Graco 312780C, ProMix 2KS Automatic Systems, Repair-Parts Owner's Manual

Add to my manuals
80 Pages

advertisement

Graco 312780C, ProMix 2KS Automatic Systems, Repair-Parts Owner's Manual | Manualzz

Repair-Parts

ProMix

®

2KS

Plural Component Proportioner

312780C

ENG

Automatic systems for proportional mixing of plural component coatings, with Wall Mount

Fluid Station or RoboMix Fluid Station. For professional use only.

For use in explosive atmospheres (except the EasyKey).

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See pages 4-7 for model information, including maxi-

mum working pressure. Equipment approval labels are

on page 3. Some components shown are not included

with all systems.

Automatic System with RoboMix Fluid Station

Automatic System with Wall Mount Fluid Station

TI12553a

0359

# 53

II 2 G

TI12552a

2

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Equipment Approvals . . . . . . . . . . . . . . . . . . . . . . . 3

System Configuration and Part Numbers . . . . . . . 4

Wall Mount Fluid Station Configurator Key . . . . . 4

RoboMix Fluid Station Configurator Key . . . . . . . 6

Standard Features . . . . . . . . . . . . . . . . . . . . . . . 7

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Important Two-Component Material Information 11

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . 11

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . 11

Keep Components A and B Separate . . . . . . . . 11

Moisture Sensitivity of Isocyanates . . . . . . . . . . 11

Changing Materials . . . . . . . . . . . . . . . . . . . . . . 11

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Check Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 12

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . 12

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Solenoid Troubleshooting . . . . . . . . . . . . . . . . . 16

Wall Mount Fluid Manifold Troubleshooting . . . . 18

EasyKey Barrier Board Diagnostics . . . . . . . . . 19

EasyKey Display Board Diagnostics . . . . . . . . . 20

Discrete I/O Board Diagnostics . . . . . . . . . . . . . 22

Fluid Station Control Board Diagnostics . . . . . . 25

Color Change Board Diagnostics . . . . . . . . . . . 28

Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . 30

System Pneumatic Schematic . . . . . . . . . . . . . 30

EasyKey Electrical Schematic . . . . . . . . . . . . . . 31

System Electrical Schematic . . . . . . . . . . . . . . . 32

RoboMix Panel Board Schematic . . . . . . . . . . . 34

Tubing Schematic . . . . . . . . . . . . . . . . . . . . . . . 36

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Before Servicing . . . . . . . . . . . . . . . . . . . . . . . . 38

After Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Servicing EasyKey . . . . . . . . . . . . . . . . . . . . . . . 39

Replacing Air Filter Element . . . . . . . . . . . . . . . 44

Wall Mount Fluid Station . . . . . . . . . . . . . . . . . . 44

Servicing Flow Meters Mounted on Wall Panel . 48

Servicing Fluid Manifold . . . . . . . . . . . . . . . . . . 49

Servicing Color Change Module, Color/Catalyst

Valves, and Dump Valves . . . . . . . . . . . . . . 49

RoboMix Fluid Station . . . . . . . . . . . . . . . . . . . . 50

Servicing Flow Control . . . . . . . . . . . . . . . . . . . 57

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

ProMix 2KS Automatic Wall Panel System . . . . 59

ProMix 2KS Automatic RoboMix Panel System 63

EasyKey Controls . . . . . . . . . . . . . . . . . . . . . . . 66

Available Cables . . . . . . . . . . . . . . . . . . . . . . . . 67

Wall Mount Fluid Station . . . . . . . . . . . . . . . . . . 68

RoboMix Fluid Station . . . . . . . . . . . . . . . . . . . . 70

256654 RoboMix Manifold . . . . . . . . . . . . . . . . . 74

249849 Flow Control Regulator . . . . . . . . . . . . . 76

Color Change Accessory Kits . . . . . . . . . . . . . . 77

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 80

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 80

312780C

Related Manuals

Component Manuals in English

Manual

312778

312779

312781

312782

312783

312787

312784

310745

312786

312785

308778

313599

313212

313290

313542

313386

406800

Description

ProMix 2KS Automatic System

Installation

ProMix 2KS Automatic System

Operation

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/G250/G250HR Flow

Meter

Coriolis Flow Meter

Gun Flush Box Integration Kit

Floor Stand Kit

Beacon Kit

Basic Web Interface/Advanced Web

Interface

15V825 Discrete I/O Board Kit

Related Manuals

Equipment Approvals

Equipment approvals appear on the following labels which are attached to the Fluid Station and EasyKey

.

See F IG . 1 on page 4 and F IG . 2 on page 6 for label locations.

EasyKey and Fluid Station Label

ATEX Certificate is listed here

!"#$" %#$!

(

78

3

4

$#$+" , +-!

!./%0!$# - ( ++ 1

2 1 3/% 1 4

5 6'( # &'(

&'( )'*

!"#$#%%

& '(

( )*

+ )

,-

(

+. /+01%

2* 3

3 :

3( (

9 88

$$!% +1

&&88

Fluid Station Label

C

PART NO.

Artwork No. 293538

SERIES SERIAL MFG. YR.

US

Intrinsically safe equipment for Class I, Div 1, Group D, T3

Ta = -20°C to 50°C

Install per 289833

FLUID PANEL

MAX AIR WPR

FM08ATEX0073

II 2 G

Ex ia IIA T3

.7

7

MPa

100 bar PSI

GRACO INC.

P.O. Box 1441

Minneapolis, MN

55440 U.S.A.

TI13581a

ATEX Certificate is listed here

EasyKey Label

PART NO.

SERIES NO. MFG. YR.

POWER REQUIREMENTS

VOLTS

AMPS

85-250 ~

2 AMPS MAX

GRACO INC.

P.O. Box 1441

Minneapolis, MN

55440 U.S.A.

C US

Intrinsically safe connections for Class I, Div 1, Group D

Ta = -20°C to 50°C

Install per 289833

Um: 250 V

50/60 Hz

II (2) G

[Ex ia] IIA

FM08ATEX0072

TI13582a

ATEX Certificate is listed here

312780C 3

System Configuration and Part Numbers

System Configuration and Part Numbers

Wall Mount Fluid Station Configurator Key

The configured part number for your equipment is printed on the equipment identification labels. See F IG . 1 for location of the identification labels. The part number includes one digit from each of the following six categories, depending on the configuration of your system.

Automatic

System

A

Control and Display A and B Meter Color Valves

D = EasyKey with LCD Display 0 = No Meters 0 = No Valves

(single color)

1 = G3000 (A and B)

2 = G3000HR (A and B)

1 = Two Valves

(low pressure)

3 = 1/8 in. Coriolis (A) and

G3000 (B)

2 = Four Valves

(low pressure)

4 = G3000 (A) and 1/8 in.

Coriolis (B)

3 = Seven Valves

(low pressure)

5 = 1/8 in. Coriolis (A) and

G3000HR (B)

6 = G3000HR (A) and 1/8 in.

Coriolis (B)

4 = Twelve Valves

(low pressure)

7 = 1/8 in. Coriolis (A and B)

Catalyst Valves Flow

Control

0 = No Valves

(single catalyst)

N = No

Y = Yes

1 = Two Valves

(low pressure)

2 = Four Valves

(low pressure)

Label Location on Fluid Station

TI12423a

Maximum Fluid

Working Pressure is listed here

!"#$" %#$!

(

78

3

4

$#$+" , +-!

!./%0!$# - ( ++ 1

2 1 3/% 1 4

5 6'( # &'(

!"#$#%%

& '(

( )*

+ )

,-

(

+. /+01%

2* 3

3 :

&'( )'*

F IG . 1: Identification Label, Automatic Wall Fluid Station Systems

3( (

9 88

$$!% +1

&&88

Label Location on EasyKey

TI12418a

Configured Part Number

4 312780C

System Configuration and Part Numbers

Hazardous Location Approval

Models using a G3000, G3000HR, or intrinsically safe Coriolis meter for both A and B meters are approved for installation in a Hazardous Location - Class I, Div I, Group D, T3 or Zone I Group IIA T3.

Maximum Working Pressure

Maximum working pressure rating is dependent on the fluid component options selected. The pressure rating is

based on the rating of the lowest rated fluid component. Refer to the component pressure ratings below.

Example: Model AD110Y has a maximum working pressure of 190 psi (1.31 MPa, 13.1 bar).

See the identification label on your EasyKey or fluid station for the system maximum working pressure.

See F IG . 1.

ProMix Fluid Components Maximum Working Pressure

Base System (no meters [option 0], no color change [option 0], and no flow control [option N]) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000 psi (27.58 MPa, 275.8 bar)

Meter Option 1 and 2 (G3000 or G3000HR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000 psi (27.58 MPa, 275.8 bar)

Meter Option 3, 4, 5, 6, and 7 (one or two Coriolis Meters) . . . . . . . . . . . . . . . . . 2300 psi (15.86 MPa, 158.6 bar)

Color Change Option 1, 2, 3 and 4 and

Catalyst Change Option 1 and 2 (low pressure valves) . . . . . . . . . . . . . . . . . . . . . . . 300 psi (2.07 MPa, 20.6 bar)

Flow Control Option Y (Yes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 psi (1.31 MPa, 13.1 bar)

Flow Meter Fluid Flow Rate Range

G3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-3800 cc/min. (0.02-1.0 gal./min.)

G3000HR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-1900 cc/min. (0.01-0.50 gal./min.)

Coriolis Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3800 cc/min. (0.005-1.00 gal./min.)

S3000 Solvent Meter (accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-1900 cc/min. (0.01-0.50 gal./min.)

Standard Features

Feature

EasyKey with LCD

Fiber Optic and Power Cables, 50 ft (15.25 m)

Wall Mount Fluid Station, 50 cc Integrator and Static Mixer

Discrete I/O Board

A Side Dump Valve, if color valve(s) selected

B Side Dump Valve, if catalyst valve(s) selected

Flow Control with 15 ft (4.57 m) Cable (if selected)

Basic Web Interface

312780C 5

System Configuration and Part Numbers

RoboMix Fluid Station Configurator Key

The configured part number for your equipment is printed on the equipment identification labels. See F IG . 2 for location of the identification labels. The part number includes one digit from each of the following six categories, depending on the configuration of your system.

Control and Display A and B Meter Color Valves Catalyst Valves RoboMix

System

R

Flow

Control

N = No

Y = Yes

D = EasyKey with LCD Display 0 = No Meters 0 = No Valves

(single color)

1 = G250 (A and B)

2 = G250HR (A and B)

1 = Two Valves

(low pressure)

2 = Four Valves

(low pressure)

3 = Seven Valves

(low pressure)

4 = Twelve Valves

(low pressure)

0 = No Valves

(single catalyst)

1 = Two Valves

(low pressure)

2 = Four Valves

(low pressure)

Label Location on

RoboMix Fluid Station

TI12512a

Maximum Fluid

Working Pressure is listed here

!"#$" %#$!

(

78

3

4

$#$+" , +-!

!./%0!$# - ( ++ 1

2 1 3/% 1 4

5 6'( # &'(

!"#$#%%

& '(

( )*

+ )

,-

(

+. /+01%

2* 3

3 :

&'( )'*

F IG . 2: Identification Label, Automatic RoboMix Fluid Station Systems

3( (

9 88

$$!% +1

&&88

Label Location on EasyKey

TI12418a

Configured Part Number

6 312780C

System Configuration and Part Numbers

Hazardous Location Approval

Models using a G250 or G250HR for both A and B meters are approved for installation in a Hazardous Location -

Class I, Div I, Group D, T3 or Zone I Group IIA T3.

Maximum Working Pressure

Maximum working pressure rating for RoboMix Fluid Station Systems is 190 psi (1.31 MPa, 13.1 bar).

See the identification label on your EasyKey or RoboMix fluid station for the maximum working pressure.

See F IG . 2.

ProMix RoboMix Systems Maximum Working Pressure

RoboMix Panel Options (all) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 psi (1.31 MPa, 13.1 bar)

Flow Meter Fluid Flow Rate Range

G250 Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-3800 cc/min. (0.02-1.0 gal./min.)

G250HR Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-1900 cc/min. (0.01-0.50 gal./min.)

Standard Features

Feature

EasyKey with LCD

Fiber Optic and Power Cables, 50 ft (15.25 m)

Remote Fluid Station, 25 cc Integrator

Discrete I/O Board

A Side Dump Valve, if color valve(s) selected

B Side Dump Valve, if catalyst valve(s) selected

Flow Control with 15 ft (4.57 m) Cable (if selected)

Basic Web Interface

312780C 7

8

Accessories

Accessories

Accessory

15V354 Third Purge Valve Kit

15V202 Third Purge Valve Kit

15V536 Solvent Flow Switch Kit

15V213 Power Cable, 100 ft (30.5 m)

15G710 Fiber Optic Cable, 100 ft (30.5 m)

15G614 Flow Control Extension Cable, 40 ft (12.2 m)

15U955 Injection Kit for Dynamic Dosing

15V034 10 cc Integrator Kit

15V033 25 cc Integrator Kit

15V021 50 cc Integrator Kit

24B618 100 cc Integrator Kit

15W034 Strobe Light Alarm Indicator Kit

15V331 Gateway Ethernet Communication Kit

15V963 Gateway DeviceNet Communication Kit

15V964 Gateway Profibus Communication Kit

15V337 Advanced Web Interface

280555 S3000 Solvent Flow Meter Kit

312780C

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 symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground all equipment in the work area. See Grounding instructions in your system installation manual.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment.

• Connect only to grounded power source.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

INTRINSIC SAFETY

Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe equipment will create a hazardous condition and can cause fire, explosion, or electric shock. Follow local regulations and the following safety requirements.

• Only models with a G3000, G250, G3000HR, G250HR, or intrinsically safe Coriolis meter are approved for installation in a Hazardous Location - Class I, Div I, Group D, T3 or Zone I Group IIA

T3.

• Do not install equipment approved only for a non-hazardous location in a hazardous area. See the

ID label for the intrinsic safety rating of your model.

• Do not substitute or modify system components as this may impair intrinsic safety.

312780C 9

Warnings

WARNING

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

• Tighten all fluid connections before operating the equipment.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS forms from distributor or retailer.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine 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 chemically impermeable gloves when spraying or cleaning equipment.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

• Gloves

• Hearing protection

10 312780C

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 MSDS 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 MSDS.

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.

312780C 11

Grounding

Grounding

Your system must be grounded. See the Grounding instructions in your ProMix 2KS Installation manual.

Pressure Relief

Procedure

NOTE: The following procedures relieve all fluid and air pressure in the ProMix 2KS system. Use the procedure appropriate for your system configuration.

Check Resistance

Relieve pressure when you stop spraying, before changing spray tips, and before cleaning, checking, or servicing equipment.

To ensure proper grounding, resistance between Pro-

Mix components and true earth ground must be less than 1 ohm.

Have a qualified electrician check resistance between each ProMix component and true earth ground. If resistance is greater than 1 ohm, a different ground site may be required. Do not operate the system until the problem is corrected.

Single Color Systems

1.

While in Mix mode (gun triggered), shut off the A and B fluid supply pumps/pressure pots. Close all fluid shutoff valves at the pump outlets.

2.

With the gun triggered, push the manual override on the A and B dose valve solenoids to relieve pressure. See F IG . 5.

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 in your system

Operation manual.

4.

Shut off the fluid supply to the solvent purge valve

(SPV) and the air supply to the air purge valve

(APV), F IG . 4.

5.

With the gun triggered, push the manual override on the A and B purge valve solenoids to relieve air and solvent pressure. See F IG . 5. Verify that solvent pressure is reduced to 0.

NOTE: If a Purge Volume alarm (E-11) occurs, clear the alarm.

12 312780C

Pressure Relief Procedure

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 12.

2.

Close the A side shutoff valve (SVA), F IG . 4. Open the A side sampling valve (RVA).

3.

Direct the A side sampling tube into a waste container.

4.

See F IG . 3. Open the color change module. Using the solenoid identification labels as a guide, press and hold the override button on each color solenoid until flow from the sampling valve stops.

5.

Press and hold the solvent solenoid override until clean solvent comes from the sampling valve, then release.

6.

Shutoff the solvent supply to the color change stack solvent valve.

7.

Press and hold the solvent solenoid override until solvent flow from the sampling valve stops.

8.

Open the A side shutoff valve (SVA), F IG . 4. Close the A side sampling valve (RVA).

Systems with Color/Catalyst Change and

Dump Valves

NOTE: This procedure relieves pressure through the dump valves.

1.

Complete all steps under Single Color Systems, page 12.

2.

Shut off all color and catalyst supplies to the valve stacks.

3.

Press and hold the dump valve A solenoid override,

F IG . 5.

4.

See F IG . 3. 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,

F IG . 5.

6.

See F IG . 3. 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 A solenoid override,

F IG . 5.

8.

Press and hold the A side (color) solvent solenoid override until clean solvent comes from the dump valve, then release.

9.

Press and hold the dump valve B solenoid override,

F IG . 5.

10. Press and hold the B side (catalyst) solvent solenoid override until clean solvent comes from the dump valve, then release.

11. Shutoff the solvent supply to the color/catalyst change stack solvent valves.

12. Press and hold the A and B solvent solenoid overrides and dump valve overrides until solvent flow from the dump valves stops.

312780C 13

Pressure Relief Procedure

Solenoid

Identification

Label

Solenoid

Identification

Label

TI12826a

Solvent Solenoid

Overrides

F IG . 3: Color Change Solenoids

MA

AT

DVA FI DVB

APV RVA SVA

F IG . 4. Wall Mount Fluid Station

SM SVB SPV

MB

MS

RVB

TI12556b

Key:

MA Component A Meter

DVA Component A

Dose Valve

RVA Component A

Sampling Valve

SVA Component A

Shutoff Valve

MB Component B Meter

DVB Component B

Dose Valve

RVB Component B

Sampling Valve

SVB Component B

Shutoff Valve

MS Solvent Meter

(accessory)

SPV Solvent Purge Valve

APV Air Purge Valve

SM Static Mixer

FI Fluid Integrator

AT Air Purge Valve Air

Supply Tube

14 312780C

Troubleshooting

Troubleshooting

Follow Pressure Relief Procedure, page 12, before

cleaning, checking, or servicing equipment.

NOTE: Do not use the fluid in the line that was dispensed off ratio as it may not cure properly.

Alarm Codes

Table 1 lists the system alarm codes. See the system operation manual for complete information on alarm troubleshooting.

Table 1: System Alarm Codes

Code Description

E-1 Communication Error Alarm

E-2 Potlife Alarm

E-3 Ratio High Alarm

E-4 Ratio Low Alarm

E-5 Overdose A/B Dose Too Short Alarm

E-6 Overdose B/A Dose Too Short Alarm

E-7 Dose Time A Alarm

E-8 Dose Time B Alarm

E-9 Mix in Setup Alarm

E-10 Remote Stop Alarm

E-11 Purge Volume Alarm

E-12 CAN Network Communication Error Alarm

E-13 High Flow Alarm

E-14 Low Flow Alarm

E-15 System Idle Warning

E-16 Setup Change Warning

E-17 Power On Warning

E-18 Defaults Loaded Warning

E-19 I/O Alarm (see Operation Manual for details)

E-20 Purge Initiate Alarm

E-21 Material Fill Alarm

E-22 Tank A Low Alarm

E-23 Tank B Low Alarm

E-24 Tank S Low Alarm

E-25 Auto Dump Complete Alarm

E-26 Color/Catalyst Purge Alarm

E-27 Color/Catalyst Fill Alarm

312780C 15

Troubleshooting

Solenoid Troubleshooting

RoboMix Fluid Station

Dose Valve B

Override Button

Dose Valve A

Override Button

TI12655a

Wall Mount Fluid Station

J1

F1 F2

Valve Overrides

J13

J12

Dose A

Dose B

J3

1

J9

1

J14

1

J15

1

J8

Power

CAN

Fiber

Optic

CAN

Dose Valve A

Solenoid

Dose Valve B

Solenoid

Purge Valve A

Solenoid

F IG . 5: Fluid Station Board and Solenoids

Purge Valve B

Solenoid

16

Dump Valve A

Dump Valve B

GFB 1

GFB 2

3rd Purge Valve

Solenoid

Optional Solenoid

Locations

TI12652b

312780C

Troubleshooting

NOTE: Refer to the Schematic Diagrams, page 30.

If the dispense or purge valves are not turning on or off correctly, it could be caused by one of the following.

Cause Solution

1.

Air regulator pressure set too high or too low.

2.

Air or electrical lines damaged or connections loose.

Visually inspect air and electrical lines for kinks, damage, or loose connections. Service or replace as needed.

3.

Solenoid failure

Check air pressure. 80-90 psi (550-630 kPa, 5.5-6.3 bar) is commonly used.

Do not go below 70 psi (490 kPa, 4.9 bar) or above 120 psi (0.8 MPa, 8 bar).

Manually operate the valves by removing the Fluid Station cover and pressing and releasing solenoid valve override buttons. F IG . 5.

4.

Solenoid, cable, or fluid station control board failure.

5.

Blown fuse.

Use the control board diagnostics to check the signals. If signals do not occur correctly, go to Cause 4.

Valves should snap open and shut quickly. If the valves actuate slowly, it could be caused by:

• Air pressure to the valve actuators is too low. See Cause 1.

• Solenoid is clogged. Make sure air supply has 10 micron filter installed.

• Something is restricting the solenoid or tubing. Check for air output from air line for corresponding solenoid when valve is actuated. Clear restriction.

• A dose valve is turned in too far. See ProMix 2KS Operation manual for settings.

• Fluid pressure is high and air pressure is low.

Check voltage level to solenoid by pulling solenoid connector and checking voltage between pins.

If voltage is 9-15 VDC, the solenoid is damaged. Replace solenoid or correct electrical line problem.

If there is no voltage, replace the board.

Check condition of fuses F1 and F2. F1 powers J9 and J14 (Dose Valve A and B and Purge Valve A and B solenoids). F2 powers J8 and J15 (3rd

Purge Valve, Dump Valve A and B, and GFB 1 and 2 solenoids).

312780C 17

Troubleshooting

Wall Mount Fluid Manifold Troubleshooting

See F IG

. 6. To remove the fluid manifold, see page 49.

See manual 312781 for complete information on the fluid manifold.

ASL ACV DVA OFF

FI

DVB OFF

DVB ON

BCV BSL

MA

DVA

DVA ON

AT

APV ON

SSL

MB

SCV

MS

DVB

APV OFF APV

RVA

Key:

Component A Side

MA Component A Meter

DVA Component A Dose Valve

RVA Component A Sampling Valve

SVA Component A Shutoff Valve

APV Air Purge Valve

AT Air Purge Valve Air Supply Tube

ASL Component A Supply Line

ACV Meter A Check Valve

SVA

SM

SVB

RVB

Component B Side

MB Component B Meter

DVB Component B Dose Valve

RVB Component B Sampling Valve

SVB Component B Shutoff Valve

BSL Component B Supply Line

BCV Meter B Check Valve

SPV Solvent Purge Valve

SSL Solvent Supply Line

MS Solvent Meter (accessory)

SCV Solvent Meter Check Valve

F IG . 6. Wall Mount Fluid Manifold

SPV ON SPV

Mixed Material

SM Static Mixer

FI Fluid Integrator

SPV OFF

TI12556b

18 312780C

Troubleshooting

EasyKey Barrier Board Diagnostics

See F IG

. 7 and Table 2 to troubleshoot the EasyKey barrier board. Also see the EasyKey Electrical Schematic on

page 31 and the System Electrical Schematic on pages 32 and 33.

J4, Pin 1 J1, Pin 1

D5

F1

F2

F4

F3

D4

J5, Pin 1

F IG . 7: 255786 EasyKey Barrier Board

Table 2: EasyKey Barrier Board Diagnostics

Connector Description

J1

J4

J5

AC Power Input

24 Vdc Power Input to

EasyKey Display Board

12 Vdc Power Output to

Fluid Station Board

Diagnosis n/a

D5 turns on.

D4 turns on if barrier board is functioning. If D4 does not turn on, fuses F3 or F4 (Graco Part No. 15D979) are blown or there is no input power at J4.

If there is no input power (D5 does not light), fuses F1 and F2 (Graco Part

No. 114788) may be blown.

312780C 19

Troubleshooting

EasyKey Display Board Diagnostics

See F IG

. 8 and Table 3 to troubleshoot the EasyKey display board. Also see the EasyKey Electrical Schematic on

page 31 and the System Electrical Schematic on pages 32 and 33.

Multiple Station

D7

TI12923a

Integration Control

J10

J5

J6

P1

J1

J4

J9

RT1

TI12924a

BK885 or CR1220 Battery

(3V, 12.5 mm, lithium coin)

D11

J7

F IG . 8: 255767 EasyKey Display Board

J8

20

R5

312780C

Troubleshooting

Connector/

Indicator

J1

J4

J5

J6

J7

J8

Description

Table 3: EasyKey Display Board Diagnostics

Graphic Display Backlight

Ribbon Cable to Membrane

Inputs and Outputs

Remote I/O

Fiber Optic Cable Input (black)

Fiber Optic Cable Output (blue)

Connector/

Indicator Description

J9

J10

24 Vdc Power Input/Alarm Output

RS485 Communication Terminals

D7 (green) LED turns on when power is supplied to board

D11 (yellow) LED blinks (heartbeat) when board is operating

P1

R5

Ethernet Port

Display Contrast/Dimmer Switch (turn by hand)

312780C 21

Troubleshooting

Discrete I/O Board Diagnostics

See F IG

. 9 and F IG

. 10 to troubleshoot the Discrete I/O board. Also see the System Electrical Schematic on pages

32 and 33.

I/O Terminal Strip Detail

Pin 1

Pin 1

RS485 Integration A

RS485 Integration B

RS485 Integration Ground

RS485 Network A

RS485 Network B

RS485 Network Ground

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

Display Board Barrier Board Terminal Strips

(see detail above)

F IG . 9: EasyKey Control Boards and Terminal Strips

22

Discrete I/O Board

(see F IG . 10)

TI12496b

312780C

LED D1

(green)

JLS

F IG . 10: 255766 Discrete I/O Board

312780C

Troubleshooting

Digital Output Common/Power

Flow Rate Alarm Output

Flow 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

23

Troubleshooting

24 312780C

Troubleshooting

Fluid Station Control Board Diagnostics

See F IG

. 11 and Table 4 to troubleshoot the fluid station control board. Also see the System Electrical Schematic

on pages 32 and 33.

J4

(Fiber Optic Output - blue)

D19

D18

F1 (Fuse) F2 (Fuse)

J6 (Fiber Optic Input - black)

D15

D45

J10 (Power Input)

D16

J11 (Color Change Module)

D46

D17 Set Switch S1 as shown below.

J7 (Not Used)

D44

D20

TI15223a

Set switch S1 to OFF

(up) if system has

Booth Control AND

Color Change.

D43

D28 D30 D27 D41

F

IG

. 11: 255765 Fluid Station Control Board Indicators

D33 D31

D29 TI15224a

Set switch S1 to ON

(down) if system has

Booth Control OR Color

Change, or neither.

312780C 25

Troubleshooting

J1

Pin 1

AFS #1

AFS #2

Solvent Switch

GFB 1 PS

GFB 2 PS

J13

(Not Used)

J12

Pin 1

Solvent Meter

Spare

J3

Pin 1

Flow Meter A

Flow Meter B

J9

Pin 1

Dose Valve A

Dose Valve B

Spare

Pin 7 (plugged)

+

G s

+

G s

+

G s

+

G s

+

+

+

J4

J6

+ + + + + + + + +

J10

J11

J7

J14 J15

F IG . 12: 255765 Fluid Station Control Board Input/Output Connections

J8

26 312780C

Troubleshooting

Table 4: Fluid Station Control Board Diagnostics

LED

Connector and Pin Nos.

Signal Description

D15

D16

J1, 1 & 2

J1, 5 & 6

D17 J1, 9 & 10

D18 J10

D19

D20 n/a n/a

D27 J15, 1 & 2

D28 J14, 3 & 4

D29 J8, 5 & 6

D30 J14, 5 & 6

D31

D33

J8, 3 & 4

J8, 1 & 2

D41

D43

D44

D45

J15, 5 & 6

J9, 3 & 4

J9, 1 & 2

J1, 3 & 4

D46 J1, 7 & 8

F1 n/a

F2 n/a

Diagnosis

Air Flow Switch 1

Solvent Flow Switch

Turns on when gun 1 is triggered.

Turns on when solvent is flowing.

Gun Flush Box 2 Pressure Switch Turns on when a gun is in Gun Flush Box 2.

Power Turns on when power is supplied to the board.

Communication (yellow)

Board OK

Purge Valve C (Water Purge)

Purge Valve A (Air Purge)

Turns on when board is communicating with EasyKey.

Blinks (heartbeat) during normal operation.

Dump Valve B

Purge Valve B (Solvent Purge)

Gun Flush Box 1 Trigger

Gun Flush Box 2 Trigger

D27 through D44 turn on when ProMix sends a signal to actuate the related solenoid valve.

Dump Valve A

Dose Valve B

Dose Valve A

Air Flow Switch 2 Turns on when gun 2 is triggered.

Gun Flush Box 1 Pressure Switch Turns on when a gun is in Gun Flush Box 1.

Replaceable Fuse for Flow Meter A and B, Dose Valve A and B Solenoids, and Purge Valve A and B

Solenoids

Check fuse condition if Flow Meters, Dose Valves, and Purge Valves are not working.

Replaceable Fuse for Solvent

Meter, Dump Valve A and B Solenoids, 3rd Purge Valve Solenoid, and Gun Flush Box 1 and 2 Solenoids

Check fuse condition if Solvent Meter, Dump Valves,

3rd Purge Valve, and Gun Flush Boxes are not working.

312780C 27

Troubleshooting

Color Change Board Diagnostics

See F IG

. 13 and Table 5 to troubleshoot the color change board. Also see the System Electrical Schematic on

pages 32 and 33. To replace the color change board, see manual 312787.

J8, Pin 1

D33

D34

D43

D31

D29

D44

J9, Pin 1

J15, Pin 1

D41

D35

D27

J14, Pin 1

D39

D32

D38

J16, Pin 1

D37

D45

D30 D46

D28

J10, Pin 1

D36

D9

D8

J7

F

IG

. 13: 256172 Color Change Board

28

D10

F1 (Fuse)

J11

312780C

Troubleshooting

Table 5: Color Change Board Diagnostics

LED

D8

D9

D10 J7

D27 J15, 5 & 6

D28 J14, 3 & 4

D29 J8, 5 & 6

D30 J14, 1 & 2

D31 J8, 3 & 4

D32

D33

J16, 3 & 4

J8, 1 & 2

D34 J9, 5 & 6

D35 J15, 3 & 4

D36 J14, 5 & 6

D37 J10, 5 & 6

D38

D39

J16, 1 & 2

J16, 5 & 6

D41 J15, 1 & 2

D43 J9, 3 & 4

D44

D45

D46

F1

J9, 1 & 2

J10, 3 & 4

J10, 1 & 2

Replaceable

Fuse

Connector and Pin Nos.

n/a n/a

Board 1 Signal

Description

Board 2 Signal

Description

Board OK

Communication

(yellow)

Power

Color 3

Color 1

Color 6

Color 2

Color 7

Catalyst 4

Color 8

Color 9

Color 4

Solvent (Color)

Catalyst 2

Catalyst 3

Color 12

Color 5

Color 10

Color 27

Color 25

Color 18

Color 23

Color 11

Catalyst 1

Color 24

Color 29

Solvent (Catalyst) Color 30 n/a n/a

Board OK

Communication

(yellow)

Power

Color 16

Color 14

Color 19

Color 15

Color 20

Color 26

Color 21

Color 22

Color 17

Color 13

Color 28

Diagnosis

Blinks (heartbeat) during normal operation.

Turns on when board is communicating with ProMix

2KS.

Turns on when power is supplied to the board.

D27 through D46 turn on when ProMix 2KS sends a signal to actuate the related solenoid valve.

Check fuse condition if there is no power to the board or if communication is interrupted between the fluid station and the color change module.

312780C 29

Schematic Diagrams

Schematic Diagrams

System Pneumatic Schematic

AIR INPUT

3/8 AIR FILTER

MANUAL DRAIN

5 MICRON

WALL MOUNT ONLY

05

AIR INPUT

MANIFOLD

AIR EXHAUST MUFFLER

12 VDC

4-WAY SOLENOID

12 VDC

4-WAY SOLENOID

12 VDC

4-WAY SOLENOID

12 VDC

4-WAY SOLENOID

12 VDC

4-WAY SOLENOID

AIR EXHAUST MUFFLER

12 VDC

3-WAY SOLENOID

12 VDC

3-WAY SOLENOID

12 VDC

3-WAY SOLENOID

12 VDC

3-WAY SOLENOID

A B

A B

A B

A B

A B

A

A

A

A

MANIFOLD

CLOSE

5/32 TUBE

OPEN

CLOSE

5/32 TUBE

OPEN

CLOSE

5/32 TUBE

OPEN

CLOSE

5/32 TUBE

OPEN

CLOSE

5/32 TUBE

OPEN

5/32 TUBE

OPEN

DUMP A

(OPTIONAL)

5/32 TUBE

OPEN

DUMP B

(OPTIONAL)

5/32 TUBE

OPEN

VALVE

(OPTIONAL)

5/32 TUBE

OPEN

COLOR

CHANGE

CONTROL

COLOR

VALVE

STACKS

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

COLOR SOLVENT

COLOR 9

COLOR 10

COLOR 11

COLOR 12

CATALYST 1

CATALYST 2

CATALYST 3

CATALYST 4

CATALYST SOLVENT

COLOR 13

COLOR 14

COLOR 15

COLOR 16

COLOR 17

COLOR 18

COLOR 19

COLOR 20

COLOR 21

COLOR 22

COLOR 23

COLOR 24

COLOR 25

COLOR 26

COLOR 27

COLOR 28

COLOR 29

COLOR 30

MAC

36 SERIES SOLENOID VALVES

30 312780C

EasyKey Electrical Schematic

- +

L L N N

HIGH VOL

24 VDC+ OUTPUT

- - + DC OK

GND L1 N

BROWN 16 A

GND L1 N

L1 N

BROWN 16 A

1 2

1A 2A

POWER ROCKER SWIT

BROWN 16 A

RED/BLA BLA RED 18 A

RED 18 A

J4-3 J4-2 J4-1 J1-5 J1-4 J1-3 J1-2 J1-1 J5-3 J5-2 J5-1

J4 24 VDC+ IN

IS POWER 12

Schematic Diagrams

312780C 31

Schematic Diagrams

System Electrical Schematic

NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS system. Some components shown are not included with all systems.

Non-Hazardous Area

MEMBRANE

SWITCH

WITH

RIBBON

CABLE

DISPLAY

POWER HARNESS

DC OK

+24 VDC

COMMON

COMMON

J2

13

14

15

16

9

10

11

12

17

18

19

20

7

8

5

6

3

4

1

2

J4

7

8

5

6

3

4

1

2

9

10

11

DISPLAY

BOARD

J6

RJ45

J9

3

4

1

2

RJ45

J5

7

8

5

6

3

4

1

2

9

10

-

+

POWER DIST.

TERMINAL

BLOCKS

-

+

+

-

+

+

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)

I/O HARNESSES

OPERATOR INTERFACE

-

-

+

+

POWER

SUPPLY

BARRIER

BOARD

1

2

J1

J5

3

4

1

2

5

1

2

3

J4

1

2

3

NON-HAZARDOUS AREA

L1

N

85-250 VAC

L1

N

LINE

FILTER

L1

N

GND

L1

N

GND

TERMINAL

BLOCK

L1

N

GND

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

HARNESS

+12VDC I/S (RED)

COM (BLACK)

SHIELD

+24VDC

OPEN

COMMON

ALARM

-

+

3'

1

2

3

4

5

6

7

8

9

10

OPEN

OPEN

RJ45 RJ45

REMOTE

I/O

INTEGRATION

BOARD

J3

J2

J4

J5

4

3

2

1

6

5

8

7

6

5

4

3

2

1

6

5

4

3

8

7

2

1

6

5

4

3

2

1

1

2

3

1

2

1A

1B

2A

2B

GND LUG

POWER

ROCKER

SWITCH

CABLE

(50' STD.)/

(100' OPTION)

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

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

DIGITAL OUTPUT COMMON/POWER

SPECIAL OUTPUT #1

SPECIAL OUTPUT #2

SPECIAL OUTPUT #3

SPECIAL OUTPUT #4

DIGITAL OUTPUT COMMON/POWER

GND N L1

85-250

VAC

(+24) YEL

(COM) GRAY

ORG

BRN

RED

BEACON

J10 3

4

1

2

5

6

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)

3

4

1

2

5

6

TERMINAL

BLOCKS

CABLE

J7

J8

FO IN (BLK)

FO OUT (BLU)

P1

RJ45 RJ45

3'

RJ45

BULKHEAD

3'

(25'-200' OPTIONS)

WEB SERVER

MODULE

32 312780C

Schematic Diagrams

System Electrical Schematic

NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS system. Some components shown are not included with all systems.

Hazardous Area

FO OUT

(BLU)

FO IN

(BLK)

FLUID PANEL CONTROL BOX

FLUID

PANEL

CONTROL

BOARD

J3

4

3

2

1

6

5

J12

J10

1

2

3

+12VDC I/S

COM

SHIELD

J13

J5

MH2

4

3

2

1

6

5

4

3

2

1

6

5

4

3

2

1

6

5

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

HAZARDOUS AREA

3X CABLE

PWR (RED)

COM (BLACK)

SIG (WHITE)

SHIELD/GRN

PWR (RED)

COM (BLACK)

SIG (WHITE)

SHIELD/GRN

PWR (RED)

COM (BLACK)

SIG (WHITE)

SHIELD/GRN

GROUND

TERMINAL

(10')/

(40')

6' STD.

(3'-100' OPTIONS)

J11

2

5

J7

4

5

1

2

3

50' STD.

GRD (BLK)

+12VDC (RED)

SHIELD (BARE)

CAN H (WHT)

CAN L (BLU)

4

5

1

2

3

BOOTH

CONTROL

BOARD

J4

J6

J8

J15

J14

J9

J1

4

3

6

5

2

1

4

3

6

5

2

1

4

3

6

5

2

1

4

3

6

5

2

1

7

8

5

6

3

4

1

2

9

10

BLACK

RED

BLACK

RED

BLACK

RED

BLACK

RED

BLACK

RED

BLACK

RED

BLACK

RED

RED

BLACK

RED

BLACK

RED

BLACK

RED

BLACK

RED

SIG

COM

SIG

COM

SIG

COM

SIG

COM

SIG

COM

MANIFOLD

MANIFOLD

DUMP B

GFB #1

GFB #2

DUMP A

NOT USED

PURGE C

PURGE B

PURGE A

NOT USED

NOT USED

DOSE B

DOSE A

AIR FLOW SWITCH 1

AIR FLOW SWITCH 2

SOLVENT FLOW SWITCH

GFB 1 PRESSURE SWITCH

GFB 2 PRESSURE SWITCH

FLOW METER A

FLOW METER B I.S. METERS

FLOW METER SOLVENT

V/P ANALOG OUT (WHT)

PRESS. (GRN)

+12 V (RED)

GND (BLK)

CHASSIS (BARE)

J1

4

3

5

2

1 FLOW

CONTROL

BOARD

4

3

5

2

1

2

1

J2

SIG (RED)

COM (BLK)

J4

+ PRESSURE (GRN)

COM (RED)

EX+ (WHT)

- PRESSURE (BLK)

SHIELD (BARE)

CLR 8

CLR 7

CLR 6

CLR 5

CLR 4

CLR 3

MANIFOLD

CLR 2

CLR 1

SOL CLR

CLR 21

CLR 20

CLR 19

CLR 18

CLR 17

CLR 16

MANIFOLD

CLR 15

CLR 14

CLR 13

+12VDC

COM

J7/J11

1 4 5 2 3

COLOR

BOARD 1

(COLORS

1 THRU 12,

CATALYST

1 THRU 4)

J8 J9

5

4

+12VDC

COM

J15 J16

5

4

+12VDC

COM

4

6

J14

1 4 5 2 3

J7/J11

J10

6' STD.

J7/J11

1 4 5 2 3

COLOR

BOARD 2

(COLORS

13 THRU 30)

COM

+12VDC

MANIFOLD

CLR 9

CLR 10

CLR 11

CLR 12

CAT 4

CAT 3

CAT 2

CAT 1

SOL CAT

+12VDC

COM

+12VDC

COM

2

3 J8

J15 J16

J14

J9

2

1

J10

6

5

COM

+12VDC

MANIFOLD

CLR 22

CLR 23

CLR 24

+12VDC

+12VDC

CLR 25

CLR 26

CLR 27

CLR 28

CLR 29

CLR 30

TECNO

V/P

FLUID

PRESS.

SENS.

312780C 33

Schematic Diagrams

RoboMix Panel Board Schematic

TO COLOR

CHANGE

TO

EASYKEY

GRD (BLK)

+12VDC (RED)

SHIELD (BARE)

CAN H (WHT)

CAN L (BLU)

NOT USED

DOSE B

DOSE A

PURGE B

PURGE A

NOT USED

MANIFOLD

DUMP A

NOT USED

NOT USED

DUMP B

NOT USED

NOT USED

+12VDC I/S

COM

SHIELD

BLACK

RED

BLACK

RED

BLACK

RED

BLACK

RED

BLACK

RED

BLACK

RED

BLACK

RED

BLACK

RED

BLACK

RED

BLACK

RED

BLACK

RED

BLACK

RED

J10

1

2

3

J7

3

2

5

4

1

J9

4

3

6

5

2

1

J8

6

5

4

3

2

1

J15

4

3

6

5

2

1

J14

4

3

6

5

2

1

1

2

3

4

5

6

J3

1

2

3

4

5

6

J12

MH2

5

6

3

4

1

2

J5

8

9

10

5

6

7

1

2

3

4

J1

J13

1

2

3

4

5

6

NOT USED

NOT USED

NOT USED

NOT USED

SIG

COM

NOT USED

NOT USED

NOT USED

NOT USED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

PWR (RED)

COM (BLACK)

SIG (WHITE)

SHIELD/GRN

PWR (RED)

COM (BLACK)

SIG (WHITE)

SHIELD/GRN

PWR (RED)

COM (BLACK)

SIG (WHITE)

SHIELD/GRN

NOT USED

NOT USED

NOT USED

GROUND TERMINAL

TO FLOW

REGULATOR

SOLVENT FLOW SWITCH

FLOW METER A

FLOW METER B

FLOW METER

SOLVENT

34 312780C

Schematic Diagrams

312780C 35

Schematic Diagrams

Tubing Schematic

B1

A2

A6

B5

AT

A4 A8

TI13857a

B1 B3 B5 B7

B3

13

14

B7

DB

14

DA

TI13858a

13

A2 A4 A6 A8 DA DB

TI13856a

TI13859a

36 312780C

Schematic Diagrams

Color

Green

Green

Green

Green

Green

Green

Red

Red

Red

Red

Natural

Natural

Natural

Description

Dose A On

Dose B On

Purge A On

Purge B On

Dump A

Dump B

Dose A Off

Dose B Off

Purge A Off

Purge B Off

Solenoid Air Supply

Flow Control Air Supply

Purge Air Supply

B1

B3

B5

B7

13

14

Starting Point

A2

A4

A6

A8

DA

DB

Table 6: Tubing Chart

Ending

Point

A2

A4

A6

A8

DA

DB

Tube OD in. (mm) Tube Ref. No.

5/32 (4)

5/32 (4)

5/32 (4)

5/32 (4)

5/32 (4)

5/32 (4)

5/32 (4)

5/32 (4)

5/32 (4)

5/32 (4)

1/4 (6)

1/4 (6)

1/4 (6)

337

337

337

337

336

336

336

336

Included in optional

Dump Valve Kit

15V821 (Wall Panel) or

15V822 (RoboMix)

334

User supplied. Connects air manifold to flow control regulator.

338 Use as a separate line connected directly to the main shop air line. Do not connect to the unit’s main air supply or to the air manifold (335).

AT

B1

B3

B5

B7

13

14

312780C 37

Service

Service

Before Servicing

3.

Shut off ProMix 2KS power (0 position). F IG . 14.

4.

If servicing EasyKey, also shut off power at main circuit breaker.

• To avoid electric shock, turn off EasyKey power before servicing.

• Servicing EasyKey display exposes you to high voltage. Shut off power at main circuit breaker before opening enclosure.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

• Do not substitute or modify system components as this may impair intrinsic safety.

Read Warnings, page 9.

0 = OFF

TI12657a

F IG . 14: Power Off

NOTICE

To avoid damaging circuit board when servicing, wear

Part No. 112190 grounding strap on wrist and ground appropriately.

1.

Flush system and follow Pressure Relief Proce-

dure, page 12, if service time may exceed pot life

time and before servicing fluid components.

2.

Close main air shutoff valve on air supply line and on ProMix 2KS.

After Servicing

After servicing the system, be sure to follow the

Start Up checklist and procedure in the ProMix 2KS

Operation manual.

38 312780C

Service

Servicing EasyKey

Updating Software

To update software, upload new software from your PC using the basic web interface. See manual 313386.

NOTE: If using the Graco Gateway in your system, disconnect its cable from the EasyKey before updating the

ProMix 2KS software.

Replacing Display Board or Graphic

Display

NOTICE

To avoid damaging circuit board when servicing, wear

Part No. 112190 grounding strap on wrist and ground appropriately.

5.

Disconnect graphic display power cable (J1) from the display board (210c).

6.

Separate graphic display (210b) from display board

(210c) [connector J2 on back of board].

7.

To assemble the new parts, align connector J2 on the display board (210c) with the socket on the graphic display (210b). Press them together. See

F IG . 15.

8.

Reconnect the graphic display power cable (J1) to the display board (210c).

9.

Mount display board assembly with screws (210e).

10. Plug all connectors into display board (210c). F IG .

15. Confirm that the cables do not pinch when opening or closing the door.

11. Locate the battery on the board (see F IG . 8 on page

20). Pull the strip to remove the protective isolator and activate the battery.

12. Close and lock EasyKey door with key.

13. Turn EasyKey power on to test display board.

Replacing Power Supply

1.

Follow Before Servicing, page 38.

2.

Unlock and open EasyKey door with its key.

3.

Note position of all external connections (J4, J5, J6,

J7, J8, J9, J10) to display board, then unplug the connectors. See F IG . 8 on page 20.

4.

Remove 4 screws (210e) and the display board assembly (210b, 210c). F IG . 15.

210d

J1

210a

TI12554a

1.

Follow Before Servicing, page 38.

2.

Unlock and open EasyKey door with its key.

3.

Note position of power supply input and output

wires. See EasyKey Electrical Schematic, page

31. Disconnect wires from power supply (214f). See

F IG . 16.

4.

Remove power supply from din rail.

5.

Install new power supply (214f). Reconnect input and output wires in positions noted in step 3.

6.

Close and lock EasyKey door with key.

7.

Turn on power at main circuit breaker.

8.

Turn EasyKey power on to test operation.

F IG . 15: Display Interface

210c

210e

210b

312780C 39

Service

Replacing Line Filter Replacing Power Switch

1.

Follow Before Servicing, page 38.

2.

Unlock and open EasyKey door with its key.

3.

Note position of line filter input and output wires.

See EasyKey Electrical Schematic, page 31. Dis-

connect wires and remove line filter (214l) from

bracket (214m). See F IG . 16.

4.

Install new line filter (214l). Reconnect wires in positions noted in step 3.

5.

Close and lock EasyKey door with key.

6.

Turn on power at main circuit breaker.

7.

Turn EasyKey power on to test operation.

1.

Follow Before Servicing, page 38.

2.

Unlock and open EasyKey door with its key.

3.

Note position of power switch wires. See EasyKey

Electrical Schematic, page 31. Disconnect wires

and remove switch (202, F IG . 16).

4.

Install new power switch (202). Reconnect wires in positions noted in step 3.

5.

Close and lock EasyKey door with key.

6.

Turn on power at main circuit breaker.

7.

Turn EasyKey power on to test operation.

Power Supply

Outputs (Vdc)

214f

202

Power Supply

Inputs (Vac)

214l,

214m

Input Power

Terminal Block

TI13349b

F IG . 16: Power Supply

40 312780C

Service

312780C 41

Service

Replacing Barrier Board

NOTICE

To avoid damaging circuit board when servicing, wear

Part No. 112190 grounding strap on wrist and ground appropriately.

8.

Install the cover (214b) with 2 screws (214k), using the security tool.

9.

Connect cables to J1, J4, and J5.

10. Close and lock EasyKey door with key.

11. Turn on power at main circuit breaker.

12. Turn EasyKey power on to test operation.

Replacing Barrier Board Fuses

1.

Follow Before Servicing, page 38.

2.

Unlock and open EasyKey door with its key.

3.

Disconnect the cables and connectors from J1, J4, and J5. F IG . 18.

4.

Using the security tool provided (Part No. 122239), remove 2 screws (214k) and the cover (214b). See

F IG . 17.

5.

Noting their location, remove 5 screws (214g, 214h) from the barrier board (214a). Do not remove the screw noted in F IG . 18. Remove board.

6.

Apply thermal compound to the heatsink (Z) on the back of the new barrier board (214a). F IG . 18.

7.

Install the new barrier board with the 5 screws

(214g, 214h).

Fuse Part No.

Description

F1, F2 114788 Power In Fuses; 2 amp, time lag

F3, F4 15D979 Power Out Fuses; 0.4 amp, quick acting

1.

Follow Replacing Barrier Board, steps 1-4.

2.

Remove the fuse (F1, F2, F3, or F4) from its fuse holder. F IG . 18.

3.

Snap new fuse into holder.

4.

Follow Replacing Barrier Board, steps 8-12.

J4 J1

214c

214g

214b

J5

TI12649b

214k

F IG . 17: Replacing Barrier Board

214h 214g 214a

42 312780C

Service

214g

J4 (Power to Display Board)

F4

F3

214h

J1 (Power In)

214g

F2

F1

J5

(Power to Fluid Station)

Do not remove this screw

214h

Front of Barrier Board, showing Fuses and Connectors

214g

1

Z

1 Apply thermal compound to surface of heatsink (Z).

Back of Barrier Board, showing Heatsink (Z)

F IG . 18: Barrier Board Connectors and Fuses

312780C 43

Service

Replacing Air Filter Element Wall Mount Fluid Station

Preparation

Removing a pressurized air filter bowl could cause serious injury. Depressurize air line before servicing.

Check the 5 micron air manifold filter daily and replace element (317a, Part No. 114228) as needed.

1.

Close main air shutoff valve on air supply line and on unit. Depressurize air line.

2.

Remove filter cover (A). See F IG . 19.

3.

Unscrew filter bowl (B).

4.

Remove and replace element (317a).

5.

Screw filter bowl (B) on securely. Install cover (A).

1.

Follow Before Servicing, page 38.

2.

Loosen the 4 screws (307), then remove the Wall

Mount Fluid Station cover (322). F IG . 20.

317a

B

A

TI12691a

F IG . 19: Replacing Air Filter Element

44

TI13069a

312780C

Service

305

306

314

343

319

320

316

322

307

340

303

302

See Detail Below

301

314 315

341

339

318, 332

325 321 335

317

311

309

Solenoid Manifold Detail

308

323

342

328

313

F IG . 20: Wall Mount Fluid Station

324 331 312

330

328

TI12426a

TI12425a

312780C 45

Service

Replacing Control Board

To avoid damaging circuit board when servicing, wear

Part No. 112190 grounding strap on wrist and ground appropriately.

NOTICE

1.

Follow Preparation, page 44.

2.

Disconnect fiber optic wires (J4, J6) and all cables

(J1, J3, J5, J7, J8, J9, J12, J13, J14, J15) from con-

trol board (302). F IG . 21.

3.

Remove 4 screws (303). Remove connector jam nuts on the outside of the enclosure (301). Remove control board (302). F IG . 20.

4.

Install new control board (302) with 4 screws (303).

5.

Connect cables to control board (302). F IG . 21.

Insert fiber optic cable connectors (J4, J6) into board connectors (E), matching blue with blue, black with black, and hand-tighten connectors. Do not pinch or kink the fiber optic cables; the cables require a 2 in. (51 mm) bend radius.

6.

Replace the cover (322).

7.

Turn EasyKey power on to test operation.

J4

(F.O. Output - blue)

F1 (343)

J1

(Digital Input)

J6

(F.O. Input - black)

J10

(Power Input)

J11

(Color Change Module)

J13

(Not Used)

J12

(Solvent Meter Input)

J7

(Not Used)

J3

(Meter A and B Input)

J5

(Flow Control)

J9

(Solenoid Output:

Dose Valves A and B)

J14

(Solenoid Output:

Air Purge Valve and Solvent Flush Valve)

F IG . 21: 255765 Fluid Station Control Board

46

J8

(Solenoid Output: Dump Valve B)

J15

(Solenoid Output:

3rd Flush Valve: Dump Valve A)

312780C

Replacing Solenoids

The Wall Mount Fluid Station has a minimum of 4 solenoids. If you have options installed, you have additional

(optional) solenoids for each. See Table 7 and Sche-

matic Diagrams, page 30.

To replace a single solenoid:

1.

Follow Preparation, page 44, and shut off power at

main circuit breaker.

2.

Disconnect 2 solenoid wires from control board

(302). See F IG

. 21 and System Electrical Sche-

matic, page 33.

3.

Unscrew 2 screws (P) and remove solenoid (313).

F IG . 22.

4.

Install new solenoid (313).

5.

Connect 2 wires (N) to control board (302). Solenoid

wires are polarized (red +, black –). Refer to Sys-

tem Electrical Schematic, page 33.

6.

Replace the cover (322).

Replacing Control Board Fuse

Table 7: Wall Panel Solenoids

Solenoid Actuates

Standard

3

4

1

2

Optional

7

8

5

6

9

Dose Valve A

Dose Valve B

Air Purge Valve

Solvent Purge Valve

Third Flush Valve

Dump Valve A

Dump Valve B

Gun Flush Box 1

Gun Flush Box 2

Fuse

F1

F1

F1

F1

F2

F2

F2

F2

F2

302 343

N

Service

Replacing a fuse (F1 or F2) with a non-Graco fuse voids the IS system safety approval.

Fuse Part No.

Description

F1, F2 123690 Fuse; 125 mA, intrinsically safe

1 2 3 4 5

6 7

8 9

1.

Follow Preparation, page 44.

2.

Locate fuse F1 or F2 on the control board. See F IG .

22. Remove the screw and metal strap.

3.

Pull the fuse away from the board.

4.

Install the new fuse (343).

5.

Replace the cover (322).

P

313

F IG . 22: Replacing Solenoids and Fuse

TI12652b

312780C 47

Service

Servicing Flow Meters Mounted on Wall Panel

Coriolis Meter

1.

Follow Before Servicing, page 38.

2.

To remove and service the Coriolis meter, see manual 313599.

G3000 or G3000HR Meter

Removal

1.

Follow Before Servicing, page 38.

2.

Unscrew cable connector (CC) from meter (M). F IG .

23.

3.

Unscrew four 1/4-20 screws (MS) holding the meter mounting plate (MP). F IG . 23.

4.

Unscrew fluid line from meter inlet (P).

5.

Unscrew meter (M) from dose valve connector (H).

F IG . 23.

6.

Service meter as instructed in the meter manual

308778.

Installation

1.

Screw meter (M) securely onto the dose valve connector (H), using a wrench.

NOTE: To avoid leakage, secure the meter (M) to the dose valve connector (H) before connecting it to the fluid station.

2.

Secure meter (M) and plate (MP) to fluid station with screws (MS).

NOTE: You must assemble the meter sensor to the meter body before connecting the cable to the sensor for the meter to function properly.

3.

Connect meter cable (CC). See F IG . 23.

4.

Connect fluid line (P).

5.

Calibrate meter as instructed in ProMix Operation manual.

M

CC

MS

P

F IG . 23: G3000/G3000HR Flow Meters

MP

H

TI12653a

Cable Length

241799 5 ft (1.52 m)

241800 16 in. (406 mm)

241801 13 in. (330 mm)

3X CABLE

J3 *

J12 *

4

3

2

1

6

5

4

3

2

1

6

5

COM (BLACK)

SIG (WHITE)

PWR (RED)

COM (BLACK)

SIG (WHITE)

SHIELD/GRN

COM (BLACK)

SIG (WHITE)

SHIELD/GRN

GROUND

TERMINAL

*Connectors on Fluid Station Control Board

FLOW METER A

FLOW METER B

FLOW METER SOLVENT

F IG . 24: Meter Cable Schematic

48 312780C

Service

Servicing Fluid Manifold

Removal

1.

Follow Servicing Flow Meters Mounted on Wall

Panel, Removal steps 1-5, page 48.

2.

Disconnect air and fluid lines from the manifold (4).

3.

Holding onto the fluid manifold (4), loosen the three screws (341) holding the bracket (325) to the fluid station. Lift the fluid manifold (4) and pull it away from the panel. Service as instructed in the Fluid

Mix Manifold manual 312781.

Installation

1.

Secure the fluid manifold (4) and mounting plate

(325) with three screws (341).

2.

Install meters. See Installation steps 1-3, page 48.

3.

Connect air and fluid lines.

4.

Calibrate meters as instructed in ProMix Operation manual.

341

325

4

TI12654a

F IG . 25: Fluid Manifold

Servicing Color Change Module,

Color/Catalyst Valves, and

Dump Valves

312780C

1.

Follow Before Servicing, page 38.

2.

See manual 312787 for the color change module.

3.

See manual 312783 for the color/catalyst valve stacks.

4.

See manual 312786 for the dump valve kits.

5.

See manual 312782 to service an individual valve.

49

Service

RoboMix Fluid Station

Preparation

1.

Follow Before Servicing, page 38.

2.

Remove the RoboMix cover (410). F IG . 26.

3.

Note the position of all RoboMix hoses, then disconnect them.

410

F IG . 26: RoboMix Fluid Station

B Inlet

B Dump Outlet

Air Logic Inlet

A Inlet

Air Purge Inlet

Solvent Inlet

A Dump Outlet

TI12512a

50 312780C

Replacing Control Board

1.

Follow Preparation, page 50.

2.

Remove the control board cover (427). F IG . 27.

427

Service

4.

Remove 4 screws (428). Remove control board

(426). F IG . 28.

426

428

427

TI12579a

F IG . 27: Remove Control Board Cover

3.

Disconnect fiber optic wires (J4, J6) and all cables

(J1, J3, J5, J7, J8, J9, J12, J13, J14, J15) from con-

trol board (426). F IG . 29.

TI12648a

F IG . 28: Remove Control Board

5.

Install new control board (426) with 4 screws (428).

6.

Connect cables to control board (426). F IG . 29.

Insert fiber optic cable connectors (J4, J6) into board connectors (E), matching blue with blue, black with black, and hand-tighten connectors (E). Do not pinch or kink the fiber optic cables; the cables require a 2 in. (51 mm) bend radius.

7.

Reinstall covers (427, 410).

8.

Reconnect all hoses. F IG . 26.

9.

Turn EasyKey power on to test operation.

312780C 51

Service

Replacing Control Board Fuse

Replacing the fuse with a non-Graco fuse voids the

IS system safety approval.

1.

Follow Preparation, page 44.

2.

Locate fuse F1 on the control board. See F IG . 29.

Remove the screw and metal strap.

3.

Pull the fuse away from the board.

4.

Install the new fuse (497).

5.

Reinstall covers (427, 410).

Fuse

F1

Part No.

Description

123690 Fuse; 125 mA, intrinsically safe

J4

(F.O. Output - blue)

F1 (497)

J6

(F.O. Input - black)

J1

(Digital Input)

J10

(Power Input)

J13

(Not Used)

J11

(Color Change Module)

J12

(Solvent Meter Input)

J7

(Not Used)

J3

(Meter A and B Input)

J5

(Flow Control)

J9

(Solenoid Output:

Dose Valves A and B)

J14

(Solenoid Output:

Air Purge Valve and Solvent Flush Valve)

F IG . 29: 255765 Fluid Station Control Board

J8

(Solenoid Output: Dump Valve B)

J15

(Solenoid Output:

3rd Flush Valve, Dump Valve A)

52 312780C

Service

Replacing Solenoids

The RoboMix Fluid Station has a minimum of 4 solenoids. If you have optional 3rd flush valve or dump valve kits installed, you have additional (optional) solenoids for

each additional valve. Refer to Table 8 and Schematic

Diagrams, page 30.

To replace a single solenoid:

1.

Follow Preparation, page 50. Shut off power at the

main circuit breaker.

2.

Remove the control board cover (427). F IG . 27.

3.

Disconnect 2 solenoid wires from control board

(426). See F IG

. 29 and System Electrical Sche-

matic, page 33. Swing the control board up and out

of the way. F IG . 30.

4.

Unscrew 2 screws (P) and remove solenoid (486).

See F IG . 31 and Table 8.

7 6 5 4

F IG . 31: RoboMix Solenoids

3

486

2 1

N

P

TI12655a

F IG . 30: Accessing Solenoids and Meters

427

TI12741a

Table 8: RoboMix Solenoids

Solenoid Actuates

Standard

3

4

1

2

Optional

5

6

7

Dose Valve A

Dose Valve B

Air Purge Valve

Solvent Purge Valve

3rd Purge Valve

Dump Valve A

Dump Valve B

5.

Install new solenoid (486).

6.

Connect 2 wires (N) to control board (426). Solenoid

wires are polarized (red +, black –). Refer to Sys-

tem Electrical Schematic, page 33.

7.

Reinstall covers (427, 410).

312780C 53

Service

G250 and G250HR Flow Meters

Removal

1.

Follow Preparation, page 50.

2.

Unscrew cable from meter connector (CC). F IG . 32.

3.

Unscrew M6 screws (442) and washers (440) from bottom of meter mounting plate (438) with socket wrench. F IG . 32.

4.

Disconnect the fluid line from the meter inlet (P).

5.

Disconnect the meter outlet (H) fitting from the dose valve.

6.

Service meter as instructed in the meter manual

308778.

Installation

1.

Screw meter outlet fitting (H) securely onto the dose valve inlet, using a wrench.

NOTE: To avoid leakage, secure the meter outlet fitting

(H) to the dose valve before connecting the meter to the plate (438).

2.

Secure meter (M) to plate (438) with screws and washers (442, 440).

NOTE: You must assemble the meter sensor to the meter body before connecting the cable to the sensor for the meter to function properly.

3.

Connect cable to cable connector (CC). F IG . 32.

4.

Connect fluid line to meter inlet fitting (P).

5.

Calibrate meter as instructed in ProMix Operation manual.

6.

Place board into its correct position and reassemble

RoboMix Panel.

412

438

419

P

M

F

IG

. 32: G250/G250HR Flow Meters

CC

H

412

419

439

440

442

TI12646a

J3 *

4

3

2

1

6

5

J12 *

4

3

2

1

6

5

3X CABLE

PWR (RED)

COM (BLACK)

SIG (WHITE)

SHIELD/GRN

PWR (RED)

COM (BLACK)

SHIELD/GRN

PWR (RED)

SIG (WHITE)

SHIELD/GRN

GROUND

TERMINAL

FLOW METER A

FLOW METER B

FLOW METER SOLVENT

*Connectors on Fluid Station Control Board

F IG . 33: Meter Cable Schematic

54 312780C

Service

Servicing RoboMix Manifold

Manifold Service Kit 15V480 is available. Kit parts are marked with an asterisk, for example (502*). For best results, use all parts in the kit. Lubricate all o-rings during assembly.

1.

Follow Preparation, page 50.

2.

Disconnect all fluid and air lines from the RoboMix manifold (477).

3.

Unscrew the flexible mixer (474) from the integrator cap (511).

4.

Remove the screws (403, 478) and the spacer (465, on the B side). Remove the manifold assembly

(477) from the RoboMix fluid station. F IG . 34.

B Side

A Side

477

465

511

478

403

TI12651a

F

IG

. 34: RoboMix Manifold

312780C 55

Service

5.

Unscrew the integrator cap (511) and housing (510).

Keep A side and B side parts separate when disassembling, to prevent contamination during reassembly.

Inspect the mixer (508) and mix cap (509). Replace

the o-rings (504*). F IG . 35.

6.

Unscrew the integrator manifold plug (507). Remove the integrator base (503). Replace both o-rings

(502*, 504*).

NOTICE

7.

Unscrew the A and B dose valves (521) from the valve adapters (517). Replace the o-rings (518*).

NOTE: To repair the dose valves (521), see manual

312782.

8.

Remove the screws (520) and adapters (517).

Inspect the seat (516). Replace the o-rings (515*).

9.

Remove the screws (513) and the A and B valve mounts (512). Replace the o-rings (505*).

10. Remove the seal screw (506) from the integrator housing (501). Replace the o-ring (505*).

11. Remove the check valves (519*) from each valve adapter (517) and from the elbow (528) on the A side of the manifold. Replace all three check valves.

The arrow on the check valves must face toward the manifold.

12. Remove the pipe plugs (522*) from each valve adapter (517). Replace the plugs.

13. Reassemble in reverse order, following all assembly

notes in F IG . 35.

521

514

2 *518

3 520

506

505*

2

2

2

*504

503

*502

507

1

501

2

505*

512

3

513

F

IG

. 35: Manifold Repair

517

510

1

504*

2

511

1

509

504*

2

515*

516

2

515*

2

522*

508

1 Apply pipe sealant to tapered threads.

2 Lubricate all o-rings.

3 Apply thread sealant.

529

519*

528

TI12513a

56 312780C

Service

Servicing Flow Control

Preparation

1.

Follow Before Servicing, page 38.

2.

Disconnect all air and fluid lines from the flow control regulator.

3.

Disconnect the flow control cable from connector

(624). F IG . 37.

4.

Remove the four screws (605) holding the air plate

(607) to the housing (611). Carefully lift the plate off the housing and disconnect the three cables from

J1, J2, and J4 on the circuit board (618). F IG . 36.

Servicing the Regulator and Pressure

Sensor

Regulator Service Kit 15G843 is available. Kit parts are marked with an asterisk, for example (602*). For best results, use all parts in the kit.

Sensor Service Kit 15G867 is available to service the pressure sensor only. Kit parts are marked with a symbol, for example (602‡). For best results, use all parts in the kit.

1.

Follow Preparation, above.

2.

Remove the four screws (605) and the nut (601) from the underside of the air plate (607). Separate the air plate and fluid plate.

3.

Unscrew the pressure sensor (620) from the fluid plate (606).

NOTE: If you are only replacing the pressure sensor

kit 15G867, skip to step 6.

4.

Remove the plug (615) and o-ring (604) from the top of the fluid plate (606). Remove the parts of the diaphragm assembly (613, 610, 609, 612, 617, 616).

Remove and discard the dowels (623).

5.

Reassemble the diaphragm assembly using the new parts from the kit. Be sure the AIR SIDE of the diaphragm (617) faces down. Torque the nut (601) to

8-10 in-lb (0.9-1.1 N•m).

6.

Install a new o-ring (602) on the pressure sensor

(620) and screw the sensor into the fluid plate (606).

7.

Reinstall the fluid plate on the air plate. Be careful not to pinch the pressure sensor cable. Torque the screws (605) to 30-40 in-lb (3.4-4.5 N•m).

8.

Reconnect the three cables to J1, J2, and J4 on the circuit board (618). F IG . 36.

9.

Reattach the air plate (607) to the housing (611).

Torque the screws (605) to 30-40 in-lb (3.4-4.5

N•m).

10. Reattach the flow control cable and all air and fluid lines.

Servicing the Flow Control Board

1.

Follow Before Servicing, page 38.

2.

Remove the four screws (605) holding the bracket

(614) to the housing (611). F IG . 37.

3.

Carefully separate the bracket from the housing and disconnect the three cables from J1, J2, and J4 on the circuit board (618). F IG . 36.

4.

Remove the screws (621). Replace the old board with the new board.

5.

Reconnect the three cables to J1, J2, and J4 on the circuit board (618). F IG . 36.

6.

Reattach the bracket (614) to the housing (611).

Torque the screws (605) to 30-40 in-lb (3.4-4.5

N•m).

312780C 57

Service

Servicing the V/P Valve

1.

Follow Before Servicing, page 38.

2.

Remove the four screws (605) holding the bracket

(614) to the housing (611). F IG . 37.

3.

Carefully separate the bracket from the housing and disconnect the V/P valve cable from J2 on the circuit board (618). F IG . 36.

4.

Remove the two screws (619a) and o-rings (619b).

Install the new valve (619) with new screws and o-rings.

5.

Reconnect the V/P valve cable to J2 on the circuit board (618). F IG . 36.

6.

Reattach the bracket (614) to the housing (611).

Torque the screws (605) to 30-40 in-lb (3.4-4.5

N•m).

*613

*610

*609

*612

*617

*623

*616

2

605

622

J2 (V/P Valve)

D7 D8 D9

R3

J2

R4

R21

C11

U5

C12 L1

R22

C10

J4

R25

R7

U3

R27

U1

J1

R20

624

619b

619

3

619a

J4 (Pressure Sensor)

F IG . 36: 249179 Flow Control Board

J1 (Power Input)

1 Torque to 8-10 in-lb (0.9-1.1 N•m)

2 Torque to 30-40 in-lb (3.4-4.5 N•m)

3 Torque to 5-7 in-lb (0.6 -0.8 N•m)

F IG . 37: Flow Control

615

604*

Flow direction

606

602*‡

620*‡

601*

1

607

611

603

605

2

621

618

614

605

2

TI12506a

58 312780C

Parts

Parts

ProMix 2KS Automatic Wall Panel System

Configurator Key

The configured part number for your equipment is printed on the equipment identification labels. See the illustrations below for location of the identification labels. The part number includes one digit from each of the following six categories, depending on the configuration of your system. The digits in this table do not correspond to ref. nos. in the parts lists or parts drawings.

Automatic

System

Control and Display

A

A and B Meter Color Valves

D = EasyKey with LCD Display 0 = No Meters 0 = No Valves

(single color)

1 = G3000 (A and B)

2 = G3000HR (A and B)

1 = Two Valves

(low pressure)

3 = 1/8 in. Coriolis (A) and

G3000 (B)

2 = Four Valves

(low pressure)

4 = G3000 (A) and 1/8 in.

Coriolis (B)

3 = Seven Valves

(low pressure)

5 = 1/8 in. Coriolis (A) and

G3000HR (B)

6 = G3000HR (A) and 1/8 in.

Coriolis (B)

4 = Twelve Valves

(low pressure)

Catalyst Valves Flow

Control

0 = No Valves

(single catalyst)

N = No

Y = Yes

1 = Two Valves

(low pressure)

2 = Four Valves

(low pressure)

7 = 1/8 in. Coriolis (A and B)

Label Location on

Fluid Station

TI12423a

Maximum Fluid

Working Pressure is listed here

!"#$" %#$!

(

78

3

4

$#$+" , +-!

!./%0!$# - ( ++ 1

2 1 3/% 1 4

5 6'( # &'(

&'( )'*

!"#$#%%

& '(

( )*

+ )

,-

(

+. /+01%

2* 3

3 :

3( (

9 88

$$!% +1

&&88

Label Location on EasyKey

TI12418a

6-Digit Configured Part No.

312780C 59

Parts

Part No. AD000N to AD742Y, includes EasyKey with LCD display

2

10

2

310

11

329

2

16

12

15

3

8

4

2 Items 310 and 329 are part of the Wall

Mount Fluid Station. See the parts list

beginning on page 69 for descriptions.

9

Detail of Automatic Upgrade Kit (26)

14

TI12553a

60

26 26a

TI12496a

312780C

Parts

4

8

Part No. AD000N to AD742Y, includes EasyKey with LCD display

Ref.

No.

2

3

Configured Digit

(see page 59) or

part usage Part No.

D 277869

Description

CONTROL/DISPLAY, EasyKey; used on AD000N to AD742Y;

see page 66

PANEL, fluid standard part see page

68

standard part 289695

9

10

11

12

6

7

4

5

0 - 4

2

3

0

1

6

7

4

5

2

3

0

1

0 - 4

0 - 2 none

15V804

15V827

15V806

15V804

15V806

15V827

15V806 none

15V804

15V827

15V804

15V806

15V827

15V806

15V806 see page

77

see page

77

see page

77

MANIFOLD, mix; see manual 312781

KIT, flow meter A none

KIT, G3000 flow meter; see manual 308778

KIT, G3000HR flow meter; see manual 308778

KIT, Coriolis flow meter; see manual 313599

KIT, G3000 flow meter; see manual 308778

KIT, Coriolis flow meter; see manual 313599

KIT, G3000HR flow meter; see manual 308778

KIT, Coriolis flow meter; see manual 313599

KIT, flow meter B none

KIT, G3000 flow meter; see manual 308778

KIT, G3000HR flow meter; see manual 308778

KIT, G3000 flow meter; see manual 308778

KIT, Coriolis flow meter; see manual 313599

KIT, G3000HR flow meter; see manual 308778

KIT, Coriolis flow meter; see manual 313599

KIT, Coriolis flow meter; see manual 313599

MODULE, control, color/catalyst change; see page 77

VALVE STACK, color change; see page 77

VALVE STACK, catalyst change; see page 77

14

15

16

26

26a

N

Y used with flow control only used with color change only none

249849

15U977

15U532 standard part 15V256 standard part 15V825

FLOW CONTROL none

REGULATOR, flow control

CABLE, flow control; connects flow control regulator to fluid station; 40 ft (12.2 m)

CABLE, CAN, intrinsically safe; connects color change control module to fluid station; 3 ft (1 m)

KIT, automatic upgrade; includes item 26a

• KIT, board, discrete I/O; part of item 26

Qty

1

1

1 see page

77

see page

77

see page

77

1

1

1

1

1

1

0

1

0

1

0 or 1

1

1

1

1

1

1

0

1

0 or 1

1

1

312780C 61

Parts

62 312780C

Parts

ProMix 2KS Automatic RoboMix Panel System

Configurator Key

The configured part number for your equipment is printed on the equipment identification labels. See the illustrations below for location of the identification labels. The part number includes one digit from each of the following six categories, depending on the configuration of your system. The digits in this table do not correspond to ref. nos. in the parts lists or parts drawings.

Automatic

System

Control and Display

R

A and B Meter

D = EasyKey with LCD Display 0 = No Meters

1 = G250 (A and B)

2 = G250HR (A and B)

Color Valves

0 = No Valves

(single color)

1 = Two Valves

(low pressure)

Catalyst Valves Flow

Control

0 = No Valves

(single catalyst)

N = No

Y = Yes

1 = Two Valves

(low pressure)

2 = Four Valves

(low pressure)

2 = Four Valves

(low pressure)

3 = Seven Valves

(low pressure)

4 = Twelve Valves

(low pressure)

Label Location on

RoboMix Panel

TI12512a

Maximum Fluid

Working Pressure is listed here

!"#$" %#$!

(

78

3

4

$#$+" , +-!

!./%0!$# - ( ++ 1

2 1 3/% 1 4

5 6'( # &'(

&'( )'*

!"#$#%%

& '(

( )*

+ )

,-

(

+. /+01%

2* 3

3 :

3( (

9 88

$$!% +1

&&88

Label Location on EasyKey

TI12418a

6-Digit Configured Part No.

312780C 63

Parts

Part No. RD000N to RD242Y, includes EasyKey with LCD display

2 10

11 12

484

2

2

483

27

25

1

3

2

474

16

15 14

1 Meters (8 and 9) are underneath the

RoboMix cover. See page 72 for location.

2 Items 474, 483, and 484 are part of the

RoboMix Fluid Station. See the parts list

beginning on page 70 for descriptions.

Detail of Automatic Upgrade Kit (26)

27

24

23

25

TI12552a

64

26 26a

TI12496a

312780C

Parts

15

16

23

24

25

10

11

12

14

Part No. RD000N to RD242Y, includes EasyKey with LCD display

Ref.

No.

2

3

Configured Digit

(see page 59) or

part usage Part No.

D 277869 standard part see page

70

Description

CONTROL/DISPLAY, EasyKey; used on RD000N to RD242Y;

see page 66

PANEL, fluid, RoboMix

8

0

1 none

249426

2 249427

9

0

1

2

0 - 4

0 - 4

0 - 2 none

249426

249427 see page

77

see page

77

see page

77

26

26a

27

N

Y used with flow control only used with color change only none

249849

15G611

15U533 standard part 570122 standard part 15G768 standard part

114158

114158 standard part 15V256 standard part 15V825 standard part n/a

Qty

1

1

1

1

1

2

A/R

312780C 65

Parts

EasyKey Controls

277869 EasyKey, with Display

Detail of Display Interface Kit (210)

210a

210d

208

206

214c 214f 201

202

214h

214l,

214m

210b

210e

210c (not part of kit)

TI12554a

214k

214b

214g

214a

201

214d

221

214f

211

TI12417b

66

203

207

212

218

209

205, 206, 209

213, 223, 206

204 215 221

214l,

214m

214e,

214j

211

TI12496b

312780C

Parts

277869 EasyKey, with Display

Ref.

No.

Part No. Description

201 n/a CONTROL BOX, with display

202 116320 SWITCH, power

203 n/a LATCH; includes item 3a

203a 117818 • KEY

204 111987 CONNECTOR, cord strain relief

205 110911 NUT, hex; M5 x 0.8

206 111307 WASHER, lock, external tooth;

M5

207 n/a HOLDER, tie

208 C19293 NUT, hex

209 194337 WIRE, grounding, door

210 15X779 KIT, display, interface; includes items 210a, 210b, 210d, and

210e; does not include 210c

210a n/a

210b n/a

• MEMBRANE

• GRAPHIC, display

210c 255767 • BOARD, EasyKey display

(not part of kit)

210d n/a

210e n/a

• PLATE

• SCREW; 4-40 x 1 in. (25 mm)

211 15D568 ALARM

212 ▲ 15W776 LABEL, warning

213 223547 GROUND WIRE; 25 ft (7.6 m)

214 n/a PLATE, application; includes items 214a-214m

214a 255786 • BOARD, barrier, IS; (includes fuses 15D979 and 114788, see page 43 for fuse location)

214b n/a • COVER

214c 117526 • SPACER

214d 119257 • BAR, ground

214e 114095 • BLOCK, terminal

214f 121314 • POWER SUPPLY; 24 Vdc;

2A

214g n/a • SCREW, machine, pan-hd;

6-32 x 3/8 in. (10 mm)

214h n/a

214j n/a

• SCREW, machine, pan-hd;

6-32 x 1-1/2 in. (38 mm)

• SCREW, machine, pan-hd;

8-32 x 3/4 in. (19 mm)

214k n/a • SCREW, machine, pan-hd;

10-24 x 3/8 in. (10 mm)

Qty

1

4

9

1

1

1

1

1

3

2

2

11

1

4

1

1

8

6

1

1

1

1

1

1

1

1

1

1

3

1

Part No.

15U531

15U532

15V205

15V206

15V207

15V208

15U533

15V213

Ref.

No.

Part No. Description

214l 123823 • FILTER, line, single-phase;

110/250 V; 3 A

214m 123824 • BRACKET, line filter

215 15V280 HARNESS, connection

216 15G569 LABEL, EasyKey inputs

218 15R642 HARNESS, wire

220 n/a SOFTWARE, application

221 198165 CONNECTOR, RJ45, with bulkhead fitting

223 116343 SCREW, ground; M5 x 0.8

224 15G869 CABLE, ethernet, CAT5; 6 ft

(1.8 m); to make web interface connection to a computer

Qty

1

1

1

1

1

1

1

1

1

▲ Replacement Danger and Warning labels, tags, and cards are available at no cost.

Parts labeled n/a are not available separately.

Available Cables

Part No.

15D320

15G710

CAN Cables

Length ft (m) Usage

2 (0.61)

3 (0.92)

6 (1.83)

10 (3.05)

Option

Standard color change

Option

Option

15 (4.57)

25 (7.62)

Option

Option

50 (15.25) Standard power

100 (30.50) Option

Fiber Optic Cables

Length

50 (15.25) Standard

100 (30.50) Option

Usage

312780C 67

Parts

Wall Mount Fluid Station

305

306

314

316

322

307

319

320

340

303

302

See Detail Below

301

314 315

341 325 321 335

317

339

318, 332

Control Board Fuses

TI12425a

343

313

68

311

309

Solenoid Manifold Detail

308

323

342

328

324 331 312

330

328

TI12426a TI12652b

312780C

Parts

Wall Mount Fluid Station

NOTE: Parts are shown on page 68, unless noted.

Ref.

No.

Part No. Description

301 256529 ENCLOSURE

302 255765 BOARD, circuit

303 n/a SCREW, machine, pan hd;

4-40 x 3/16 in. (5 mm)

304 119257 CONNECTOR, bar, ground

305 119162 CONNECTOR, plug, 6-position

306 116773 CONNECTOR, plug,10-position

307 113783 SCREW, machine, pan hd;

1/4-20 x 1/2 in. (13 mm)

308 15R668 MANIFOLD, solenoid, 5 station

309 C06061 MUFFLER

310 15U533 CABLE, CAN, intrinsically safe;

50 ft (15.25 m); see page 60 for

location

311 112781 ELBOW, swivel, 90°; 1/8 npt(m) x 1/4 in. (6 mm) OD tube

312 114263 FITTING, tube; 1/8 npt(m) x

5/32 in. (4 mm) OD tube

313 121374 VALVE, solenoid, 4-way, intrinsically safe; 12 Vdc

314 111987 CONNECTOR, cord strain relief

315 114669 SCREW, machine, phillips pan hd; M5 x 0.8; 10 mm

316 n/a PLATE, mounting

317 114124 FILTER, air; 3/8 npt; includes

317a

317a 114228 • ELEMENT, filter; 5 micron

318 116343 SCREW, ground

319 100985 WASHER, lock, external tooth;

1/4

320 101345 NUT, hex, jam; 1/4-20

321 120685 GROMMET

322 15U507 COVER, enclosure

323 100139 PLUG, pipe; 1/8 npt

324 552183 PLATE, blanking

Qty

1

1

4

1

8

4

5

2

1

1

1

4

1

6

1

2

1

1

1

4

1

2

4

2

1

Ref.

No.

Part No. Description

325 15U510 BRACKET, mounting, mix manifold

327 n/a COVER, fluid station

328 121072 MUFFLER

329 15D320 CABLE, fiber-optic, twin; 50 ft

(15.25 m); see page 60 for

location

330 104644 PLUG, screw; 10-32 x 5/32 in.

(4 mm)

331 121628 SCREW, machine, self-sealing; 4-40 x 1/4 in. (6 mm)

332 223547 WIRE, ground; 25 ft (7.6 m)

334 n/a TUBE, nylon; to connect air manifold (335) to elbow (311) at solenoid manifold (308); 1/4 in.

(6 mm) OD; 2.5 ft (0.76 m)

335 15U679 MANIFOLD, air; 3/8 npt(m) x six 1/4 in. (6 mm) OD tube ports

336 n/a TUBE, nylon, green; for control air to turn valves on; 5/32 in.

(4 mm) OD; four 2 ft (0.6 m) lengths

337 n/a TUBE, nylon, red; for control air to turn valves off; 5/32 in.

(4 mm) OD; four 2 ft (0.6 m) lengths

338 16J457 TUBE, nylon; for purge air supply; 1/4 in. (6 mm) OD; 25 ft

(7.6 m); includes caution label

626413

339

186620 LABEL, symbol, ground

340

15W775 LABEL, warning

341 C19798 SCREW, cap, socket-hd; 1/4-20 x 3/8 in. (10 mm)

342 104640 GASKET

343

123690 FUSE; 125 mA

Qty

1

2

8

1

A/R

1

A/R

A/R

1

3

2

1

2

1

1

1

3

Replacement Danger and Warning labels, tags, and cards are available at no cost.

Replacing the fuse with a non-Graco fuse voids the

IS system safety approval.

Parts labeled n/a are not available separately.

312780C 69

Parts

RoboMix Fluid Station

NOTE: Parts are shown on pages 72 and 73, unless noted.

RoboMix Panel, no dump valve

RoboMix Panel, one dump valve

RoboMix Panel, two dump valves (shown)

Ref.

No.

Part No. Description

401 15U712 PANEL, RoboMix

402 C19979 SCREW, cap, socket-hd; 10-24 x 3/8 in. (10 mm)

Panel with no dump valve

Panel with one dump valve

Panel with two dump valves

403 C19798 SCREW, cap, socket-hd;

1/4-20 x 3/8 in. (10 mm)

404 114339 UNION, swivel; 1/4 npt(m) x

1/4 npsm(f); sst

Panel with no dump valve

Panel with one dump valve

Panel with two dump valves

406 111307 WASHER, lock, external tooth;

M5

407 110911 NUT, hex; M5 x 0.8

408 15U713 VALVE, adapter, RoboMix

Panel with no dump valve

Panel with one dump valve

Panel with two dump valves

409 15U714 VALVE, adapter, RoboMix

410 15U716 COVER, panel, RoboMix

411 15U853 FITTING, bulkhead, 1/4 npt x

M20

412 104371 SCREW, cap, socket-hd; 10-32 x 3/8 in. (10 mm)

413 15U717 HOSE, component B supply;

1/4 npt(mbe); ptfe; 7.5 in. (191 mm)

414 15U718 HOSE, component A supply;

1/4 npt(mbe); ptfe; 8 in. (203 mm)

415 15U719 HOSE, solvent; 1/4 npt(mbe); ptfe; 12 in. (305 mm)

Qty

1

1

6

1

1

1

8

12

16

4

7

1

5

6

3

1

1

2

1

2

Ref.

No.

Part No. Description

416 15U720 HOSE, component A dump;

1/4 npt(mbe); ptfe; 15.5 in. (394 mm)

Panel with no dump valve

Panel with one dump valve

Panel with two dump valves

417 15U721 HOSE, component B dump;

1/4 npt(mbe); ptfe; 10.5 in. (267 mm)

Panel with no dump valve

Panel with one dump valve

Panel with two dump valves

419 104116 WASHER, plain; no. 10

420 700332 SCREW, thumb; 8-32

421 15X304 VALVE, dispense; includes item 422; see 312782

Panel with air and solvent purge valves, no dump valve

Panel with air and solvent purge valves, one dump valve

422 n/a

Panel with air and solvent purge valves, two dump valves

O-RING; ptfe

Panel with no dump valve

Panel with one dump valve

Panel with two dump valves

423 166421 NIPPLE; 1/4 npt

Panel with no dump valve

Panel with one dump valve

Panel with two dump valves

424 101970 PLUG, pipe; 1/4 npt; sst

425 15U723 SUPPORT, board, RoboMix

426 255765 BOARD, circuit

427 15U724 COVER, board, RoboMix

Qty

2

3

4

0

1

1

1

6

0

0

6

2

3

4

1

1

1

2

1

0

1

70 312780C

Parts

Ref.

No.

Part No. Description

428 107295 SCREW, machine, pan-hd;

4-40 x 3/16 in. (5 mm)

429 15U725 MANIFOLD, solenoid, RoboMix

431 109193 ELBOW, tube; 10-32 x 5/32 in.

(4 mm) OD tube

432 108382 FITTING, seal, o-ring; 10-32

433 120053 ELBOW, tube; 10-32 x 1/4 in.

(6 mm) OD tube

434 111328 CONNECTOR, male; 10-32 x

5/32 in. (4 mm) OD tube

435 113933 ELBOW, 45°; 1/4 npt (m x f)

436 111987 CONNECTOR, cord strain relief

437 120030 PLATE, blank, solenoid

Panel with no dump valve

Panel with one dump valve

Panel with two dump valves

438 15U726 METER, mount, RoboMix

439 15U727 SPACER, meter, RoboMix

440 117018 WASHER

441 116899 SCREW, cap, socket-hd; M6 x

1; 10 mm; sst

442 117028 SCREW, cap, socket-hd; M6 x

1.0; 16 mm

443 114446 ELBOW, swivel, 90°; 1/4 npt(m) x 1/4 npsm(f); sst

Panel with no dump valve

Panel with one dump valve

Panel with two dump valves

458 501867 VALVE, check; 1/4 npt (mbe)

463 119257 CONNECTOR, bar, ground

464 801012 GROMMET

465 15U730 SPACER, valve mount, Robo-

Mix

466 15U928 CABLE, 90°, for G250 and

G250HR meters; see page 34

for connection points

474 949122

KIT, flexible mixer; see page 64

477 256654 MANIFOLD, RoboMix; see

page 74

Qty

4

5

2

2

1

4

8

1

2

3

1

1

1

4

2

1

1

3

2

1

2

1

2

1

0

1

Ref.

No.

Part No. Description

478 C19810 SCREW, cap, socket-hd;

1/4-20 x 1 in. (25 mm)

479 15X764 SEAT, valve

Panel with no dump valve

Panel with one dump valve

Panel with two dump valves

480 116343 SCREW, ground; M5 x 0.8

483 15D320 CABLE, fiber-optic, twin; 50 ft

(15.25 m); see page 64 for

location

484 15U533 CABLE, CAN, intrinsically safe;

50 ft (15.25 m); see page 64 for

location

485 ▲ 15G809 LABEL, safety

486 121795 VALVE, solenoid, 4-way

Panel with no dump valve

Panel with one dump valve

Panel with two dump valves

488 104176 BULKHEAD, tube; 1/4 in. (6 mm) OD both ends

489 223547 WIRE, ground, 25 ft (7.6 m)

490 116658 FITTING, tube; 1/4 npt(m) x 1/4 in. (6 mm) OD tube

492 n/a TUBE, air; polyethylene; 1/4 in.

(6 mm) OD; 1-1/2 ft (0.46 m)

493 15V267 KIT, ratio check, RoboMix

494 15G795 CONNECTOR, plug, 6 position

495 15V409 CONNECTOR, plug, 10 position

496 15V888 RETAINER, seat, valve

Panel with no dump valve

Panel with one dump valve

Panel with two dump valves

497 ◆ 123690 FUSE; 125 mA

Qty

2

1

1

▲ Replacement Danger and Warning labels, tags, and cards are available at no cost.

◆ Replacing the fuse with a non-Graco fuse voids the

IS system safety approval.

Parts labeled n/a are not available separately.

1

2

4

1

2

3

1

6

1

4

5

1

1

4

1

4

1

2

3

312780C 71

Parts

RoboMix Fluid Station

410

427

420

412

419

72

401

See page 73

for detail.

412

419

434

TI12507a

432

437

Detail of Flow Meter Assembly

1

See page 65

for description.

404

1

8

429

433

486

440

441

Detail of Circuit Board Assembly

426

428

497

428

420

464

463

425

420

436

TI12508a

9

1

439

403

404

438

440

442

TI12509a

312780C

RoboMix Fluid Station

Detail of Connection Ports

B Inlet

402

488

423;

B Dump Outlet

421

422

496

A Inlet

Air

Logic

Inlet

490;

Air Purge

Inlet

423;

A Dump

Outlet

458;

Solvent

Inlet

TI12511a

480, 489

411 406 407

Parts

Detail of Ratio Check Kit (493)

TI12514a

477

See page 74

for detail.

465

312780C

479

435

424

409

490

414

408

404

415

492 416

413

467

417

478

403

TI12510a

73

Parts

256654 RoboMix Manifold

Ref.

No.

Part No. Description

501 15U728 HOUSING, integrator, RoboMix

502

◆ n/a O-RING; ptfe

*

503 15T943 BASE, integrator

504

◆ n/a O-RING; ptfe

*

505* n/a O-RING; ptfe

506 15T748 SEAL, screw; 1/4-28

507 15T592 PLUG, integrator manifold

508

◆ n/a

509

◆ n/a

510

◆ n/a

511

◆ n/a

MIXER, integrator, 25cc

CAP, mix

HOUSING, 25 cc

CAP, housing

512 15U729 VALVE, mount, RoboMix

513 101885 SCREW, cap, socket-hd; 1/4-20 x 1-3/4 (44 mm)

514 114446 UNION, 90°; 1/4 npt(m) x 1/4 npsm(f)

515* n/a O-RING; ptfe

516 15U686 SEAT, valve needle, high pressure

Qty

1

1

1

1

3

4

2

1

2

1

1

4

1

1

3

1

Ref.

No.

Part No. Description

517 15T600 ADAPTER, valve

518* n/a O-RING; ptfe

519* 501867 VALVE, check

520 15T875 SCREW, cap, socket-hd;

5/16-24 x 5/8 in. (16 mm)

521 15X303 VALVE, dispense; includes item

518; see 312782

522* 101970 PLUG, pipe

528 166866 ELBOW, street; 1/4 npt (m x f)

529 114112 FITTING; 1/4 npt(f) x 1/4 in. (6 mm) OD tube

Qty

3

4

2

2

2

2

1

1

* Parts included in Manifold Service Kit 15V480.

Purchase separately.

Parts included in 25cc Integrator Service Kit 15V033.

Purchase separately.

Parts labeled n/a are not available separately.

74 312780C

Parts

256654 RoboMix Manifold

521

*518

520

506

505*

514

*

502

503

* ◆ 504

507

501

505*

512

513

515*

516

515*

517

522*

508

504 ◆ *

509 ◆

510 ◆

504 ◆ *

511

529

519*

528

TI12513a

312780C 75

Parts

249849 Flow Control Regulator

Ref.

No.

Part No. Description

601* 102980 NUT, full, hex; 4-40

602‡* n/a O-RING; chemically resistant fluoroelastomer

603 112698 ELBOW; 1/8 npt(m) x 1/4 in.

(6 mm) OD tube

604* n/a O-RING; chemically resistant fluoroelastomer

605

606

607

609* n/a

610* n/a n/a SCREW, cap, socket-hd;

10-32 x 1/2 in. (13 mm) n/a PLATE, fluid, regulator

15F799 PLATE, air, regulator

SEAT, regulator

RETAINER, seat

611 n/a

612* n/a

613* n/a

614 n/a

HOUSING, flow control

SPACER, regulator

NEEDLE, regulator

BRACKET, flow control

615 15F806 PLUG, regulator

616* 168881 GASKET; acetal

617* 178321 DIAPHRAGM, regulator

618 249179 BOARD, circuit assembly

619 120013 VALVE, proportional, V/P; includes items 619a and 619b

619a n/a • SCREW, cap, socket-hd;

M3 x 0.5 x 44 mm

619b n/a

620‡* n/a

621

• O-RING, mounting

SENSOR, pressure control

107295 SCREW, machine, pan-hd;

4-40 x 3/16 in. (5 mm)

622 104765 PLUG, pipe; 1/8 ptf

623* 192387 PIN, dowel

624 15G613 WIRE HARNESS, flow control

Qty

1

1

1

1

12

2

2

1

4

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

* Parts included in Regulator Service Kit 15G843.

Purchase separately.

Parts included in Sensor Service Kit 15G867.

Purchase separately.

Parts labeled n/a are not available separately.

*613

*610

*609

*612

*617

*623

*616

2

605

622

624

619b

619

3

619a

614

1 Torque to 8-10 in-lbs (0.9-1.1 N•m)

2 Torque to 30-40 in-lbs (3.4-4.5 N•m)

3 Torque to 5-7 in-lbs (0.6 -0.8 N•m)

615

604*

Flow direction

606

602*‡

620*‡

601*

1

607

611

605

2

621

618

603

605

2

TI12506a

76 312780C

Color Change Accessory Kits

Low Pressure Color Change Kits

Kit Part

No.

256581

256582

256583

256584

256585

256586

256587

256588

256589

256590

256591

256592

256593

256594

256595

Kit Description

2 color

4 color

7 color

12 color

2 color/2 catalyst

4 color/2 catalyst

4 color/4 catalyst

7 color/2 catalyst

7 color/4 catalyst

12 color/2 catalyst

12 color/4 catalyst

13-18 color

13-24 color

13-30 color

1 catalyst/1 flush

Control Module

(10; see 312787)

277752

277753

277754

277755

277756

277757

277771

277758

277772

277759

277773

278113

278114

277773

278095

Color Change

Valve Stack (11; see 312783)

15V812

15V813

15V814

15V815

15V812

15V813

15V813

15V814

15V814

15V815

15V815

256293

15V815

256305 none

Catalyst Change

Valve Stack (12; see 312783) none none none none

15V812

15V812

15V813

15V812

15V813

15V812

15V813 none none none

256994

Parts

312780C 77

Parts

78 312780C

Technical Data

Technical Data

Maximum fluid working pressure . . . . . . . . . . . . . . . Base system: 4000 psi (27.58 MPa, 275.8 bar)

Low pressure color change: 300 psi (2.07 MPa, 20.6 bar)

Coriolis meter: 2300 psi (15.86 MPa, 158.6 bar)

RoboMix system: 190 psi (1.31 MPa, 13.1 bar)

Flow control: 190 psi (1.31 MPa, 13.1 bar)

Maximum working air pressure. . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7 bar)

Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 - 100 psi (0.5 - 0.7 MPa, 5.2 - 7 bar)

Air filter inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 npt(f)

Air filtration for air logic and purge air

(Graco-supplied). . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 micron (minimum) filtration required; clean and dry air

Air filtration for atomizing air (user-supplied) . . . . . . 30 micron (minimum) filtration required; clean and dry air

Mixing ratio range . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1:1- 50:1*

On-ratio accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . up to + 1%, user selectable

Fluids handled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . one or two component:

• solvent and waterborne paints

• polyurethanes

• epoxies

• acid catalyzed varnishes

• moisture sensitive isocyanates

Viscosity range of fluid . . . . . . . . . . . . . . . . . . . . . . . 20- 5000 cps*

Fluid filtration (user-supplied) . . . . . . . . . . . . . . . . . . 100 mesh minimum

Fluid flow rate range*

G3000, G250 Meter . . . . . . . . . . . . . . . . . . . . . .

G3000HR, G250HR Meter. . . . . . . . . . . . . . . . .

75 - 3800 cc/min. (0.02-1.00 gal./min.)

38 - 1900 cc/min. (0.01-0.50 gal./min.)

Coriolis Meter. . . . . . . . . . . . . . . . . . . . . . . . . . .

S3000 Solvent Meter (accessory) . . . . . . . . . . .

20 - 3800 cc/min. (0.005-1.00 gal./min.)

38 - 1900 cc/min. (0.01-0.50 gal./min.)

Fluid inlet sizes

Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dose Valve/Color Valve Adapters . . . . . . . . . . .

1/4 npt(f)

1/4 npt(f)

Fluid outlet size (static mixer) . . . . . . . . . . . . . . . . . . 1/4 npt(f)

External Power Supply Requirements . . . . . . . . . . . 85 - 250 Vac, 50/60 Hz, 2 amps maximum draw

15 amp maximum circuit breaker required

8 to 14 AWG power supply wire gauge

Operating temperature range . . . . . . . . . . . . . . . . . . 41- 122° F (5-50° C)

Environmental Conditions Rating . . . . . . . . . . . . . . . indoor use, pollution degree (2), installation category II

Noise Level

Sound pressure level . . . . . . . . . . . . . . . . . . . . .

Sound power level . . . . . . . . . . . . . . . . . . . . . . .

below 70 dBA below 85 dBA

Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303, 304 SST, Tungsten carbide (with nickel binder), perfluoroelastomer; PTFE

* Dependent on programmed K-factor and application. The maximum allowable flow meter pulse frequency is 425

Hz (pulses/sec). For more detailed information on viscosities, flow rates, or mixing ratios, consult your Graco distributor.

See individual component manuals for additional technical data.

312780C 79

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 312780

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441

Copyright 2009, Graco Inc. is registered to ISO 9001 www.graco.com

Revised 05/2011

advertisement

Was this manual useful for you? Yes No
Thank you for your participation!

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

Related manuals

Download PDF

advertisement

Table of contents