFS 1”.
In Discrete mode the gun trigger control is read by an
EasyKey digital input and sent to the Fluid Panel. In Network mode it is written to the EasyKey over the Modbus
interface. In AFS 1 mode it is applied to the Fluid Panel
in the Hazardous location.
FIG. 61. Configure Screen 5
Several control interface options are available when
using Automatic mode.
50
NOTE: Discrete I/O is recommended. It is easy to connect in the normal location to the PLC. AFS 1 mode is
used for special cases where the gun trigger timing is
critical.
NOTE: Network gun trigger with Flow Control has a long
time delay through the PLC to ProMix communications
structure. This will negatively affect Flow Control operation.
313885F
ProMix Integration Specifics
Control Network ID
Select the Modbus address of the ProMix. The range is
from 1 though 247.
Modbus communications for reading back information is
available even when Discrete I/O control is enabled.
Status Verification of Automatic
Operation
Several screens allow viewing of control interface status
information.
Discrete I/O bits as used on the ProMix are available in
Advanced Setup Screen 8 and Advanced Setup
Screen 9 If control is through the Network interface the
status data comes from those registers.
This data is updated live.
Discrete I/O vs Network
Communications
The ProMix Automatic system does not use a Booth
Control. Instead, it uses Discrete I/O or Network Communications to drive the system. Each method can be
used exclusively, or both at the same time.
In Automatic mode, the following fields can be set to
“Discrete” or “Network” (see Configure Screen 6 on
page 33):
•
•
•
Flow Control
Proportioning
Gun 1 Trigger
NOTE: In Semi-automatic mode, only the Proportioning
field is available.
NOTE: The Manual Override function enables you to
operate the system before the automation (PLC) is available. Manual Override still requires some communication through Discrete I/O or Network Communications.
Although Manual Override is not intended to be the main
mode of control, it can be used if proper Gun Trigger
Input is provided.
FIG. 63. Advanced Setup Screen 8
FIG. 64. Advanced Setup Screen 9
313885F
51
ProMix Integration Specifics
Discrete I/O
Discrete I/O requires a 24 Vdc power supply which must
be supplied on site. The ProMix 3KS does not supply
power for Discrete I/O.
See Table 4 on page 55, FIG. 73 on page 64, and Table
9 on page 65 for inputs and outputs. Understanding
these inputs and outputs is necessary to properly integrate the ProMix to the automation.
Input and output connections are made at the Discrete
I/O terminal strips (FIG. 66) and the discrete I/O board
(FIG. 67) inside the EasyKey. Also see the System
Electrical Schematic on page 128.
Display Board
Review the Color Change Charts (FIG. 100-FIG. 109). A
full understanding of the color change sequence is necessary to properly drive the inputs and monitor the outputs.
See Advanced Setup Screen 7, page 40. This screen
shows the actual status of all inputs and outputs. It is
important to ensure that each input from local automation (PLC) is received by the EasyKey and to verify that
the ProMix 3KS is sending outputs to the automation.
The following paragraphs describe each discrete I/O
function in detail.
Barrier Board
Terminal Strips
(see FIG. 66)
Discrete I/O Board (see FIG. 67)
TI12496a
FIG. 65: EasyKey Control Boards
52
313885F
ProMix Integration Specifics
Digital Inputs
See Automation Flow Charts, pages 56-60.
Mix Start: This is a maintained input. When High, the
ProMix will attempt to enter Mix mode. This Mix Start
input should not be attempted unless the Mix_Ready
output is recognized. This ensures that there are no
alarms and that the Mix Start input is appropriate.
This input stays High at all times when mixing on
demand is required. When Low, the intent is to stop mixing material and perform a purge or recipe change.
Do not toggle this input to set the unit to Standby mode
during short work stoppages. The ProMix will automatically go into Idle mode after 2 minutes of inactivity.
When a Gun Trigger input is seen, the ProMix will automatically leave Idle mode and resume mixing material
where it left off.
Purge Start: This is a maintained input. When recognized by the ProMix, the Purge Sequence will start,
using the Purge Time from the active recipe. This will
also include the Solvent Fill Time. Proper monitoring of
the Purge/Color Change Output is required to ensure
this function has begun. Once this output is removed,
the system will immediately go to Standby mode.
Color Change Start: This is a momentary input, 100
msec minimum. When recognized by the ProMix, the
Color Change sequence will begin, starting at the
Color/Catalyst Dump.
NOTE: If the new recipe has the same color as the
active recipe, then the Color/Catalyst Dump and
Color/Catalyst Fill times are skipped and the Color
Change Sequence starts with the Purge. Also, the recipe bit configuration for the Color Change must be
loaded at least 100 msec before the Color Change Start
input is turned on. The recipe bit configuration must
remain on while the Color Change Start input is
removed. Graco recommends the recipe bits stay active
and do not change until a new color is required. The
PLC should monitor the Purge/Color Change Output as
well as the Fill Active Output to ensure the process happens as required. A complete color change without
errors (resulting in a Mix Ready Output state) is a completed color change.
Gun Trigger: When High, this input signals the ProMix
that the gun is actually triggered. It should be sent every
time the gun is triggered. This input provides timing for
alarm functions and also drives the flow control functions. Without it, no flow control functions will start.
Job Complete: This is a momentary input, 100 msec
minimum. When recognized by the ProMix, the Job
totals are cleared and a time/date stamp is added for
retrieval.
Remote Stop: Use this input when external equipment
is used to stop the system. Clear any alarms before
using this input. For more information about when this
input is needed, contact your Graco distributor.
Alarm Reset: This is a momentary input, 100 msec
minimum. When recognized by the ProMix it clears any
active alarms and allows the automation to take the next
step.
Common: This is not an input, but the ProMix expects
to have the COM side of the 24 Vdc supply connected
as shown in Table 9. This ensures proper operation of
each input and output.
I/O Terminal Strip Detail
Pin 1
RS485 Integration A
RS485 Integration B
RS485 Integration Ground
RS485 Network A (unused)
RS485 Network B (unused)
RS485 Network Ground (unused)
Pin 1
Flow Control Calibrate
Gun Trigger
Digital Common
Remote Stop
INPUTS
Alarm Reset
General Alarm
Digital Common
Potlife Alarm
OUTPUTS
Flow Rate Analog In
Flow Rate Analog Common
TI12958a
FIG. 66: EasyKey Terminal Strips
NOTE: This also applies if using the Modbus Registers
(see the Modbus Map table in manual 312785).
313885F
53
Digital Output
Common/Power
Special Output #1
Special Output #2
Special Output #3
Digital Output
Common/Power
Special Output #4
ProMix Integration Specifics
JLS
Digital Output Common/Power
Flow Rate Alarm Output
Flow Control Calibrate Active
Fill Active
Mix Ready Output
Mix Active Output
Purge/Recipe Change Active Output
Digital Output Common/Power
Recipe Change Input
Recipe Bit 5 Input
Recipe Bit 4 Input
Recipe Bit 3 Input
Recipe Bit 2 Input
Recipe Bit 1 Input
Recipe Bit 0 Input
Digital Input Common
Solvent Push Enable
External Color Change Ready
Job Complete Input
Purge Input
Mix Input
Digital Input Common
FIG. 67: 255766 Discrete I/O Board
54
313885F
ProMix Integration Specifics
Digital Outputs
Analog Inputs
See Automation Flow Charts, pages 56-60.
Purge_CC_Active: This output will remain High during
the manual Purge or Color Change purge sequence.
See the Color Change Charts (FIG. 100-FIG. 109) for further information.
Flow Command: This is the positive side of the 0 – 10
Vdc signal. (See Common under Digital Inputs, page
53.) This input corresponds to the Flow Range setting in
Advanced Setup Screen 5, page 39. For example, if
the setting is 0 – 300 cc/min, the 0 Vdc analog input is 0
cc/min, therefore the 10 Vdc analog input is 300 cc/min.
Fill_Active: This output will remain High while the ProMix is in the Mixed Material Fill at the end of a typical
color change sequence.
Table 4: Sourcing/Sinking Inputs and Outputs
Mix_Active: This output will remain High while the ProMix is in Mix mode. There may be alarm outputs while
this output is High; these are typically High/Low Flow
Warnings. Always monitor this output and the alarm outputs to provide feedback of the actual status of the ProMix. (See the Modbus Charts in the Graco Gateway
manual 312785.)
Inputs (Automation Sourcing)
1
Flow Control Calibration
Black
+
2
Gun Trigger
White
+
3
Digital In Common
Red
-
4
Remote Stop
Green
+
5
Alarm Reset
Brown
+
Mix_Ready: This output will remain High while there are
no alarms and the ProMix is ready to go to Mix mode.
General Alarm: This output will remain High when any
alarm is active. See Table 17 on page 114 for a complete list of alarms.
NOTE: It is important to monitor this output along with
Mix_Active to understand the alarm’s true meaning.
Alarm_Potlife: This output will remain High along with
the Alarm output when the potlife time has been
reached for the active recipe. The Mix_Active output will
drop Low, even if the Mix_Start input is High. This output
will remain High until the potlife volume is dispensed or
the ProMix completes a Purge or a Color Change. The
Alarm Reset input will not stop this output but will
silence the audible alarm on the EasyKey.
NOTE: The Alarm Reset
Outputs (Automation Sourcing)
6
Alarm Output
Blue
+
7
Digital Out Common
Orange
-
8
Pot Life
Yellow
+
Outputs (Automation Sinking)
6
Alarm Output
Blue
-
7
+24 Volts
Orange
+
8
Pot Life
Yellow
-
Automation
9
Flow Rate Analog In
Purple
+
10
Flow Rate Analog Common
Gray
-
key will also reset the
audible alarm.
To dispense the potlife volume, the ProMix Mix_Start
input must be turned Off then back to High to spray
material. At this point, Mix_Active, Alarm, and
Alarm_Potlife outputs will be High until the potlife volume is sprayed.
Digital Out Supply: This is the supply for the digital outputs. It is the same supply for the digital inputs. (See
Common under Digital Inputs, page 53.)
313885F
55
ProMix Integration Specifics
Automation Flow Charts
Start Mix Mode Process
See FIG. 68, Table 5, and Table 6.
Start Mix Mode
Process
NO
YES
Is Mix Ready
bit = 1?
Must be Alarm Condition or Active Recipe
61. See Alarm Processing on page 60,
or Startup from Recipe
61 (see NOTE below)
Set Mix bit = 1
NO
Is Mix Active
bit = 1?
NOTE: At power up the system
defaults to Recipe 61, which is
not a valid recipe number. Initiate
a color change to Recipe 0 or a
valid recipe number (1-60).
YES
ProMix in Mix Mode
(Complete) Mix
Active = 1 while the
ProMix is in Mix
mode
FIG. 68. Start Mix Mode Process Flow Chart
56
313885F
ProMix Integration Specifics
Mixing Mode Process
See FIG. 69, Table 5, and Table 6.
Mixing Mode
Process
Mixing Mode is desired.
PLC is polling to ensure
Mixing Mode is maintained.
NO
Is Mix Active
bit = 1?
YES
Mixing Process active
Check Alarm
Condition: is Alarm_
General bit = 1?
NO
Go to Start Mix Mode
Process, page 56
YES
Go to Alarm Processing, page 60
FIG. 69. Mixing Mode Process Flow Chart
313885F
57
ProMix Integration Specifics
Purge Mode Process
See FIG. 70, Table 5, and Table 6.
Start
NO
Is Mix Ready
bit = 1?
Must be Alarm
Condition or Active
Recipe 61. See
Alarm Processing
on page 60, or
Startup from Recipe
61 (see NOTE
below).
Set Purge bit = 1?
NO
NO
(Wait for Mix Ready)
Is Mix Ready
bit = 1?
NOTE: At power up the system
defaults to Recipe 61, which is
not a valid recipe number. Initiate
a color change to Recipe 0 or a
valid recipe number (1-60).
YES
YES
Is Purge_CC_Active
bit = 1?
YES
ProMix in Purge_CC
Mode (Process
Started)
ProMix Purge
Process (Complete)
FIG. 70. Purge Mode Process Flow Chart
58
313885F
ProMix Integration Specifics
Color Change Mode Process
See FIG. 71, Table 5, and Table 6.
Color Change
Process
(basic)
Do nothing.
Spraying at
desired recipe.
Is Active Recipe =
to desired recipe?
(Register 40005).
YES
NO
Load ccNewRecipe
(Register 40046) with
recipe number to Color
Change to (0 through
60 is valid).
Ensure ColorChange bit is
seen by ProMix
NO
Is Purge_CC_Active bit = 1?
YES
NO
Set ColorChange (CC)
bit = 1.
Clear ColorChange (CC)
bit (momentary input).
CC process started.
(Wait for Mix Ready)
Is Mix Ready
bit = 1?
NO
Check Alarm
Condition: is Alarm_
General bit = 1?
YES
YES
ProMix Color Change
Process (Complete)
Process Alarm. See
Alarm Processing,
page 60.
FIG. 71. Color Change Mode Process Flow Chart
313885F
59
ProMix Integration Specifics
Alarm Processing
See FIG. 72, Table 5, Table 6, and Table 7.
Alarm Processing
An Alarm Condition
has been found
previously. Alarm_General = 1.
Check if Potlife
Alarm: is Alarm_
Potlife bit = 1?
NO
Two options:
Determine the exact alarm
from Table 7 on page 63
and solve what caused the
alarm, as required.
• Purge or Color Change to remove
mixed material in the line.
• Place in Mix mode and spray the
Potlife Volume set in the ProMix.
NOTE: The Reset key only silences
the alarm. To clear the alarm you must
use one of these two options.
Reset the alarm.
Reset_Alarm = 1.
NO
Is Mix Ready
bit = 1?
YES
YES
Go to next process,
as desired.
FIG. 72. Alarm Processing Flow Chart
60
313885F
ProMix Integration Specifics
Table 5: ProMix Digital Inputs (Modbus Register 40040)
Bit
Digital Input Binary
Name
Details
0:5
0 0 0 0 0 0 0 0 0 0 X X X X X X Recipe
Binary bits for viewing discrete inputs only.
6
0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 Color Change
(CC)
Set bit to “1” to initiate Color Change (momentary)
7
0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 Mix
Set bit to initiate Mix mode (maintained)
8
0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 Purge
Set bit to “1” to initiate Purge sequence (maintained)
9
0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 Job_Complete Set bit to “1” to initiate Job Complete input (momentary)
10
0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 External CC
Ready
Set bit to “1” to initiate External Color Change
(momentary)
11
0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 Solvent Push
Enable
Set bit to “1” to initiate Solvent Push
12
0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 FC _Calibrate
Set bit to “1” to initiate a Flow Control Calibrate input
(momentary)
13
0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 Gun_Trigger
Set bit to “1” to indicate the gun is actually triggered
(maintain while gun is triggered, remove when gun is
closed)
14
0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Reset_Alarm
Set bit to “1” to clear an active Alarm (momentary)
15
1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Remote Stop
Set bit to remotely stop unit (momentary)
NOTE: Shaded cells relate to the flow charts on pages 56-60.
313885F
61
ProMix Integration Specifics
Table 6: ProMix Digital Outputs (Modbus Register 40041)
Bit
Digital Input Binary
Name
Details
0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 Purge_CC_Active
“1” indicates Purge or Color Change is in progress
1
0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 Mix_Active
“1” indicates Mix is in progress
2
0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 Mix_Ready
“1” indicates No Alarms and OK to Mix
3
0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 CC_Fill_Active
“1” indicates the Fill portion of a Color Change is
in progress
4
0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 FCalActive
“1” indicates the Flow Control Calibrate routine is
in progress
5
0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 Flow_Rate_Alarm
“1” indicates the Flow Rate Alarm/Warning is
active
6
0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 Special_1
“1” indicates the Special_1 output is on (monitor
only)
7
0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 Special_2
“1” indicates the Special_2 output is on (monitor
only)
8
0 0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 Special_3
“1” indicates the Special_3 output is on (monitor
only)
9
0 0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 Special_4
“1” indicates the Special_4 output is on (monitor
only)
10
0 0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 GFB _1_Copy
“1” indicates the output for GFB 1 is on
11
0 0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 GFB _2_Copy
“1” indicates the output for GFB 2 is on
12
0 0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 Alarm_General
“1” indicates a General Alarm is in process. (If
Mix_Active is still High, then a Warning only.)
See the Modbus charts in the Graco Gateway
manual 312785 for details on type.
13
0 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 Alarm_Potlife
“1” indicates a Potlife Alarm is in process.
14
0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 AFS _1_Copy
“1” indicates the AFS 1 input to the Fluid Panel is
on
15
1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 AFS _2_Copy
“1” indicates the AFS 2 input to the Fluid Panel is
on
NOTE: Shaded cells relate to the flow charts on pages 56-60.
62
313885F
ProMix Integration Specifics
Table 7: ProMix Low Word Active Alarms (Modbus Register 40010)
Code
Hex
Binary Code
Name
None
0000
0000 0000 0000 0000
No bits set / no active low-word alarm
E-1
0001
0000 0000 0000 0001
Communication Error Alarm
E-2
0002
0000 0000 0000 0010
Potlife Alarm
E-3
0004
0000 0000 0000 0100
Ratio High Alarm
E-4
0008
0000 0000 0000 1000
Ratio Low Alarm
E-5
0010
0000 0000 0001 0000
Overdose A/B Dose Too Short Alarm
E-6
0020
0000 0000 0010 0000
Overdose B/A Dose Too Short Alarm
E-7
0040
0000 0000 0100 0000
Dose Time A Alarm
E-8
0080
0000 0000 1000 0000
Dose Time B Alarm
E-9
0100
0000 0001 0000 0000
Not used
E-10
0200
0000 0010 0000 0000
Remote Stop Alarm
E-11
0400
0000 0100 0000 0000
Purge Volume Alarm
E-12
0800
0000 1000 0000 0000
CAN Network Communication Error
E-13
1000
0001 0000 0000 0000
High Flow Alarm
E-14
2000
0010 0000 0000 0000
Low Flow Alarm
E-15
4000
0100 0000 0000 0000
System Idle Warning
E-16
8000
1000 0000 0000 0000
Setup Change Warning
Table 8: ProMix High Word Active Alarms (Modbus Register 40010)
Code
Hex
Binary Code
Name
None
0000
0000 0000 0000 0000
No bits set / no active high-word alarm
E-17
0001
0000 0000 0000 0001
Power On Warning
E-18
0002
0000 0000 0000 0010
Defaults Loaded Warning
E-19
0004
0000 0000 0000 0100
I/O Alarm. See Alarm Troubleshooting, page 115
E-20
0008
0000 0000 0000 1000
Purge Initiate Alarm
E-21
0010
0000 0000 0001 0000
Material Fill Alarm
E-22
0020
0000 0000 0010 0000
Tank A Low Alarm
E-23
0040
0000 0000 0100 0000
Tank B Low Alarm
E-24
0080
0000 0000 1000 0000
Tank S Low Alarm
E-25
0100
0000 0001 0000 0000
Auto Dump Complete Alarm
E-26
0200
0000 0010 0000 0000
Color/Catalyst Purge Alarm
E-27
0400
0000 0100 0000 0000
Color/Catalyst Fill Alarm
E-28
0800
0000 1000 0000 0000
Material Advance Complete
E-29
1000
0001 0000 0000 0000
Tank C Low Alarm
E-30
2000
0010 0000 0000 0000
Overdose C Alarm
E-31
4000
0100 0000 0000 0000
Dose Time C Alarm
E-32
8000
1000 0000 0000 0000
Audible Buzzer Active
313885F
63
ProMix Integration Specifics
PLC Output
(Sourcing)
ProMix EasyKey Digital Input
Input
Common
Output
Input
24
Vdc
Common
PLC Input
(Sinking)
ProMix EasyKey Digital Output
24
Vdc
Output
Common
Input
Output
Common
ProMix EasyKey Digital Output
PLC Input
(Sourcing)
Output
Common
Output
Input
24
Vdc
Common
FIG. 73. Automation 24 Vdc Sourcing Input Diagram
64
313885F
ProMix Integration Specifics
Table 9: Discrete I/O Terminal Connections
Pin
Port
Name
Details (also see pages 61 and 62)
Digital Inputs to Remote I/O Board for Proportioning
1
J2
Mix
Set Bit to Initiate Mix Mode (maintain)
2
J2
Purge
Set Bit to “1” to initiate Purge Sequence (maintained)
3
J2
Job_Complete
Set Bit to “1” to initiate Job Complete Input (momentary)
4
J2
External CC Ready
Set Bit to “1” to initiate External Color Change (maintained)
5
J2
Solvent Push Enable
Set Bit to “1” to initiate Solvent Push
6*
J2
Digital Input Common
Set Binary Bits for Recipe to Change To (hold until changing
again)
Digital Inputs to Remote I/O Board for Color Change
1*
J3
Digital Input Common
2
J3
Recipe Bit 0
Set Binary Bits for Recipe to Change To (hold until changing
again)
3
J3
Recipe Bit 1
Set Binary Bits for Recipe to Change To (hold until changing
again)
4
J3
Recipe Bit 2
Set Binary Bits for Recipe to Change To (hold until changing
again)
5
J3
Recipe Bit 3
Set Binary Bits for Recipe to Change To (hold until changing
again)
6
J3
Recipe Bit 4
Set Binary Bits for Recipe to Change To (hold until changing
again)
7
J3
Recipe Bit 5
Set Binary Bits for Recipe to Change To (hold until changing
again)
8
J3
Color Change (CC)
Set Bit to “1” to initiate Color Change (momentary)
Digital Inputs to EasyKey 10-Pin Terminal Block for Gun Trigger and Alarm Processing
1
J5
Flow Control Calibrate
Set Bit to “1” to initiate Flow Control Calibrate (momentary)
2
J5
Gun Trigger
Set Bit to “1” to indicate Gun is Triggered (fluid flow expected)
3†
J5
Digital Input Common
4
J5
Remote Stop
Set Bit to “1” to initiate a Remote Stop (momentary)
5
J5
Reset_Alarm
Set Bit to “1” to Clear an Active Alarm (momentary)
*
Digital inputs tied together on the I/O board (see FIG. 67).
† Digital inputs tied together on the EasyKey Display Board.
Multiple connection points for convenience.
313885F
65
ProMix Integration Specifics
Table 9: Discrete I/O Terminal Connections
Pin
Port
Name
Details (also see pages 61 and 62)
Digital Outputs from Remote I/O Board for Proportioning
1
J4
Digital Output Common/Power
2
J4
Purge CC Active
“1” Indicates Purge or Color Change is in progress
3
J4
Mix Active
“1” Indicates Mix is in progress
4
J4
Mix Ready
“1” Indicates No Alarms and OK to Mix
5
J4
CC Fill Active
“1” Indicates the Fill Portion of a Color Change is in progress
6
J4
FC Cal Active
“1” Indicates the Flow Control Calibrate routine is in progress
7
J4
Flow Rate
“1” Indicates the Flow Rate Alarm/Warning is active
8
J4
Digital Output Common/Power
Digital Outputs from Remote I/O Board for Special Outputs
1
J5
Digital Output Common/Power
2
J5
Special_1
“1” Indicates the Special_1 Output is on
3
J5
Special_2
“1” Indicates the Special_2 Output is on
4
J5
Special_3
“1” Indicates the Special_3 Output is on
5
J5
Special_4
“1” Indicates the Special_4 Output is on
6
J5
Digital Output Common/Power
Digital Outputs from EasyKey 10-Pin Terminal Block for Alarm and Potlife Indication
6
J5
General Alarm Output
7
J5
Digital Output Common/Power
8
J5
Potlife Alarm
“1” Indicates the General Alarm Output is on
“1” Indicates the Potlife Alarm Output is on
Analog Input to EasyKey 10-Pin Terminal Block for Flow Rate Set Point
9
J5
Flow Rate Analog In (0-10 VDC) 0 - 10VDC input for Flow Setpoint relative to flow range set in
2KS Flow Range Screen
10
J5
Flow Rate Common to Pin 9
Common side of Flow Setpoint from Terminal 9
Modbus Network Communications on EasyKey 6-Pin Terminal Block
1
J10
RS485 Integration A
2
J10
RS485 Integration B
3
J10
RS485 Integration Shield/Ground
4
J10
RS485 Network A
5
J10
RS485 Network B
6
J10
RS485 Network Shield/Ground
Communication to External PLC/Controller
Not used
 Digital outputs tied together on the I/O board (see FIG. 67).
 Digital outputs tied together on the EasyKey Display Board.
66
313885F
Modbus and I/O Data
Modbus and I/O Data
See Table 10 and Table 11 for Modbus register
addresses and input/output data.
Reference the Discrete I/O listing of all the inputs and
outputs (see page 61). Ensure these are fully understood. The same implementation used for Discrete I/O is
used for the Network communication protocol.
For example: The Gun Trigger Input will now be a specific bit of Modbus Register 40040. Monitoring of Modbus Register 40041 for specific output status conditions
will be required as explained in the Discrete I/O section
of the ProMix Operation manual. The PLC will have to
read the various bits, and in some cases (40040 and
40041 for example) must mask out the various bit positions to determine each of the separate input and output
statuses. This requires experience and should not be
done on the job site. A full understanding of the color
change process as well as the required timing of various
inputs and outputs is required.
NOTE: Analog input for flow control set point will now be
a dedicated Modbus register. Register 40137 will require
the specific flow rate (i.e. 125 cc/min). This is not a voltage reading but the actual flow target.
Start Mix Process
See FIG. 68, Table 5, and Table 6.
1. Verify that the Mix Ready bit (bit 2 of 40041) is on.
material where it left off. Do not toggle the Mix bit; doing
so restarts the Mix process from the beginning.
Color Change Process
See FIG. 71, Table 5, and Table 6.
1. Verify that Mix Ready is set. This ensures that there
are no alarms and that the system is ready for the
next command.
2. Load ccNewRecipe (Modbus 40046) with a recipe
number to color change to.
3. Set color change (40040 bit 6).
4. Verify that Purge_CC_Active is seen (40041 bit 0).
5. Clear color change bit (momentary only).
6. Do not change the ccNewRecipe value until a new
recipe change is requested.
7. The color change process will stop automatically as
programmed. Monitor Purge_CC_Active bit for completion.
Purge Process
See FIG. 70, Table 5, and Table 6.
2. Turn on the Mix bit (bit 7 of 40040).
1. Verify that Mix Ready is set. This ensures that there
are no alarms and that the system is ready for the
next command.
3. Verify that the Mix Active bit (bit 1 of 40041) is on, to
ensure that the Mix request was received.
2. Set purge (40040 bit 8).
3. Verify that Purge_CC_Active is seen (40041 bit 0).
Stop Mix Process
See FIG. 69, Table 5, and Table 6.
1. Clear the Mix bit.
2. The Mix Active output should clear and Mix Ready
should now be set.
NOTE: The ProMix will automatically go into Idle mode
after 2 minutes of inactivity. A general alarm will be present and Mix Active will remain High. The Alarm bit
(40010) will indicate the system Idle alarm. When a new
Gun Trigger input is seen, the ProMix will resume mixing
313885F
4. When Purge_CC_Active bit clears, clear
Purge_Start bit. Clearing this bit in the middle of a
purge sequence will abort the purge sequence.
NOTE: It only requires three Modbus registers to provide full communications from the PLC to the ProMix. All
other registers are on a need to view and monitor basis.
40040Robot Digital In (Send/Edit Values in ProMix)
40041Robot Digital Out (READ ONLY - Active values)
40046Go To Recipe value for next ProMix recipe
67
Modbus and I/O Data
Table 10: ProMix Modbus/TCP Variable Map
EasyKey
* Read/Write Modbus
Status
Register
Read Only
40003
Read Only
40004
Read Only
40005
Read Only
40006
Read/Write
40007
Read/Write
40008
Read Only
40009
Read Only
40010
Read Only
40032
Read/Write
40040
Read Only
40041
Read/Write
40046
Read Only
40048
Read Only
40049
Read Only
**40056
Read Only
40114
Description
Current flow rate
Actual ratio
Active recipe
Potlife 1 remaining
Job complete
Reset job total
Potlife 2 remaining
Active fault
Control version
Robot digital input
Robot digital output
CC New recipe
Current fluid pressure
V/P percent output
Actual ratio reducer
Flow control option
Size
16 Bit
16 Bit
16 Bit
16 Bit
16 Bit
16 Bit
16 Bit
32 Bit
32 Bit
16 Bit
16 Bit
16 Bit
16 Bit
16 Bit
16 Bit
16 Bit
Read/Write
40115
Flow setpoint data source 16 Bit
Read/Write
Read/Write
40120
40125
Manual override pct. drive 16 Bit
***FC range
16 Bit
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
Read/Write
40126
40127
40128
40129
40137
40159
40171
43123
FC tolerance
FC proportional gain Kp
FC integral gain Ki
FC alarm time
FC setpoint
FC Learn Strength
FC Learn Threshold
FC override mode
16 Bit
16 Bit
16 Bit
16 Bit
16 Bit
16 Bit
16 Bit
16 Bit
Read/Write
43141
FC enable
16 Bit
*
Units
cc/min
none
none
sec
none
none
sec
none
none
none
none
none
1/100 psi
%
none
0=proportioning only
1=1K flow control (future)
2=2K flow control
3=pressure override
4=manual pct. override
0=discrete
1=network
%
0=0-300 cc/min
1=0-600 cc/min
2=0-1200 cc/min
%
default=400
default=40
sec
cc/min
%
cc/min
0=off (normal)
1=% open
2=pressure mode
0=off
1=on
Low
Limit
0
0
0
0
0
0
0
0
0
0x0000
0x0000
0
0
0
0
0
High Limit
5000
9999
60
9999
0xFFFF
9
9999
0xFFFF FFFF
0xFFFF FFFF
0xFFFF
0xFFFF
60
50000
100
9999
4
0
1
0
0
100
2
0
0
0
0
0
0
0
0
99
9999
9999
99
1200
100
1200
2
0
1
This column represents the rule that must be implemented by automation. Writing to Read Only registers must be
avoided.
**For ProMix 3KS Systems only.
***Flow Control
68
313885F
Modbus and I/O Data
Table 11: ProMix Recipe Bits
Recipe Bits
5
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
4
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
313885F
3
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
2
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
Number
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Recipe Bits
5
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
3
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
2
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
Number
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
69
Modbus and I/O Data
Typical PLC Interaction with
ProMix
This section describes a typical interaction when a local
PLC is directly connected to the Discrete I/O connections of the ProMix.
See ProMix Integration Specifics on page 50 for a
detailed explanation of inputs and outputs.
NOTE: Communications fields of Configure Screen 6
must be set to DISCRETE (see page 33).
During the short On state, the recipe will be read from
this binary sequence and the status bar of the EasyKey
will display COLOR CHANGE XX. The Purge_CC_Active output will be High for the duration of the color
change purge process. During the Mixed Material Load
portion at the end of the Color Change sequence, the
Fill_Active output will be on, indicating that portion of the
color change. These will not be on at the same time.
Once the Mix_Ready output goes High with no alarms,
then the PLC has assurance that the requested color
change has taken place with the requested recipe being
the current active recipe. If any error occurs during the
process, the requested recipe will not be loaded, and
the old recipe will remain active.
Start Mixing
To start the mix process, the PLC will monitor and
ensure the Mix_Ready output is High. This provides
assurance it is ready to mix. PLC will drive High the Mix_Start input, keep it High and monitor the Mix_Active
output to ensure the ProMix followed through on the
request.
Stop Mixing
To stop mixing (to perform a purge or color change),
remove the Mix_Start input (the status bar on the
EasyKey will show STANDBY). Monitor the Mix_Ready
output to ensure the Mix_Active output goes Low.
Color Change
To perform a color change, ensure there are no alarms
(except the Potlife Alarm). If alarms are present, the
Alarm_Reset input should be sent momentarily to clear
the alarm (>100 msec).
NOTE: Alarm_Reset will not reset a Potlife alarm. Only
dispensing the Potlife Volume or a complete
Purge/Color Change will reset a Potlife alarm.
The Alarm Reset Input will silence the audible alarm.
Turn the Color_Change_Start input on momentarily
(>100 msec) while the proper sequence of recipe bits
are set.
NOTE: The Recipe Bits must be presented at least 100
msec before the Color Change Start input is turned on
and remain until a new recipe is required.
NOTE: It is not possible to read the active recipe
through Discrete I/O alone. Only by monitoring networked registers through the Gateway is it possible to
view the active recipe. Proper management of the alarm
status outputs during the color change process will
ensure the active recipe is what is expected.
Purge
To start a Purge (no color change), drive the
Purge_Start input High (maintained) while ensuring Mix_Ready output is High (ensuring no active alarms). An
exception is Potlife alarm (see Color Change above if
alarms are present.) The Purge_CC_Active output is
High for the entire Purge process. Ensure there are no
alarms during this process. Fill_Active is High when Mix
is on. When complete, Mix _Ready output will be High,
indicating a completed purge.
NOTE: No change is made to the active recipe.
Gun Trigger Input
This input is sent and expected every time the gun is
actually triggered, and this input is turned off when the
gun is not triggered. Never tie this input with any other
signal. Without this input, some critical mixing alarms
are eliminated.
IMPORTANT: This input must be provided through Discrete I/O for integrated flow control applications, to
ensure fast coordination with the flow control process.
Applications without flow control can use Gun Trigger
input through Network Communications or Discrete I/O.
NOTE: The Gun Trigger input has the same effect as the
air flow switch used on manual ProMix systems.
70
313885F
Modbus and I/O Data
Alarm Monitoring/Reset (Discrete I/O)
Anytime an alarm occurs, the Alarm Reset input will
reset the alarms and allow for processing of the next
step by automation, except for the following conditions:
•
key. Only a Purge/Color Change or spraying the Potlife volume will reset a Potlife alarm. (See
Alarm_Potlife output information on page 55.)
•
ProMix has four specials that can each be turned off and
on twice throughout a color change sequence. See
Advanced Setup Screen 8 on page 41 or Recipe
Setup Screen 7 on page 46.
Potlife Alarms cannot be reset by the Alarm Reset
input or through the EasyKey Alarm Reset
•
For Applications with Dump Valves (for quick
purges/color changes at or near the gun):
When Flow Control is turned on (see Configure
Screen 5 on page 32), the Flow_Rate_Alarm output
will be High when the instantaneous flow rate is
above or below the Flow Rate tolerance setting.
(High Flow or Low Flow will be the condition, indicating in the status bar of the EasyKey.) This output will
be High along with the Mix_Active output. The PLC
should monitor the amount of time this condition
exists and take action at a predetermined time. With
Flow Control there will be times (for example during
flow rate changes) where the general alarm as
described here will be High (typically momentarily).
The PLC must read this Alarm output (i.e. general
alarm), see if Mix_Active is still High, and if so, start
a timer. A typical example would be to ensure all
parts are sprayed within a specific flow rate range. A
maximum predetermined time would be set to allow
a Low or High flow condition to exist continuously.
Shutdown or go to Standby after the flow rate alarm
time expires.
Job_Complete Input
Every time a momentary Job_Complete input is seen by
the ProMix, a job log will be recorded, logging the A and
B meter volumes (cc) with a time and date stamp. The
volumes will then be reset to 0. (Volume totals are accumulated since the last reset.)
For example, a dump valve at a gun on a robot could be
opened at the appropriate times to facilitate fast color
changes. Another output could be used to automatically
drive an air-operated fluid regulator High during the
Purge or Color Change process.
NOTE: With integrated Flow Control, the flow control
regulator automatically is driven High. See Advanced
Setup Screen 5 on page 39 for specifics on setting up
these values. Each of the specials can be monitored, but
can only be controlled through the times entered within
the setup screens of the EasyKey or by managing the
proper registers on the network.
The following ProMix inputs should never be on (High)
at the same time:
•
Mix_Start
•
Purge_Start
•
Color_Change_Start
The Recipe Bits (0-6) are always on at the same time.
The only time these bits are recognized is when the Color_Change_Start input is High. The Recipe Bits should
be loaded and stay loaded for the current recipe. Do
not change the Recipe Bits until a color change is
required again. Inconsistent results are possible if this is
not followed.
Integration Timing Charts
Refer to FIG. 74 - FIG. 80 for integration timing charts.
NOTE: A Color Change accomplishes the same Job
Complete Reset functions. The Job_Complete input is
commonly used to record material usage for a specific
set of parts. These volumes are sprayed material volumes.
313885F
71
313885F
FIG. 74. Integration Control Recipe Change X to Y
Modbus and I/O Data
72
Modbus and I/O Data
73
FIG. 75. Integration Control Recipe Change X to Y External Color Change
313885F
313885F
FIG. 76. Integration Control Y Purge
Modbus and I/O Data
74
Modbus and I/O Data
75
FIG. 77. Integration Control Y Fill
313885F
313885F
FIG. 78. Integration Control Y Purge and Fill
Modbus and I/O Data
76
Modbus and I/O Data
77
FIG. 79. Integration Control Mix Sequences
313885F
313885F
Modbus and I/O Data
78
FIG. 80. Integration Control Alarm Processing
System Operation
System Operation
Operation Modes
Mix
System mixes and dispenses material.
Standby
Stops the system.
General Operating Cycle,
Sequential Dosing
1. The system enters and loads the desired color.
2. The system enters Mix mode to begin operation.
3. The controller sends signals to activate the solenoid
valves. The solenoid valves activate Dose Valves A,
B, and C. Fluid flow begins when the Gun Trigger
input is seen.
Stage 1 (see FIG. 81, ProMix 2KS Detail)
Purge
Purges the system, using air and solvent.
Sequential Dosing
Components A, B, and C dispense sequentially in the
necessary volumes to attain the mix ratio.
Recipe (Color) Change
4. Components A and B are introduced into the 2KS
fluid integrator (FI) one at a time as follows.
a. Dose Valve B (DVB) opens, and fluid flows into
the integrator.
b. Flow Meter B (MB) monitors the fluid volume
dispensed and sends electrical pulses to the
ProMix 2KS controller. The controller monitors
these pulses and signals.
c.
The process when the system automatically flushes out
the old color and loads a new color. See pages 101-113.
Solvent Push
The Solvent Push feature enables the user to save
some mixed material by pushing it out to the gun with
solvent. The feature requires an accessory solvent
meter. See page 98 for complete information.
When the target volume dispenses, Dose Valve
B closes.
NOTE: The dispense volume of components A and
B is based on the mix ratio and dose size set by the
user and calculated by the controller.
d. Dose Valve A (DVA) opens, and fluid flows into
the 2KS integrator and is aligned proportionately with component B.
e. Flow Meter A (MA) monitors the fluid volume
dispensed and sends electrical pulses to the
ProMix 2KS controller.
f.
When the target volume is dispensed, Dose
Valve A closes.
5. Components A and B are pre-mixed in the 2KS integrator, then uniformly blended in the 2KS static
mixer (SM) before flowing through the hose to the
3KS Fluid Manifold inlet.
313885F
79
System Operation
Stage 2 (see FIG. 81, ProMix 3KS Detail)
6. Dose Valve C (DVC) opens, and fluid flows into the
3KS integrator and is aligned proportionately with
components A+B (mixed in Stage 1).
7. Flow Meter C (MC) monitors the fluid volume dispensed and sends electrical pulses to the ProMix
3KS controller.
8. When the target volume is dispensed, Dose Valve C
closes.
9. Components A+B and C are pre-mixed in the 3KS
integrator, then uniformly blended in the 3KS static
mixer (SM).
NOTE: To control output from the 3KS static mixer
to the gun, install an optional fluid pressure regulator.
10. Components A+B and C are alternately fed into the
3KS integrator as long as the Gun Trigger input is
seen.
11. If the Gun Trigger input is not seen for two minutes,
the system switches to Idle mode, which closes off
the mix manifold dose valves.
12. When the Gun Trigger input is seen again, the ProMix 3KS continues the process where it left off.
NOTE: Operation can be stopped at any time by
going to Standby mode (remove Mix input).
Table 12: Sequential Dosing Operation
Dose 1
Ratio = 2.0:1
Stage 1 (A:B)
Dose 2
Stage 2
(A+B):C
Stage 1 (A:B)
Stage 2
(A+B):C
A=2
B=1
C=1
80
313885F
System Operation
DVA
DVB
FI
MB
MS
MA
RVB
RVA
TI12556a
APV
AT
SVA
SM
SVB
SPV
Key: ProMix 2KS Fluid Station
FI
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
DVC
SVB Component B Shutoff
Valve
MS Solvent Meter
SPV Solvent Purge Valve
APV Air Purge Valve
SM Static Mixer
FI
Fluid Integrator
AT
Air Purge Valve Air Supply
Tube
Key: ProMix 3KS Fluid Station
MC
CPV
RVC
1
MC
DVC
RVC
SVC
CPV
SM
FI
Component C Meter
Component C Dose Valve
Component C Sampling Valve
Component C Shutoff Valve
Component C Purge Valve
Static Mixer
Fluid Integrator
1
3KS fluid inlet. Connect fluid supply line from
2KS fluid manifold outlet here.
2
Connect fluid supply line to gun.
SVC
SM
2
TI14382b
FIG. 81. ProMix 2KS and ProMix 3KS Wall Mount Fluid Stations
313885F
81
System Operation
General Operating Cycle, Dynamic Dosing
Overview
•
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.
A restrictor injects component B into a continuous
stream of component A. The software controls the duration and frequency of each injection. See FIG. 82 for a
schematic diagram of the process.
•
Component B Pressure: Ensure precise pressure
regulation. It is recommended that the component B
pressure be 5-15% higher than the component A
pressure.
Dynamic Dosing System Parameters
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 pulsation, 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.
Dynamic Dosing provides on-demand proportioning,
eliminating the need for an integrator and therefore minimizing undesired material contact. This feature is especially useful with shear-sensitive and waterborne
materials.
The following parameters affect dynamic dosing performance:
•
Component A Flow: Ensure that the supply pump is
sized to provide sufficient and uninterrupted flow.
Note that component A provides majority of system
flow at higher mix ratios.
Component A (continuous flow)
Proportioned Material
To Static
Mixer
Component B (pulsed injection)
FIG. 82. Schematic Diagram of Dynamic Dosing Operation
82
313885F
System Operation
Select a Component B Restrictor Size
Install the 15U955 Injection Kit in the fluid manifold as
explained in the ProMix Installation manual. Use the
charts provided in that manual to select an appropriate
restrictor size based on the desired flow and mix ratio.
Turn On Dynamic Dosing
1. On the EasyKey press the Setup
key to access
the Set Up Home screen. Select “System Configuration” to access the configuration screens. FIG. 83.
3. Selecting “DD” in System Configure Screen 4
makes the DD Setup mode available. See FIG. 85.
To enable DD setup mode, select On in the DD
Setup mode drop down menu. This disables Off
Ratio alarms E-3 and E-4, allowing uninterrupted
setup and tuning.
NOTE: Do not use the material mixed when in DD setup
mode, as it may not be on ratio due to the disabled
alarms.
NOTE: If DD setup mode is not turned Off at the end of
setup, it will automatically turn off 3 minutes after initiation of a Mix command.
FIG. 83. Set Up Home Screen
2. Navigate to System Configure Screen 4. Select
“DD” option from the “Dose Size” drop down menu.
FIG. 84.
FIG. 85. Configure Screen 4, dynamic dosing setup
mode enabled
FIG. 84. Configure Screen 4, dynamic dosing
selected
313885F
83
System Operation
Balancing A/B Pressure
If component B pressure is too high, it will push the component A stream aside during B injection. The valve will
not open long enough, causing a High Ratio alarm.
If component B pressure is too low, it will not be injected
in sufficient volume. The valve will stay open too long,
causing a Low Ratio alarm.
Selecting the correct component B restrictor size and
balancing the A/B pressures will keep the system in the
proper pressure range, resulting in a consistent mix
ratio.
FIG. 87 shows the A to B pressure balance, read at the
proportioner inlet. It is recommended that the component 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.
NOTE: In multi-flow rate systems, it is recommended
that you set up the system to run properly at the highest
flow rate, to ensure adequate fluid supply across the
flow rate range.
In dynamic dosing, component A dose valve is constantly on. Component B dose valve will cycle on and
off; one cycle every 0.5 – 1.0 seconds indicates proper
balance.
Monitor system performance by watching the EasyKey
display for warning messages which provide information
on system performance, and adjust pressures accordingly. See Table 13 on page 85.
n
Co
nge
Ra
l
o
tr
B Pressure
Too Low
B Pressure
Too High
A Pressure
B Pressure
FIG. 87. A/B Control Range with Properly Sized
Restrictor
nge
l Ra )
o
r
t
l
Co n o s m a l
(to
B Pressure
Too Low
B Pressure
Too High
A Pressure
B Pressure
NOTE: If the restrictor is too small, it may be
necessary to supply more differential pressure
than is available in your system.
FIG. 88. A/B Control Range with Too Large a
Restrictor
FIG. 86. B Pressure Too Low, displayed on EasyKey
84
313885F
System Operation
Table 13: Dynamic Dosing Troubleshooting Guide
(for complete system troubleshooting, see Table 18 beginning on page 115)
Warning/Alarm Message
Solution
B Pressure Too Low (see FIG. 86)
•
•
•
Increase B pressure.
Clean restrictor or use a larger size.
Verify B valve is opening properly.
B Pressure Too High
•
•
Increase A pressure or decrease B pressure.
Use a smaller restrictor.
Off Ratio Low
•
•
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) counterclockwise. To close, turn clockwise. See Table 14 and
FIG. 89.
E
TI11581a
FIG. 89. Valve Adjustment
Table 14: Mix Manifold Valve Settings
Valve
Setting
Function
Dose (see FIG.
89)
Hex nut (E) 1-1/4 turns out from
fully closed
Limits maximum fluid flow rate into integrator and minimizes valve response time.
Purge (see FIG.
89)
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 SVB, see
FIG. 81)
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 RVB, see
FIG. 81)
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.
313885F
85
System Operation
Start Up
1. Go through the Pre-Operation Checklist in Table 15.
Table 15: Pre-Operation Checklist

Checklist
System grounded
Verify all grounding connections were made. See
the ProMix 3KS Installation manual.
All connections tight and correct
 Graco logo, software revision, and “Establishing
Communication” will display, followed by Status
screen. See page 20.
 At power up the system defaults to Recipe 61,
which is not a valid recipe number. Initiate a
color change to Recipe 0 or a valid recipe number (1-60).
 In bottom left corner, the system status displays,
which can be Standby, Mix, Purge, or an alarm
notification.
Verify all electrical, fluid, air, and system connections 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.
1
/
4
Fluid supply containers filled
Check component A, B, and C and solvent supply
containers.
Mix manifold valves set
Check that mix manifold valves are set correctly.
Start with the settings recommended in Mix Manifold Valve Settings, page 85, then adjust as
needed.
Fluid supply valves open and pressure set
Component A, B, and C fluid supply pressures
should be equal unless one component is more
viscous and requires a higher pressure setting.
Solenoid pressure set
75-100 psi inlet air supply (0.5-0.7 MPa, 5.2-7
bar)
2. Turn the AC Power Switch on the EasyKey and on
the Power Supply Module ON (I = ON, 0 = OFF).
FIG. 91. Status Screen
3. Verify that the EasyKey is working. The active recipe
number and Standby mode should be displayed.
4. If this is the first time starting up the system, purge it
as instructed in Purging Fluid Supply System,
page 95. The equipment was tested with lightweight
oil, which should be flushed out to avoid contaminating your material.
5. Make sure that the EasyKey is in Standby (remove
Mix input).
6. Adjust component A, B, and C fluid supplies as needed for your application. Use
lowest pressure possible.
I = ON
7. Do not exceed the maximum rated working pressure shown on the system identification
label or the lowest rated component in the system.
8. Open the fluid supply valves to the
system.
TI12656a
FIG. 90. Power Switches
86
TI14372a
9. Adjust the air pressure. Most applications 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).
313885F
System Operation
Watch the fluid flow rate displayed on the Status
screen while the gun is fully open. Verify that the
flow rate of components A, B, and C are within 10%
of each other.
10. Purge air from the fluid lines.
a. Shut off air to the gun by closing the air regulator or shutoff
valve for the gun atomizing air.
b. Trigger the gun (manual or automatic) into
a grounded metal pail.
c.
If the fluid flow rate is too low: increase air pressure to component A, B, and C fluid supplies or
increase the regulated fluid pressure.
Manual
gun shown
If the fluid flow rate is too high: reduce the air
pressure, close the fluid manifold dose valves further, or adjust the fluid pressure regulator.
Go to Mix mode.
d. If the flow meters over-run because of air in the
system, an alarm will occur and operation stops.
Press the Alarm Reset
NOTE: Pressure adjustments of each component will
vary with fluid viscosity. Start with the same fluid pressure for component A, B, and C, then adjust as needed.
key to clear
NOTICE
Do not use the first 4-5 oz. (120-150 cc) of material as
it may not be thoroughly mixed due to alarms while
priming the system.
alarm.
e. Go to Mix mode.
11. Adjust the flow rate.
The fluid flow rate shown on the EasyKey Status
screen is for either component A, B, and C, depending on which dose valve is open. The fluid supply
lines on the screen highlight to show which dose
valve is open.
12. Turn on atomizing air to the gun. Check the spray
pattern as instructed in your spray gun manual.
NOTICE
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 tolerance settings of the equipment. This can further
result in spraying uncatalyzed or poorly catalyzed
material.
1
/
4
FIG. 92. Status Screen Flow Rate Display
313885F
87
System Operation
Shutdown
Pressure Relief Procedure
Overnight Shutdown
NOTE: The following procedures relieve all fluid and air
pressure in the ProMix 3KS system. Use the procedure
appropriate for your system configuration.
1. Leave the power on.
2. Run Recipe 0 to purge solvent through meters and
gun.
Service Shutdown
1. Follow Pressure Relief Procedure on page 88.
2. Close main air shutoff valve on air supply line and
on ProMix.
3. Shut OFF the Power Switch on the EasyKey and on
the Power Supply Module (0 position). FIG. 93.
4. If servicing EasyKey or Power Supply Module, also
shut off power at main circuit breaker.
0 = OFF
Relieve pressure when you stop spraying, before
changing spray tips, and before cleaning, checking, or
servicing equipment.
Single Color Systems
1. While in Mix mode (gun triggered), shut off the A, B,
and C fluid supply pumps/pressure pots. Close all
fluid shutoff valves at the pump outlets.
2. With the gun triggered, push the manual override on
the A, B, and C dose valve solenoids to relieve pressure. See FIG. 94.
NOTE: If a Dose Time alarm (E-7, E-8) occurs, clear
the alarm.
3. Do a complete system purge, following the instructions under Purging Using Recipe 0, page 95.
4. Shut off the fluid supply to the solvent purge valve
(SPV) and the air supply to the air purge valve
(APV), FIG. 97.
TI12657a
FIG. 93. Power Switches
TI14371a
5. With the gun triggered, push the manual override on
the A, B, and C purge valve solenoids to relieve air
and solvent pressure. See FIG. 94. Verify that solvent pressure is reduced to 0.
NOTE: If a Purge Volume alarm (E-11) occurs, clear
the alarm.
88
313885F
System Operation
Systems with Color Change and without
Dump Valves
NOTE: This procedure relieves pressure through the
sampling valve.
1. Complete all steps under Single Color Systems,
page 88.
2. Close the A side shutoff valve (SVA), FIG. 97. Open
the A side sampling valve (RVA).
3. Direct the A side sampling tube into a waste container.
4. See FIG. 96. Open the color change module. Using
the solenoid identification labels as a guide, press
and hold the override button on each color solenoid
until flow from the sampling valve stops.
5. Press and hold the solvent solenoid override until
clean solvent comes from the sampling valve, then
release.
6. See FIG. 96. 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.
7. Press and hold the dump valve C solenoid override,
FIG. 94.
8. See FIG. 96. 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 C stops.
9. Press and hold the dump valve A solenoid override,
FIG. 94.
10. Press and hold the A side (color) solvent solenoid
override until clean solvent comes from the dump
valve, then release.
11. Press and hold the dump valve B solenoid override,
FIG. 94.
6. Shutoff the solvent supply to the color change stack
solvent valve.
12. Press and hold the B side (catalyst) solvent solenoid
override until clean solvent comes from the dump
valve, then release.
7. Press and hold the solvent solenoid override until
solvent flow from the sampling valve stops.
13. Press and hold the dump valve C solenoid override,
FIG. 94.
8. Open the A side shutoff valve (SVA), FIG. 97. Close
the A side sampling valve (RVA).
14. Press and hold the C side solvent solenoid override
until clean solvent comes from the dump valve, then
release.
Systems with Color/Catalyst/Component C
Change and Dump Valves
NOTE: This procedure relieves pressure through the
dump valves.
1. Complete all steps under Single Color Systems,
page 88.
15. Shutoff the solvent supply to the color/catalyst/component C change stack solvent valves.
16. Press and hold the A, B, and C solvent solenoid
overrides and dump valve overrides until solvent
flow from the dump valves stops.
2. Shut off all color/catalyst/component C supplies to
the valve stacks.
3. Press and hold the dump valve A solenoid override,
FIG. 94.
4. See FIG. 96. Open the color change module. Using
the solenoid identification labels as a guide, press
and hold the override button on each color solenoid
until flow from dump valve A stops.
5. Press and hold the dump valve B solenoid override,
FIG. 94.
313885F
89
System Operation
1
AFS #1
AFS #2
SOLV SW
Power
J1
Fiber
Optic
GFB 1 PS
GFB 2 PS
CAN
Flow B
Dump C
Air
Dose A
Dose B
Valve
Dose C
J9
1
+ + +
J14
1
+ + +
J15
1
+ +
Dump B
Flow A
CAN
GFB 1
Flow C
GFB 2
+ 1
G
s
+ J12
G
s
+ 1
G
s
+ J3
G
s
+1
+
+
Purge C
Dump A
Flow Solv
3rd Flush
J13
Solvent
Not Used
+
J8
Dump Valve A
Dump Valve B
GFB 1
Optional Solenoid
Locations
GFB 2
Dose Valve A
Solenoid
Dose Valve B
Solenoid
Purge Valve A
Solenoid
Purge Valve B
Solenoid
3rd Purge Valve
Solenoid
TI12652a
FIG. 94. Component A and B Solenoids
90
313885F
System Operation
J8
(Communication)
Valve
Overrides
J3
(Power Input)
VDC
J2
(Color Change
Module)
J1
(Booth Control)
Dose Valve C
Solenoid
Purge Valve C
Solenoid
Dump Valve C
location (optional)
TI14704a
FIG. 95. Component C Solenoids
313885F
91
System Operation
Module #1
Solenoid
Identification
Label
Catalyst
Color
Color
Solenoid
Identification
Label
TI12826a
Solvent Solenoid
Overrides
Module #2
Solenoid
Identification
Label
Catalyst
Color
Color
Solenoid
Identification
Label
Mount Component C
Valves Here
Solvent Solenoid
Overrides
TI12826a
FIG. 96: Color Change Solenoids
92
313885F
System Operation
DVA
FI
DVB
MB
MS
MA
RVB
RVA
APV
TI12556a
AT
SVA
SM
SVB
SPV
Key: ProMix 2KS Fluid Station
FI
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
DVC
SVB Component B Shutoff
Valve
MS Solvent Meter
SPV Solvent Purge Valve
APV Air Purge Valve
SM Static Mixer
FI
Fluid Integrator
AT
Air Purge Valve Air Supply
Tube
Key: ProMix 3KS Fluid Station
MC
CPV
RVC
1
MC
DVC
RVC
SVC
CPV
SM
FI
Component C Meter
Component C Dose Valve
Component C Sampling Valve
Component C Shutoff Valve
Component C Purge Valve
Static Mixer
Fluid Integrator
1
3KS fluid inlet. Connect fluid supply line from
2KS fluid manifold outlet here.
2
Connect fluid supply line to gun.
SVC
SM
2
TI14382b
FIG. 97. ProMix 2KS and ProMix 3KS Wall Mount Fluid Stations
313885F
93
System Operation
Purging
If using an electrostatic gun shut off the electrostatics
before flushing the gun.
Read Warnings, page 7. Follow the Grounding
instructions in your system Installation manual.
To avoid splashing fluid in the eyes, wear eye protection.
There are 4 purging procedures in this manual:
•
•
•
•
Purging Mixed Material (below)
Purging Using Recipe 0 (page 95)
Purging Fluid Supply System (page 95)
Purging Sampling Valves and Tubes (page 97)
Use the criteria listed in each procedure to determine
which procedure to use.
Purging Mixed Material
There are times when you only want to purge the fluid
manifold, such as:
•
•
•
•
end of potlife
breaks in spraying that exceed the potlife
overnight shutdown
before servicing the fluid manifold assembly, hose or
gun.
In the first stage fluid manifold (2KS), 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. This air/solvent chop purges the hose connecting
the 2KS static mixer to the 3KS fluid manifold.
In the second stage fluid manifold (3KS), solvent purges
the component C (right) side of the mix manifold and the
inner tube of the integrator. The air/solvent chop from
the 2KS purges the left side of the 3KS fluid manifold
and the outer tube of the 3KS integrator.
2. Set the solvent supply pressure regulator at a pressure 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.
3. If using a gun flush box, place the gun into the box
and close the lid. Go to Purge mode. The purge
sequence automatically starts.
If the gun flush box is not used, trigger the gun (manual or automatic)
into a grounded metal pail until the
purge sequence is complete.
When done purging, the EasyKey automatically
switches to Standby mode.
4. If the system is not completely clean, repeat step 3.
NOTE: If necessary, adjust purge sequence so only
one cycle is required.
Trigger the gun to relieve pressure. Engage trigger
lock.
5. If spray tip was removed, reinstall it.
6. Adjust the solvent supply regulator back to its normal operating pressure.
1. Go to Standby mode (remove Mix input).
Trigger the gun to relieve pressure.
If you are using a high pressure gun, engage the trigger lock. Remove spray tip and clean tip separately.
94
313885F
System Operation
Purging Using Recipe 0
Purging Fluid Supply System
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 catalyzed material.
Follow this procedure before:
• 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.
1. Go to Standby mode (remove Mix input).
* Some steps are not necessary for initial flushing,
as no material has been loaded into the system
yet.
1. Go to Standby mode (remove Mix input).
Trigger the gun to relieve pressure.
Trigger the gun to relieve pressure.
If you are using a high pressure gun, engage the trigger lock. Remove spray tip and clean tip separately.
If you are using a high pressure gun, engage the trigger lock. Remove spray tip and clean tip separately.
If using an electrostatic gun shut off the electrostatics
before flushing the gun.
2. If using a gun flush box, place the gun into the box
and close the lid.
3. Select Recipe 0 and press Enter
If using an electrostatic gun, shut off the electrostatics
before flushing the gun.
2. Attach solvent supply lines as follows:
•
Single color/single catalyst/single component C systems: disconnect the component A,
B, and C fluid supplies at the flow meter inlets,
and connect regulated solvent supply lines.
•
Multiple color/multiple catalyst/multiple
component C systems: connect the solvent
supply lines to the designated solvent valve on
the appropriate color, catalyst, or component C
valve stack. Do not connect a solvent supply to
any flow meter.
.
4. If a gun flush box is not used, trigger
the gun (manual or automatic) into a
grounded metal pail until the purge
sequence is complete.
5. The color change LED blinks while Recipe 0 runs
and turns solid after purge sequence is complete.
6. If the system is not completely clean, you can
repeat Recipe 0 by pressing Enter
313885F
.
95
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 solenoid valves. See FIG. 94.
5. Purge as follows:
•
Single color/single catalyst/single component C 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.
Purge component C side. Press the manual
override on the Dose Valve C 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/multiple
component C systems: Select Recipe 0 and
press Enter
to purge the complete system.
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, B, and C fluid supplies.
9. See page 86 for Start Up procedure.
96
313885F
System Operation
Purging Sampling Valves and Tubes
Follow this procedure after meter calibration.
8. Close sampling valves.
NOTE: Select Abort on Calibration screen to cancel
current calibration and close dose or purge valves.
1. Go to Standby mode (remove Mix input).
2. See FIG. 97. Close both fluid shutoff valves and
sampling valves.
3. Route the sampling tubes into a grounded waste
container.
4. On a single color system, attach a solvent supply
line to Flow Meter A inlet.
5. On the EasyKey, press the Setup
9. Fully open both fluid shutoff valves.
10. On a single color system, reconnect component A
fluid supply line to flow meter A.
NOTE: After calibration it is necessary to clean out contaminated mix material. Do a manual purge and resume
the recipe just tested, or do Recipe 0 then go on to the
next recipe.
key and
access the Advanced Setup screens.
6. Press the Right Arrow
key to select the Calibra-
tion screen. Press the Down Arrow
key and
select Purge from the menu. Press the Enter
key.
Dose A, solvent purge valve (B side), component C
purge valve, and color change solvent valves (if
used) will open.
FIG. 98. 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.
313885F
97
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
entered in Advanced Setup Screen 1 on page 37. If
there are 2 guns, the smaller potlife volume is used.
Solvent Push requires an accessory solvent meter (MS).
Order Graco Part No. 16D329 S3000 Solvent Meter Kit.
See manual 308778.
light and the Recipe LED will blink. The system will
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.
NOTE: To manually interrupt Solvent Push, press the
Standby
key. The Solvent Purge Valve (SPV) or
1. See FIG. 99. Install the solvent meter (MS) on the
side of the fluid station, as explained in the ProMix
Installation Manual.
press the Mix
2. To enable Solvent Push, select “Solvent” or “3rd
Valve,” as desired. See Option Screen 2, page 35.
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.
3rd purge valve will close. To re-enter Solvent Push,
key.
mode.
NOTE: The system must be in Mix to initiate Solvent
Push.
6. Perform a manual purge or recipe change to purge
the remaining mixed material. This will clear the system out of Solvent Push, allowing you to resume Mix
mode.
3. Press and hold the Mix
key for 5 seconds
to turn on Solvent Push. The green Mix LED will
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).
Key:
DVA
DVB
MS
SPV
APV
SMC
SS
DVA is closed
DVB is closed
Component A Dose Valve
Component B Dose Valve
Solvent Meter (required)
Solvent Purge Valve
Air Purge Valve
Solvent Meter Cable
Solvent Supply Line
MS
SMC
TI12556b
SS
SPV is open
FIG. 99. Solvent Push Setup
98
313885F
Meter Calibration
Meter Calibration
4. Place the beakers (minimum size - 250 cc) in holders. Put the sampling tubes into the beakers.
To avoid splashing fluid in the eyes, wear eye protection. 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 pressurized. If you cannot turn the valve stems manually,
relieve the system pressure, then disassemble and
clean the valve to remove the resistance.
Calibrate the meter:
•
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 maintenance.
•
Whenever a flow meter is serviced or replaced.
NOTE: If tubes need replacing, use 5/32 in. or 4 mm
OD tubing.
5. On the EasyKey, press the Setup
key to access
setup screens.
6. Press the Right Arrow
key to select the Calibra-
tion Screen. Press the Enter
key to select
either Dose Valve A, B, C, or Solvent. Press the
Down Arrow
key and select Start from the menu.
Start only one at a time.
NOTE:
• K-Factors on the Calibration Screen are
updated automatically after the calibration procedure is completed.
•
K-Factor values on the screen are viewable
only. If needed, you can manually edit the
K-Factors in Advanced Setup Screen 4 (page
39) or Recipe Setup Screen 5 (page 45).
•
All values on this screen are in cc, independent
of the units set in Configure Screen 1.
•
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, B, or C, prime the system with material. For a color/catalyst/component C
change system, make sure the color/catalyst/component C valve is open.
2. Shut off all spray or dispense devices connected to
the ProMix.
3. Close all fluid shutoff valves and sampling valves.
313885F
7. Dispense component A, B, C, or Solvent into beaker.
a. To avoid splashing, slowly open sampling
valves.
b. For more accurate calibration, adjust the valve
to dispense at a flow rate similar to your production spray flow rate.
c.
Dispense a minimum of 250 cc; make sure
enough material is dispensed to accurately read
the volume with your beaker. The volumes do
not have to be equal or at any particular ratio.
d. Close sampling valve tightly.
99
Meter Calibration
8. The volume that the ProMix measured displays on
the EasyKey.
9. Compare the amounts on the EasyKey to the
amount in the beakers.
NOTE: For maximum accuracy, use a gravimetric
(mass) method to determine the actual volumes dispensed.
10. If the screen and actual volumes are different, enter
the actual dispensed volume in cc for A, B, C, or
Solvent Volume field, and press the Enter
key.
11. After the volume for A, B, C, or Solvent is entered,
the ProMix 3KS controller calculates the new flow
meter K-Factor and shows it on the Calibration
Screen.
NOTE: K-Factor values on the screen are viewable
only. If needed, you can manually edit the K-Factors
in Advanced Setup Screen 4 (page 39) or Recipe
Setup Screen 5 (page 45).
12. Always purge sampling valves after calibrating
meters. Use one of the following methods.
•
Follow the Purging Sampling Valves and
Tubes procedure, page 97.
•
Place the sampling valve fluid tubes into a compatible cleaning fluid (TSL or solvent) or cap
them.
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 calibration procedure, scroll to Abort on the Calibration
Screen menu and press the Enter
key.
NOTE: If fluid hardens in sampling tubes, replace
them with 5/32 in. or 4 mm OD tubing.
13. Make sure all sampling valves are closed and all
fluid shutoff valves are fully open.
14. Before you begin production, clear the system of
solvent and prime it with material.
a. Go to Mix mode.
b. Trigger the gun into a grounded metal pail until
mixed material flows from the gun nozzle.
c.
100
To begin operation, see Start Up, page 86.
313885F
Color Change
Color Change
Color Change Procedures
Multiple Color Systems
1. Shut off air to the gun.
2. Place the gun in the gun flush box if used, and close
the lid.
3. Go to Standby mode (remove Mix input).
4. Select the new recipe. Begin the color change
sequence.
5. If a gun flush box is not used, trigger
the gun (manual or automatic) into a
grounded metal pail until the color
change sequence is complete.
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 system enters Standby mode
(remove Mix input) at the previous color.
6. When you are ready to spray, remove the gun from
the gun flush box if used, and close its door (manual
and semi-automatic systems only).
Color Change Sequences
FIG. 100 through FIG. 109 illustrate various color change
sequences. See Table 16 to determine which figure to
reference, based on the recipe change and system configuration. The time sequences are detailed in the following paragraphs.
NOTE: See Setup Mode on page 26 to select purge
sources and set desired purge, chop, and fill times.
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.
•
The system uses the new recipe data for the fill
cycle.
•
For the one gun flush box (GFB) option, the spray
gun must be inserted in the GFB during the entire
color change cycle (purge and fill). The GFB trigger
output will be on during the recipe change cycle.
•
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.
•
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.
•
For systems without dump valves, the First Purge
begins after the Color/Catalyst/Component C
Change steps are completed.
•
Dump Valve B is required for a Catalyst Change
system.
•
Dump Valve C is required for a Component C
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 X, only the fill
cycle data from Recipe X is used.
NOTE: The gun flush box door must be closed for
the atomizing air valve to open.
7. Enter Mix mode to start spraying.
Single Color Systems
1. Follow procedure for Purging Fluid Supply System, page 95.
2. Load the new color. See Start Up, page 86.
3. Enter Mix mode to start spraying.
313885F
101
Color Change
Color Purge/Dump
•
This sequence flushes out the color with solvent,
from the color valve to the Dump A valve.
•
The color change solvent valve and the Dump A
valve open during the Purge Time.
•
The color change solvent valve closes when the
Purge Time expires.
Color Fill
•
This sequence fills the line with the new color all the
way to the Dump A valve.
•
The new color valve and the Dump A valve open
during the Fill Time.
•
The new color valve and the Dump A valve close
when the Fill Time expires.
Catalyst Purge/Dump
•
This sequence flushes out the catalyst with solvent,
from the catalyst valve to the Dump B valve.
•
The catalyst change solvent valve and the Dump B
valve open during the Purge Time.
•
The catalyst change solvent valve closes when the
Purge Time expires.
Catalyst Fill
•
This sequence fills the line with the new catalyst all
the way to the Dump B valve.
•
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.
Component C Fill
•
This sequence fills the line with the new component
C all the way to the Dump C valve.
•
The new component C valve and the Dump C valve
open during the Fill Time.
•
The new component C valve and the Dump C valve
close when the Fill Time expires.
First Purge
Select the First Purge Source (air, solvent, or 3rd valve)
and First Purge Time. For most applications, air is
selected.
The system purges the old material from the dose
valves to the gun, using only the selected purge media
(usually air). The selected purge valve opens during the
First Purge Time and closes when the time expires.
First Purge C
The First Purge C Source is the same as First Purge.
For most applications, solvent is selected. Select the
First Purge C Time.
The system purges the old material from the dose
valves to the gun, using only the selected purge media.
The purge C valve opens during the First Purge C Time
and closes when the time expires.
Chop Cycle
Select the Chop Type (air/solvent or air/3rd valve) and
Chop Times.
The air purge valve opens only during the air chop cycle,
and the solvent (or 3rd valve) opens only during the solvent chop cycle. The number of chop cycles is determined by dividing the Total Chop Time by the sum of the
Air and Solvent Chop Times.
Component C Purge/Dump
•
This sequence flushes out component C with solvent, from the component C valve to the Dump C
valve.
•
The component C change solvent valve and the
Dump C valve open during the Purge Time.
•
The component C change solvent valve closes
when the Purge Time expires.
102
313885F
Color Change
Final Purge
Fill
Select the Final Purge Source (air, solvent, or 3rd valve)
and Final Purge Time. For most applications, solvent is
selected.
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, B, and C until
the Fill Time expires.
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.
Purge Active
Final Purge C
Fill Active
The Final Purge C Source is the same as Final Purge.
For most applications, solvent is selected. Select the
Final Purge C Time.
The system turns on the Purge/Recipe Change Purge
Active output during these steps.
The system turns on the Recipe Change Fill Active output during this step.
The system fills the line with solvent from the dose
valves to the gun, using only the selected purge media.
The purge C valve opens during the Final Purge C Time
and closes when the time expires.
Table 16: Color Change Chart Reference
Starting
Recipe
Ending
Recipe
Change
Type
Dump A
X
Y
Change
Yes
NA
FIG. 100
X
Y
Change
No
NA
FIG. 101
0
Y
Fill
Yes
Yes
FIG. 102
0
Y
Fill
Yes
No
FIG. 103
0
Y
Fill
No
Yes
FIG. 104
0
Y
Fill
No
No
FIG. 105
X
0
Purge
Yes
NA
FIG. 106
X
0
Purge
No
NA
FIG. 107
0
0
Purge
Yes
NA
FIG. 108
0
0
Purge
No
NA
FIG. 109
Exiting Fill Refer to Fig.
NOTE: For manual systems, the Digital I/O signals identified in the color charts on the following pages represent
internal states.
313885F
103
313885F
104
Color Change
FIG. 100: ProMix 3KS Recipe Change Chart #1 X to Y
Color Change
105
313885F
FIG. 101: ProMix 3KS Recipe Change Chart #2 X to Y
313885F
Color Change
106
FIG. 102: ProMix 3KS Recipe Fill Chart #3 0 to Y
Color Change
107
313885F
FIG. 103: ProMix 3KS Recipe Fill Chart #4 0 to Y
313885F
Color Change
108
FIG. 104: ProMix 3KS Recipe Fill Chart #5 0 to Y
Color Change
109
313885F
FIG. 105: ProMix 3KS Recipe Fill Chart #6 0 to Y
313885F
Color Change
110
FIG. 106: ProMix 3KS Recipe Purge Chart #7 X to 0
Color Change
111
313885F
FIG. 107: ProMix 3KS Recipe Purge Chart #8 X to 0
313885F
Color Change
112
FIG. 108: ProMix 3KS Recipe Purge Chart #9 0 to 0
Color Change
113
313885F
FIG. 109: ProMix 3KS Recipe Purge Chart #10 0 to 0
Alarms and Warnings
Alarms and Warnings
NOTICE
Do not use the fluid in the line that was dispensed off
ratio as it may not cure properly.
System Alarms
System alarms alert you of a problem and help prevent
off-ratio spraying. If an alarm occurs, operation stops
and the following occurs:
•
•
Alarm sounds.
Status bar on the EasyKey Display shows the alarm
E-Code with a description (see Table 17).
System Warnings
Table 17 lists the System Warning Codes. Warnings do
not stop operation or sound an alarm. They are saved in
the date/time stamped log, which can be viewed on a
PC, using the ProMix 2KS Web Interface (see manual
313386).
To Reset Alarm and Restart
Table 17: System Alarm/Warning Codes
Code Description
Details
E-1
Communication Error Alarm
Page 115
E-2
Potlife Alarm
Page 115
E-3
Ratio High Alarm
Page 116
E-4
Ratio Low Alarm
Page 117
E-5
Overdose A/B Dose Too Short Alarm
Page 118
E-6
Overdose B/A Dose Too Short Alarm
Page 118
E-7
Dose Time A Alarm
Page 119
E-8
Dose Time B Alarm
Page 119
E-9
Not used
E-10
Remote Stop Alarm
Page 120
E-11
Purge Volume Alarm
Page 120
E-12
CAN Network Communication Error
Alarm
Page 121
E-13
High Flow Alarm
Page 122
E-14
Low Flow Alarm
Page 122
E-15
System Idle Warning
Page 122
E-16
Setup Change Warning
Page 122
NOTE: When an alarm occurs be sure to determine the
E-Code before resetting it. See Table 17. If you forget
which E-Code occurred, use the Alarms Screens (page
25) to view the last 10 alarms, with date and time
stamps.
E-17
Power On Warning
Page 122
E-18
Defaults Loaded Warning
Page 122
E-19
I/O Alarm
Page 123
E-20
Purge Initiate Alarm
Page 124
E-21
Material Fill Alarm
Page 124
To reset alarms, see Table 18. Many alarms can be
E-22
Tank A Low Alarm
Page 124
E-23
Tank B Low Alarm
Page 124
E-24
Tank S Low Alarm
Page 124
E-25
Auto Dump Complete Alarm
Page 125
E-26
Color/Catalyst Purge Alarm
Page 125
E-27
Color/Catalyst Fill Alarm
Page 125
E-28
Mix Fill Push Complete
Page 125
E-29
Tank C Low Alarm
Page 125
E-30
Overdose C Alarm
Page 125
E-31
Dose Time C Alarm
Page 125
cleared by simply pressing the Alarm Reset
114
key.
313885F
Alarm Troubleshooting
Alarm Troubleshooting
Table 18. Alarm Troubleshooting
E-1: COMM_ERROR
Cause
No power to the EasyKey.
Solution
Connect power to EasyKey.
No power to Fluid Station. The intrinsically safe power
Verify that the cable is correctly connected. See Installacable 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 Installation 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 material.
Press the Alarm Reset
NOTICE
To prevent mixed material from curing in the equipment, do not shut off power. Follow one of the solutions at right.
313885F
key to stop the audible
alarm. Purge the system with solvent, fresh mixed material, or a new color:
•
Solvent Purge - See Purging Mixed Material on
page 94. The system purges until the preset purge
time is complete.
•
New Mixed Material Purge - Go to Mix mode and
spray the required volume to restart the timer.
•
Color Change - Perform a color change, page 101.
115
Alarm Troubleshooting
Table 18. Alarm Troubleshooting
E-3: RATIO_HIGH_ALARM
Sequential Dosing System
The mix ratio is higher than the set tolerance on the previous dose cycle.
Cause
There is too little restriction in the system.
Solution
•
Check that the system is fully loaded with material.
•
Check that the supply pump’s cycle rate is set properly.
•
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, B, and C fluid supply regulator
pressures until they are about equal. If the pressures are
already about equal, verify that component A, B, and C
dose valves are operating properly.
Slow actuation of the component A, B, or C valves. This Manually operate the Dispense A, B, and C solenoid
can be caused by:
valves as instructed in the ProMix 3KS 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 recommended.
•
Something is restricting the solenoid or tubing and
interrupting valve actuation air.
•
There may be dirt or moisture in the air supply. Filter
appropriately.
•
A dose valve is turned in too far.
•
Refer to Table 14: Mix Manifold Valve Settings,
page 85, for adjustment guidelines.
•
Fluid pressure is high and air pressure is low.
•
Adjust air and fluid pressure. See recommended air
pressure above.
116
313885F
Alarm Troubleshooting
Table 18. Alarm Troubleshooting
E-4: RATIO_LOW_ALARM
Sequential Dosing System
The mix ratio is lower than the set tolerance on the previous dose cycle.
Cause
There is too much restriction in the system.
Solution
•
Check that the system is fully loaded with material.
•
Check that the supply pump’s cycle rate is set properly.
•
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, B, and C fluid supply regulator
pressures until they are about equal. If the pressures are
already about equal, verify that component A, B, and C
dose valves are operating properly.
Slow actuation of the component A, B, or C valves. This Manually operate the Dispense A, B, and C solenoid
can be caused by:
valves as instructed in the ProMix 3KS 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 recommended.
•
Something is restricting the solenoid or tubing and
interrupting valve actuation air.
•
There may be dirt or moisture in the air supply. Filter
appropriately.
•
A dose valve is turned in too far.
•
Refer to Table 14: Mix Manifold Valve Settings,
page 85, for adjustment guidelines.
•
Fluid pressure is high and air pressure is low.
•
Adjust air and fluid pressure. See recommended air
pressure above.
313885F
117
Alarm Troubleshooting
Table 18. Alarm Troubleshooting
E-5: OVERDOSE_A/B_DOSE_TOO_SHORT_ALARM,
E-6: OVERDOSE_B/A_DOSE_TOO_SHORT_ALARM, and
E-30: OVERDOSE_C_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.
E-30: the C dose overshoots and, when combined with A+B, is too large for the mix chamber capacity.
Cause
Solution
Valve seal or needle/seat are leaking. Check FIG. 14
Repair the valve (see valve manual 312782).
Totals Screen on page 24. If A, B, or C are dosing simultaneously (sequential dosing only), there is a leak.
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 3KS is reading any fluid flow.
4. If the ProMix 3KS shows there is fluid flow and there
are no leaks from the gun or any other seals or fittings, 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 3KS to reduce
the fluid supply pressure. Contact your Graco distributor for information.
Slow actuation of component A, B, or C valves.
See E-3: RATIO_HIGH_ALARM and E-4:
RATIO_LOW_ALARM, pages 116-117.
Running a high mix ratio and a high flow rate.
It may be necessary to restrict the flow rate through the
component B or C dose valve by adjusting its hex nut
(E). See page 85.
118
313885F
Alarm Troubleshooting
Table 18. Alarm Troubleshooting
E-7: DOSE_TIME_A_ALARM, E-8: DOSE_TIME_B_ALARM, and E-31: DOSE_TIME_C_ALARM
E-7: gun trigger input is active (AFS or Integration) and no A meter pulses are detected during the dose time
selected.
E-8: gun trigger input is active (AFS or Integration) and no B meter pulses are detected during the dose time
selected.
E-31: gun trigger input is active (AFS or Integration) and no C meter pulses are detected during the dose time
selected.
Cause
Solution
System is in Mix mode and gun is only partially triggered, Fully trigger the gun.
allowing air but no fluid to pass through gun.
Fluid flow rate is too low.
Increase flow rate.
Dose time setting is too short for the current flow rate.
Increase the dose time setting.
Flow meter or cable failed or flow meter clogged.
To check meter sensor operation, remove meter cap to
expose sensor. Pass a ferrous metal tool in front of the
sensor.
TI12792a
If there is a meter or cable failure, you will see a large difference between the amount of fluid dispensed and the
flow meter volume displayed by the EasyKey. Clean or
repair meter as necessary. Also see meter manual
308778.
Follow Meter Calibration procedure, page 99.
Slow actuation of component A, B, or C valves.
See E-3: RATIO_HIGH_ALARM and E-4:
RATIO_LOW_ALARM, pages 116-117.
The supply pump is not turned on.
Turn on the supply pump.
System is in Mix mode with 0 volume entered for Min
Material Fill Volume (see Option Screen 1, page 34),
and Fuse F1 is blown.
Verify condition of fuse and replace if necessary. See
Repair-Parts manual.
313885F
119
Alarm Troubleshooting
Table 18. 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 3KS 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 set too high.
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.
120
313885F
Alarm Troubleshooting
Table 18. Alarm Troubleshooting
E-12: CAN_COMM_ERROR_ALARM
Cause
Communication between the Color Change Module and
the Fluid Station is interrupted.
Communication between the Color Change Module and
the Fluid Station is interrupted. The fluid control board
fuse is blown.
313885F
Solution
•
Verify that all cables are connected securely and that
the Color Change power LED turns on. If the power
LED does not turn on, the problem is probably
caused by a bad connection. The nut on the 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 ProMix 3KS 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 electrical noise. See the ProMix 3KS 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 system 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.
Verify condition of fuse and replace if necessary. See
Repair-Parts manual.
121
Alarm Troubleshooting
Table 18. Alarm Troubleshooting
E-13: HIGH_FLOW_ALARM or E-14: LOW_FLOW_ALARM (may also be set as Warnings)
Cause
Fluid system is producing too much or too little flow.
Solution
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
The system setup parameters have been changed.
Solution
No action required. See Event Log available through
advanced web interface.
E-17: POWER_ON_WARNING
Cause
The power to the system has been cycled.
Solution
No action required. See Event Log available through
advanced web interface.
E-18: DEFAULTS_LOADED_WARNING
Cause
The factory defaults have been installed on the system.
122
Solution
No action required. See Event Log available through
advanced web interface.
313885F
Alarm Troubleshooting
Table 18. 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 may not apply to all software versions.
FP Reboot (Fluid Plate Reboot): Occurs if the system
detects a fluid plate control board reboot or power cycle
not triggered from the EasyKey. The system reverts to
Recipe 61, and mixed material may be in the lines.
Flush the system or perform a color change. If possible,
identify the origin of the reboot or power cycle.
Autokey Lost: Occurs if the Autokey is lost or changed
after having been detected. (A short term loss of the
Autokey will not be registered.) Some system functions
may become unavailable. For example, an automatic
system will not respond to PLC or robot control.
Reinstall the Autokey, or verify that the Autokey is set
properly.
Verify that the source data is from a valid recipe (1-60).
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 Autokey is set properly or that the configu2K/3K Error: Occurs if the recipe data is incompatible
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 configuration file originally made on a 2KS machine.
Config Error: Occurs if a configuration file sent to the
EasyKey specifies a different hardware setup than what
exists. For example, the configuration file specifies 2
color change boards but only 1 is present.
Verify that the configuration file specifications and the
hardware conform.
Range Error: Occurs if a valve used in a recipe is not
present in the current hardware setup. For example, a
recipe calls for valve 30 but the system has only 12
valves.
Verify that the recipe specifications and the hardware
conform.
LC (Level Control Error): Occurs if level control data is Verify that the Autokey is set properly.
received by the EasyKey, and the current Autokey setting (2K or 3K) has changed since the level control data
was originally initialized.
LC Range Error (Level Control Range Error): Occurs Set level control data correctly.
if level control data includes a valve range exceeding the
capability of the machine.
MB Overflow (Modbus Overflow): Occurs if the Modbus connection to a PLC experiences data overflow.
313885F
Verify the Modbus protocol to the EasyKey.
123
Alarm Troubleshooting
Table 18. 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
For systems with minimum mixed material fill volume
entered, the system detects that fill volume is not
achieved during mixed material fill time.
Solution
Check for restrictions or leaks in the fluid supply system.
Check if the fill volume is properly configured:
•
•
For systems without color change and with minimum
mixed material fill volume entered, Fuse F1 is blown.
Adjust fill volume.
Adjust fill time.
Verify condition of fuse and replace if necessary. See
Repair-Parts manual.
E-22: TANK_A_LOW_ALARM, E-23: TANK_B_LOW_ALARM, E-24: TANK_S_LOW_ALARM,
or E-29: TANK_C_LOW_ALARM
Cause
The tank volume reaches the low-level threshold.
Solution
The EasyKey screen will display the alarm and prompt
the user to do one of the following:
•
•
124
Refill tank volume to clear the alarm.
Resume mixing by selecting “Spray 25% of remaining 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.
313885F
Alarm Troubleshooting
Table 18. 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
at least 10cc of material from each side throughout the
Color/Catalyst fill time duration.
Check that meter cable is connected.
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.
Clean or repair meter.
E-29: TANK_C_LOW_ALARM (see above)
E-30: OVERDOSE_C_ALARM (see page 118)
E-31: DOSE_TIME_C_ALARM (see page 119)
313885F
125
Schematic Diagrams
Schematic Diagrams
System Pneumatic Schematic
COLOR
CHANGE
CONTROL
COLOR
VALVE
STACKS
AIR EXHAUST MUFFLER
COLOR 1
COLOR 2
12 VDC
COLOR 3
2
5/3 N
E
OP
A B
12 VDC
4-WAY SOLENOID
SE
O
CL
E
B
TU
E
B
TU
DOSE B
VALVE
2
5/3 N
E
OP
A B
12 VDC
E
OS
4-WAY SOLENOID
05
CL
3/8 AIR FILTER
MANUAL DRAIN
5 MICRON
WALL MOUNT ONLY
CONTROL AIR
A B
E
UB
2T
5/3 N
E
OP
COLOR 4
DOSE A
VALVE
COLOR 5
COLOR 6
1/4 TUBE
1/4 TUBE
TO MANIFOLD
OS
CL
PURGE A
VALVE
COLOR 7
COLOR 8
COLOR SOLVENT
FLUSH AIR TO FLUID INLET
E
4-WAY SOLENOID
COLOR 9
COLOR 10
COLOR 11
COLOR 12
CATALYST 1
CATALYST 2
CATALYST 3
CATALYST 4
CATALYST SOLVENT
12 VDC
E
4-WAY SOLENOID
OS
E
UB
2T
EN
P
O
CL
AIR INPUT
PURGE B
VALVE
MAC
36 SERIES SOLENOID VALVES
5/3
A B
12 VDC
E
OS
4-WAY SOLENOID
CL
E
A B
UB
2T
5/3 N
E
P
O
A
E
UB
2T
5/3 N
E
OP
A
UB
2T
5/3 N
E
P
O
A
2
5/3
A
UB
2T
5/3 N
E
P
O
PURGE C
VALVE
(OPTIONAL)
PURGE AIR
AIR EXHAUST MUFFLER
12 VDC
3-WAY SOLENOID
DUMP A
VALVE
(OPTIONAL)
AIR INPUT
12 VDC
3-WAY SOLENOID
E
12 VDC
3-WAY SOLENOID
BE
TU
N
E
OP
DUMP B
VALVE
(OPTIONAL)
GFB 1
VALVE
(OPTIONAL)
12 VDC
3-WAY SOLENOID
E
GFB 2
VALVE
(OPTIONAL)
MANIFOLD
126
313885F
Schematic Diagrams
System Pneumatic Schematic
COLOR
CHANGE
CONTROL
COLOR
VALVE
STACKS
3RD COMP. 1
3RD COMP. 2
3RD COMP. 3
3RD COMP. 4
1/4 TUBE
3RD COMP. SOLVENT
COLOR 13 (OPTIONAL)
COLOR 14 (OPTIONAL)
COLOR 15 (OPTIONAL)
TO MANIFOLD
COLOR 16 (OPTIONAL)
COLOR 17 (OPTIONAL)
COLOR 18 (OPTIONAL)
COLOR 19 (OPTIONAL)
COLOR 20 (OPTIONAL)
COLOR 21 (OPTIONAL)
COLOR 22 (OPTIONAL)
AIR EXHAUST MUFFLER
COLOR 23 (OPTIONAL)
COLOR 24 (OPTIONAL)
COLOR 25 (OPTIONAL)
12 VDC
E
E
UB
2T
5/3 N
E
OP
OS
CL
4-WAY SOLENOID
A B
DOSE C
VALVE
MAC
36 SERIES SOLENOID VALVES
12 VDC
E
OS
CL
4-WAY SOLENOID
A B
2
5/3
BE
TU
PURGE C
VALVE
EN
OP
12 VDC
3-WAY SOLENOID
A
E
UB
2T
5/3 N
E
OP
DUMP C
VALVE
(OPTIONAL)
MANIFOLD
313885F
127
DISPLAY
MEMBRANE
SWITCH
WITH
RIBBON
CABLE
J2
J4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
1
2
3
4
5
6
7
8
9
10
11
DISPLAY
BOARD
P1
J6
RJ45
1
2
3
4
RJ45
J7
J8
J10
RJ45
1
2
3
4
5
6
1
2
3
4
J5 5
6
7
8
9
10
RJ45
J9
POWER HARNESS
BARRIER
BOARD
POWER
SUPPLY
+
+
+
+
-
POWER DIST.
TERMINAL
BLOCKS
+
+
-
3'
1
2
3
1
2
3
J4
1
2
3
4
5
1
2
J5
J1
WEB SERVER
MODULE
3'
(25'-200' OPTIONS)
RJ45
BULKHEAD
RS485 INTEGRATION A (WHT/BLU)
RS485 INTEGRATION B (BLU/WHT)
RS485 INTEGRATION GROUND (SHIELD)
RS485 NETWORK A (WHT/ORG)
RS485 NETWORK B (ORG/WHT)
RS485 NETWORK GROUND (SHIELD)
I/O HARNESSES
FLOW CONTROL CAL. (BLK)
GUN TRIGGER (WHT)
DIGITAL IN COMMON (RED)
REMOTE STOP (GRN)
ALARM RESET (BRN)
ALARM OUTPUT (BLU)
DIGITAL OUTPUT COMMON (ORG)
POT LIFE (YEL)
FLOW RATE ANALOG IN (PUR)
FLOW RATE ANALOG COMMON (GRAY)
FO IN (BLK)
FO OUT (BLU)
+
-
DC OK
+24 VDC
COMMON
COMMON
RJ45
RJ45
128
+24VDC
OPEN
COMMON
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
HARNESS
+
-
3'
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
10
1
2
3
J3
GND LUG
LINE
FILTER
L1
N
GND
5
6
(+24) YEL
(COM) GRAY
ORG
BRN
RED
BEACON
DIGITAL OUTPUT COMMON/POWER
SPECIAL OUTPUT #1
SPECIAL OUTPUT #2
SPECIAL OUTPUT #3
SPECIAL OUTPUT #4
DIGITAL OUTPUT COMMON/POWER
J5 4
1
2
3
DIGITAL OUTPUT COMMON/POWER
PURGE/RECIPE CHG ACTIVE OUTPUT
MIX ACTIVE OUTPUT
MIX READY OUTPUT
FILL ACTIVE
FLOW CAL. ACTIVE
FLOW RATE ALARM OUTPUT
DIGITAL OUTPUT COMMON/POWER
MIX INPUT
PURGE INPUT
JOB COMPLETE INPUT
EXTERNAL CLR CHG READY
RESET ALARM INPUT
DIGITAL INPUT COMMON
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
1 POWER
2 ROCKER
1A SWITCH
1B
2A
2B
1
2
3
L1
N
1
2
3
4
J4 5
6
7
8
5
6
1
2
3
4
5
6
7
8
J2 4
OPEN
OPEN
REMOTE
I/O
INTEGRATION
BOARD
RJ45
TERMINAL
BLOCKS
RJ45
ALARM
+12VDC I/S (RED)
COM (BLACK)
SHIELD
L1 85-250 VAC
N
SHIELD
PROMIX 2KS EASYKEY INTERFACE
CABLE
L1 TERMINAL
N
BLOCK
GND
L1
N
GND
L1
85-250
N
VAC
GND
Schematic Diagrams
System Electrical Schematic
NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 3KS system. Some components shown are not included with all systems.
Non-Hazardous Area
313885F
313885F
POWER
HARNESS
DC OK
+24 VDC
COMMON
COMMON
+
+
-
BARRIER
BOARD
POWER
SUPPLY
1
2
3
J4
+24VDC
OPEN
COMMON
+12VDC I/S (RED)
COM (BLACK)
SHIELD
1
2
3
J5
HARNESS
N
L1
L1
N
GND
L1 85-250 VAC
N
1
2
3
4
5
J1
1
2
PROMIX 3KS BARRIER/PS ENCLOSURE
OPEN
OPEN
GND LUG
TERMINAL
BLOCK
1 POWER
2 ROCKER
1A SWITCH
1B
2A
2B
1
2
3
1
2
3
1
2
3
50' STD.
(10'-100' OPTIONS)
L1
85-250
N
VAC
GND
NON-HAZARDOUS
AREA
TO J3
3RD COMPONENT
FLUID PANEL
TO FO IN - J6
(BLK)
TO FO OUT - J4
(BLU)
TO J10
SMART FLUID PANEL
CONTROL BOX
HAZARDOUS
AREA
Schematic Diagrams
System Electrical Schematic
NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 3KS system. Some components shown are not included with all systems.
Non-Hazardous Area
129
Schematic Diagrams
System Electrical Schematic
NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 3KS system. Some components shown are not included with all systems.
Hazardous Area
130
313885F
Schematic Diagrams
System Electrical Schematic
NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 3KS system. Some components shown are not included with all systems.
Hazardous Area
313885F
131
BARRIER BOARD
132
J5
J1
J4
24 VDC+
IN
UNUSED
UNUSED
J1-2
J5-1
J5-2
J5-3
SHIELD/GRND
COMMON (BLACK)
+12 VDC I/S (WHITE)
UNUSED
UNUSED
J1-3
J1-1
UNUSED
J1-4
RED 18 AWG
BLACK 18 AWG
J1-5
J4-1
J4-2
J4-3
IS POWER
12 VDC
DC OK
+
-
-
24 VDC+
COMMON
HIGH
VOLTAGE
IN
POWER SUPPLY
24 VDC+
OUTPUT
GND LUG
N
N
L
L
N
L1
GND
TERMINAL BLOCKS
BROWN 16 AWG
BROWN 16 AWG
POWER ROCKER SWITCH
RED 16 AWG
GRN/YEL 16 AWG
RED 16 AWG
Schematic Diagrams
Power Supply Module Electrical Schematic
313885F
Technical Data
Technical Data
Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . Base system: 3000 psi (21 MPa, 210 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stage 1 (A:B): 0.1:1- 50:1*
Stage 2 (A+B:C): 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)
3KS Fluid Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 npt(m)
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 flow rate, dose size, and meter resolution.
See individual component manuals for additional technical data.
313885F
133
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This 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.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original instructions. This manual contains English. MM 313885
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441
Copyright 2010, Graco Inc. is registered to ISO 9001
www.graco.com
Revised 2019-03

* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project