Graco TI12553a - Manual

System Configuration and Part Numbers 312779E 5 Standard Features 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. Maximu...

System Configuration and Part Numbers 6 312779E 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 followin...

Accessories 8 312779E 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 Dosi...

Warnings 312779E 9 Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manua...

Important Two-Component Material Information 312779E 11 Important Two-Component Material Information Isocyanate Conditions Material Self-ignition Keep Components A and B Separate Moisture Sensitivity of Isocyanates Isocyanates (ISO) are catalysts used in two component coatings. ISO will react with m...

Glossary of Terms 12 312779E Glossary of Terms Air Chop - the process of mixing air and solvent together during the flush cycle to help clean the lines and reduce solvent usage. Air Chop Time - duration of each activation of the air purge valve during a chop sequence. User settable from 0.0-99.9 sec...

Overview 14 312779E Overview Usage The Graco ProMix 2KS is an electronic two-component paint proportioner. It can blend most two-component solvent and waterborne epoxy, polyurethane, and acid-catalyzed paints. It is not for use with “quick-setting” paints (those with a potlife of less than 15 minute...

Overview 16 312779E Wall Mount System Components F IG . 3. Wall Mount System, shown with G3000 Meters, Color/Catalyst Change, Accessory Solvent Meter, and Flow Control TI12553a FO* FC PS* EK ST ACV CCM MS MA MB FM BCV * See the ProMix 2KS Repair-Parts manual for optional cable lengths.

Overview 18 312779E RoboMix System Components F IG . 5. RoboMix System shown with Color/Catalyst Change and Flow Control TI12552a Purge Air RoboMix Control Air Air Controls FO* FC PS* EK RS ACV CCM BCV * See the ProMix 2KS Repair-Parts manual for optional cable lengths.

EasyKey Display and Keyboard 20 312779E EasyKey Display and Keyboard Display Shows graphical and text information related to setup and spray operations. Back light will turn off after 10 minutes without any key press. Press any key to turn back on. Keypad Used to input numerical data, enter setup sc...

EasyKey Display and Keyboard 312779E 21 AC Power Switch Turns system AC power on or off. I/S Power Power circuit to Fluid Station. Potlife Exceeded Audible Alarm Alerts the user when a Potlife Exceeded alarm occurs. Clear by pressing the Alarm Reset key. Graco Web Interface Port Used to communicate ...

Run Mode Screens 22 312779E Run Mode Screens NOTE: See F IG . 11 for a map of the Run screens. Detailed screen descriptions follow. Splash Screen At power up, the Graco logo and software revision will display for approximately 5 seconds, followed by the Status Screen (see page 24). The Splash screen...

Run Mode Screens 312779E 25 Manual Override Screen This screen will appear if Manual Override is set to “On” in Advanced Setup Screen 1 (page 39). It shows the active recipe, new/go to recipe, and manual override mode. If Flow Control is set to “On” in Configure Screen 5 on page 34, this screen will...

Run Mode Screens 26 312779E Global Flow Control Data Copy This field allows you to copy flow control data from the active recipe to all recipes. Press the Enter key to view the menu, then select Start or Abort. See F IG . 16. Totals Screen This screen shows the job totals, grand totals, and job numb...

Run Mode Screens 312779E 27 Alarms Screen Two screens show the last 10 alarms. Use the Up or Down keys to scroll between the two screens. See Table 16 on page 115 for a list of alarm codes. Level Control Screen This screen shows the current volume for each fluid. Adjust the current volumes on this s...

Setup Mode 28 312779E Setup Mode Press the Setup key to enter Setup mode. NOTE: See F IG . 23 for a map of the Setup screens. Detailed screen descriptions follow. F IG . 23. Setup Screens Map To access Advanced Setup Screens , page 38 and Recipe Setup Screens , page To access System Configuration Sc...

Setup Mode 312779E 29 Password Screen If a password has been activated (see Configure Screen 1 , page 32), the Password screen will appear. You must enter the password to access the Set Up Home Screen . Entering the wrong password returns the display to the Status Screen . NOTE: If you forget the pa...

Setup Mode 312779E 31 System Configuration Screens NOTE: See F IG . 27 for a map of the System Configura- tion Screens . Detailed screen descriptions follow. NOTE: Each screen displays the current screen number and the total number of screens in the group. F IG . 27. System Configuration and Option ...

Setup Mode 32 312779E Configure Screen 1 Language Defines the language of the screen text. Select English (default), Spanish, French, German, Italian, Dutch, Jap-anese (Kanji), Korean, and Chinese (Simplified). Password The password is only used to enter Setup mode. The default is 0, which means no ...

Setup Mode 312779E 33 Configure Screen 3 Run Mode Select the Run mode application from the pulldown menu: Automatic (default), Semi-Automatic (uses a manual spray gun), or Manual. NOTE: ProControl 1KS is also available as a selection. For further information, see ProControl 1KS operation manual 3A10...

Setup Mode 34 312779E DD Setup Mode See F IG . 32 and F IG . 33. Selecting “DD” makes the Dynamic Dosing Setup mode field appear. Select On to enable DD setup mode, or Off to disable. See page 86 for further information. Dose Time Alarm Enter the dose time (1 to 99 seconds). This is the amount of ti...

Setup Mode 312779E 35 Configure Screen 6 Flow Control This field only appears if Run Mode is set to “Automatic” in Configure Screen 3 , page 33 and Flow Control is set to “On” in Configure Screen 5 , page 34. Select “Dis- crete” or “Network.” Proportioning Select “Discrete” or “Network.” Gun 1 Trigg...

Setup Mode 36 312779E Option Screens NOTE: See F IG . 27 on page 31 for a map of the Option Screens . Detailed screen descriptions follow. NOTE: Each screen displays the current screen number and the total number of screens in the group. Option Screen 1 Flush Volume Check This field only appears if ...

Setup Mode 312779E 37 Option Screen 2 External Color Change If set to “Off”, Color/Catalyst Purge Time and Color/Cat-alyst Fill Time appear in Advanced Setup Screen 1 , page 39 or Recipe Setup Screen 2 , page 44 (depend- ing on whether Flush and Fill Inputs are set to “Global” or “Recipe”). If set t...

Setup Mode 312779E 39 NOTE: Each screen displays the current screen number and the total number of screens in the group. The total number of screens in a group and the fields displayed on each screen may vary depending on selections made in the System Configuration Screens and Option Screens . Advan...

Setup Mode 40 312779E Advanced Setup Screen 2 This screen appears only if Flush and Fill Input is set to “Global” in Option Screen 1 , page 36. First Purge Source Select “Air,” “Solvent,” or “3rd Flush Valve” (available only if 3rd Flush Valve is set to “On” in Configure Screen 3 on page 33). Chop T...

Setup Mode 312779E 41 Advanced Setup Screen 4 This screen appears only if K-factor Input is set to “Global” in Option Screen 1 , page 36. K-factor A Meter Enter the k-factor (cc/pulse) for flow meter A. This is the amount of material that passes through the flow meter per pulse (electrical pulse sig...

Setup Mode 42 312779E Advanced Setup Screen 6 This screen shows the status of recipe analog inputs and digital outputs. If box is shaded the input recipe is active. Advanced Setup Screen 7 This screen shows the status of digital inputs and digital outputs. If box is shaded the input is active. If no...

Setup Mode 312779E 43 Recipe Setup Screens NOTE: See F IG . 49 for a map of the Recipe screens. Detailed screen descriptions follow. F IG . 49: Recipe Screens Map TI12806a Recipe 0 Screens Recipe screens 3, 4, 5, 6, and 7 appear depending on selections made in Option screens 1 and 2

Setup Mode 44 312779E NOTE: Each screen displays the current screen number and the total number of screens in the group. The total number of screens in a group and the fields displayed on each screen may vary depending on selections made in the System Configuration Screens and Option Screens . Recip...

Setup Mode 312779E 45 Recipe Setup Screen 3 This screen appears only if Flush and Fill Input is set to “Recipe” in Option Screen 1 , page 36. First Purge Source Select “Air,” “Solvent,” or “3rd Flush Valve” (available only if 3rd Flush Valve is set to “On” in Configure Screen 3 on page 33). Chop Typ...

Setup Mode 46 312779E Recipe Setup Screen 5 This screen appears only if K-factor Input is set to “Rec-ipe” in Option Screen 1 , page 36. K-factor A Meter Enter the k-factor (cc/pulse) for flow meter A. This is the amount of material that passes through the flow meter per pulse (electrical pulse sign...

Setup Mode 312779E 47 Recipe 0 Screens NOTE: See F IG . 49 on page 43 for a map of the Recipe 0 screens. Detailed screen descriptions follow. Recipe 0 is typically used:• in multiple color systems to purge out material lines without loading a new color • at the end of a shift to prevent hardening of...

Setup Mode 48 312779E Recipe 0 Screen 3 This screen only appears if Solvent Monitor is set to “Meter” in Configure Screen 5 , page 34 and Flush Vol- ume Check is set to “On” in Option Screen 1 , page 36 or 3rd Flush Valve is set to “On” in Configure Screen 3 on page 33. Minimum Flush Volume This fie...

Setup Mode 312779E 49 Calibration Screen Use this screen to calibrate a meter. Set to “Meter A,” “Meter B,” or “Solvent Meter” (available if Solvent Moni-tor in Configure Screen 5 , page 34, is set to “Meter”). • Start - start calibration • Abort - stop calibration • Purge - purge sampling valves af...

ProMix 2KS Integration Specifics 312779E 51 ProMix 2KS Integration Specifics Discrete I/O vs Network Communications The ProMix 2KS Automatic system does not use a Booth Control. Instead, it uses Discrete I/O or Network Communications to drive the system. Each method can be used exclusively, or both ...

ProMix 2KS Integration Specifics 52 312779E Digital Inputs See Automation Flow Charts , pages 55-59. Mix Start: This is a maintained input. When High, the ProMix 2KS will attempt to enter Mix mode. This Mix Start input should not be attempted unless the Mix_Ready output is recognized. This ensures t...

ProMix 2KS Integration Specifics 312779E 53 F IG . 64: 255766 Discrete I/O Board JLS P u rge I nput Jo b Com plet e Input Ex te rnal Color C hange Re ady S pare Digital I n put Comm on S pecial O u tput #4 Mix I nput Recipe Change Input Recipe Bit 0 Input Flow Rate Alarm Output Flow Control Calibrat...

ProMix 2KS Integration Specifics 54 312779E Digital Outputs See Automation Flow Charts , pages 55-59. Purge_CC_Active: This output will remain High during the manual Purge or Color Change purge sequence. See the Color Change Charts (F IG . 109-F IG . 126) for fur- ther information. Fill_Active: This...

ProMix 2KS Integration Specifics 312779E 55 Automation Flow Charts Start Mix Mode Process See F IG . 65, Table 5, and Table 6. F IG . 65. Start Mix Mode Process Flow Chart Start Mix Mode Process Is Mix Ready bit = 1? Must be Alarm Condi- tion or Active Recipe 61. See Alarm Pro- cessing on page 59, o...

ProMix 2KS Integration Specifics 56 312779E Mixing Mode Process See F IG . 66, Table 5, and Table 6. F IG . 66. Mixing Mode Process Flow Chart Mixing Mode Process Is Mix Active bit = 1? Check Alarm Condition: is Alarm_ General bit = 1? YES NO NO YES Mixing Mode is desired. PLC is polling to ensure M...

ProMix 2KS Integration Specifics 312779E 57 Purge Mode Process See F IG . 67, Table 5, and Table 6. F IG . 67. Purge Mode Process Flow Chart Start Is Mix Ready bit = 1? Must be Alarm Condition or Active Recipe 61. See Alarm Processing on page 59, or Startup from Recipe 61 (see NOTE below). YES NO NO...

ProMix 2KS Integration Specifics 58 312779E Color Change Mode Process See F IG . 68, Table 5, and Table 6. F IG . 68. Color Change Mode Process Flow Chart Color Change Process (basic) Is Purge_CC_Active bit = 1? Check Alarm Condition: is Alarm_ General bit = 1? YES NO NO YES Is Active Recipe = to de...

Integrated Flow Control 312779E 67 Integrated Flow Control Flow Control Description Flow control is an optional feature which incorporates an intrinsically safe regulator control module with the Pro-Mix 2KS automatic system. Flow control precisely regu-lates the flow of material to a manual or autom...

Integrated Flow Control 68 312779E Fluid and Air Pressure Requirements The fluid input pressure to the fluid regulator must be high enough to provide a 15-20 psi (0.1-0.14 MPa, 1.0-1.4 bar) pressure differential across the regulator at the highest flow setting. For example, if the maximum flow rate ...

Integrated Flow Control 70 312779E Flow Control Operating Process Example Operating Ranges Flow Control operating ranges correlate the desired flow rate to the incoming flow set point signal (see below). The operating ranges are: • 0-300 cc/min • 0-600 cc/min • 0-1200 cc/min • 0-100% (% open in manu...

Integrated Flow Control 72 312779E Flow Control Setup 1. Install the intrinsically safe flow regulator (FC) as explained in the ProMix 2KS Installation Manual. 2. Ensure that the analog signal is 0-10 Vdc, or is properly provided through network communication. 3. Calibrate the system’s flow meters; ...

Integrated Flow Control 74 312779E Flow Control Calibration Flow Control Calibration is an automatic routine that establishes a pressure vs flow profile between low and high operating points. See F IG . 86. The profile may be unique to each recipe or may be globally copied to all recipes. NOTE: Cali...

Integrated Flow Control 312779E 75 5. Return to the Status Screen (see F IG . 85). The sta- tus bar at the bottom of the screen will indicate that Mix Calibration is in progress. 6. Trigger the gun and make sure the gun trigger input is high. 7. On the Status Screen (see F IG . 85), the voltage will...

Integrated Flow Control 76 312779E Global FC Data Copy Set Global FC Data Copy to Start on the Manual Over- ride Screen (see F IG . 87). Global copy provides a start- ing point for all recipes, enabling Continuous Learning (see page 76) to take over. Global copy works very well with multiple colors ...

Integrated Flow Control 312779E 77 Pressure Flow Control Mode When the Flow Control Override is set to “Pressure”, the system will only drive to the pressure associated with the flow rate request of the saved calibration table. It will not close the loop with the flow meters. This mode may be used w...

Integrated Flow Control 78 312779E Flow Control Troubleshooting Problem: Flow Command does not produce fluid output. Test the system as follows, to determine if the problem is mechanical or electrical. 1. Install a 0-100 psi (0-0.7 MPa, 0-7.0 bar), 1/8 npt(m) air pressure gauge (not supplied) as fol...

System Operation 80 312779E System Operation Operation Modes Mix System mixes and dispenses material (apply Mix input). Standby Stops the system (remove Mix input). Purge Purges the system, using air and solvent (apply Purge input). Sequential Dosing Components A and B dispense sequentially in the n...

System Operation 312779E 81 Typical PLC Interaction with ProMix 2KS This section describes a typical interaction when a local PLC is directly connected to the Discrete I/O connec-tions of the ProMix 2KS. See ProMix 2KS Integration Specifics on page 51 for a detailed explanation of inputs and outputs...

System Operation 82 312779E Alarm Monitoring/Reset (Discrete I/O) Anytime an alarm occurs, the Alarm Reset input will reset the alarms and allow for processing of the next step by automation, except for the following condi- tions: • Potlife Alarms cannot be reset by the Alarm Reset input or through ...

System Operation 312779E 85 General Operating Cycle, Dynamic Dosing Overview Dynamic Dosing provides on-demand proportioning, eliminating the need for an integrator and therefore min-imizing undesired material contact. This feature is espe-cially useful with shear-sensitive and waterborne materials....

System Operation 86 312779E Select a Component B Restrictor Size Install the 15U955 Injection Kit in the fluid manifold as explained in the ProMix 2KS Installation manual. Use the charts provided in that manual to select an appropri-ate restrictor size based on the desired flow and mix ratio. Turn O...

System Operation 312779E 87 Balancing A/B Pressure If component B pressure is too high, it will push the com-ponent A stream aside during B injection. The valve will not open long enough, causing a High Ratio alarm. If component B pressure is too low, it will not be injected in sufficient volume. Th...

System Operation 88 312779E Mix Manifold Valve Settings To open dose or purge valves, turn hex nut (E) counter- clockwise . To close, turn clockwise. See Table 13 and F IG . 99. Table 12: Dynamic Dosing Troubleshooting Guide (for complete system troubleshooting, see Table 17 beginning on page 116) W...

System Operation 312779E 89 Start Up 1. Go through the Pre-Operation Checklist in Table 14. 2. Turn the AC Power Switch ON (I = ON, 0 = OFF). ➜ Graco logo, software revision, and “Establishing Communication” will display, followed by Status screen. See page 22. ➜ At power up the system defaults to R...

System Operation 312779E 91 Shutdown Overnight Shutdown 1. Leave the power on. 2. Run Recipe 0 to purge solvent through meters and gun. Service Shutdown 1. Follow Pressure Relief Procedure on page 91. 2. Close main air shutoff valve on air supply line and on ProMix 2KS. 3. Shut off ProMix 2KS power ...

System Operation 312779E 95 Purging There are 4 purging procedures in this manual: • Purging Mixed Material (below) • Purging Using Recipe 0 (page 96) • Purging Fluid Supply System (page 96) • Purging Sampling Valves and Tubes (page 98) Use the criteria listed in each procedure to determine which pr...

System Operation 98 312779E Purging Sampling Valves and Tubes Follow this procedure after meter calibration. 1. Go to Standby mode (remove Mix input). 2. See F IG . 106, page 94. Close both fluid shutoff valves and sampling valves. 3. Route the sampling tubes into a grounded waste container. 4. On a...

System Operation 312779E 99 Solvent Push Feature The Solvent Push feature enables the user to save some mixed material by pushing it out to the gun with solvent. The quantity saved is 50% of the potlife volume entered in Advanced Setup Screen 1 on page 39. If there are 2 guns, the smaller potlife vo...

Color Change 102 312779E Color Change Color Change Procedures Multiple Color Systems 1. Shut off air to the gun. 2. Place the gun in the gun flush box if used, and close the lid. 3. Go to Standby mode (remove Mix input). 4. Select the new recipe. Begin the color change sequence. 5. If a gun flush bo...

Alarms and Warnings 312779E 115 Alarms and Warnings NOTE: Do not use the fluid in the line that was dis- pensed off ratio as it may not cure properly. System Alarms System alarms alert you of a problem and help prevent off-ratio spraying. If an alarm occurs, operation stops and the following occurs:...

Alarm Troubleshooting 116 312779E Alarm Troubleshooting Table 17. Alarm Troubleshooting E-1: COMM ERROR Cause Solution No power to the EasyKey. Connect power to EasyKey. No power to Fluid Station. The intrinsically safe power cable between the EasyKey and Fluid Station is not con-nected. Verify that...

Schematic Diagrams 312779E 127 Schematic Diagrams System Pneumatic Schematic 3/8 AIR FILTER MANUAL DRAIN 5 MICRON WALL MOUNT ONLY FL USH AIR TO FL UID INLE T 1/4 TUBE TO M ANIFOLD 1/4 TUBE 4-WAY SOLENOID 12 VDC PURGE A VALVE DUMP A VALVE (OPTIONAL) 4-WAY SOLENOID 12 VDC 3-WAY SOLENOID 12 VDC 3-WAY S...

Schematic Diagrams 128 312779E System Electrical Schematic NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS system. Some compo- nents shown are not included with all systems. Non-Hazardous Area BARRIER BOARD OPERATOR INTERFACE 1 2 L1 N 85-250 VAC GND N L1 85-...

Schematic Diagrams 312779E 129 System Electrical Schematic NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS system. Some compo- nents shown are not included with all systems. Hazardous Area HAZARDOUS AREA +12VDC I/S COM SHIELD J10 1 2 3 1 2 3 4 5 6 J3 PWR (RE...

Schematic Diagrams 130 312779E EasyKey Electrical Schematic J9 4 3 2 1 GREEN/BLA CK/WHITE 22 A W G RED/BLA CK/WHITE 22 A W G BLA CK 18 A W G RED 18 A W G - + ALARM - - + DC OK POWER SUPPL Y COMMON 24 VDC+ BARRIER BO ARD J4-3 J4-2 J4-1 J1-5 J1-4 J1-3 J1-2 J1-1 TERMINAL BL OCKS POWER ROCKER SWIT CH L ...

Meter Performance Data (G3000 on A and B) 312779E 131 Meter Performance Data (G3000 on A and B) 0 500 1000 1500 2000 2500 3000 3500 3800 1:1 2:1 3:1 4:1 5:1 6:1 7:1 8:1 9:1 10:1 11:1 12:1 13:1 14:1 15:1 16:1 17:1 18:1 19:1 20:1 21:1 22:1 23:1 24:1 25:1 26:1 27:1 28:1 29:1 30:1 Rat io Flow Rate (c c/...

Meter Performance Data (G3000 on A, Coriolis on B) 132 312779E Meter Performance Data (G3000 on A, Coriolis on B) 0 500 1000 1500 2000 2500 3000 3500 3800 1:1 2:1 3:1 4:1 5:1 6:1 7:1 8:1 9:1 10:1 11:1 12:1 13:1 14:1 15:1 16:1 17:1 18:1 19:1 20:1 21:1 22:1 23:1 24:1 25:1 26:1 27:1 28:1 29:1 30:1 Rat ...

Technical Data 312779E 133 Technical Data * Dependent on programmed K-factor and application. The maximum allowable flow meter pulse frequency is 425 Hz (pulses/sec). For more detailed information on viscosities, flow rates, or mixing ratios, consult your Graco dis-tributor. See individual component...

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 312779 Graco Headquarters: Minneapolis Int...