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Alarm Troubleshooting

312776K

E-9: Not used

E-10: REMOTE STOP ALARM

Cause

Solution

Automation has requested that the system abort all oper-
ations.

Abort operations. Troubleshoot automation system.

E-11: PURGE VOLUME ALARM

Cause

Solution

ProMix 2KS solvent flow switch is not activated while
purging.

Verify that the gun is not shut off and that the solvent
flow switch is activated while purge is taking place.

Minimum flush volume is not achieved.

Increase solvent supply or decrease minimum volume
setting.

No meter pulses during Color/Catalyst Dump.

Color change solvent supply not set up or functional.
Check Color Change setup.

Table 11. Alarm Troubleshooting

Summary of Contents for ProMix 2KS

Page 1: ...Approved for use in explosive atmospheres except the EasyKey TI12504a Important Safety Instructions Read all warnings and instructions in this manual Save these instructions See page 4 for model info...

Page 2: ...larms Screens 26 Level Control Screen 26 Setup Mode 27 Password Screen 28 Set Up Home Screen 28 System Configuration Screens 30 Option Screens 34 Advanced Setup Screens 36 Recipe Setup Screens 40 Reci...

Page 3: ...Advanced Web Inter face 406799 15V256 Automatic System Upgrade Kit 406800 15V825 Discrete I O Board Kit 0 1 2 3 0 1 2 1 3 1 4 5 6 7 8 3 4 3 9 88 1 88 3 Artwork No 293538 GRACO INC P O Box 1441 Minnea...

Page 4: ...00 A and 1 8 in Coriolis B 5 1 8 in Coriolis A and G3000HR B 6 G3000HR A and 1 8 in Coriolis B 7 1 8 in Coriolis A and B 0 No Valves single color 1 Two Valves low pressure 2 Four Valves low pressure 3...

Page 5: ...rking Pressure Base System no meters option 0 no color catalyst change option 0 4000 psi 27 58 MPa 275 8 bar Meter Option 1 and 2 G3000 or G3000HR 4000 psi 27 58 MPa 275 8 bar Meter Option 3 4 5 6 and...

Page 6: ...terface Accessory Gun Flush Box Gun Insert Selection 15V354 Third Purge Valve Kit 15V536 Solvent Flow Switch Kit 15V213 Power Cable 100 ft 30 5 m 15G710 Fiber Optic Cable 100 ft 30 5 m 15U955 Injectio...

Page 7: ...l 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...

Page 8: ...or retailer Check equipment daily Repair or replace worn or damaged parts immediately with genuine manu facturer s replacement parts only Do not alter or modify equipment Use equipment only for its i...

Page 9: ...ctions in the manual To prevent inhalation of isocyanate mists vapors and atomized particulates everyone in the work area must wear appropriate respiratory protection Always wear a properly fitting re...

Page 10: ...up or reservoir if installed filled with appropriate lubricant The lubricant creates a barrier between the ISO and the atmosphere Use only moisture proof hoses compatible with ISO Never use reclaimed...

Page 11: ...y include a supplied air respirator Ventilate the work area according to instructions in the acid manufacturer s SDS Avoid all skin contact with acid Everyone in the work area must wear chemically imp...

Page 12: ...er a non intrusive flow meter often used in low flow applications or with light viscosity shear sensi tive or acid catalyzed materials This meter uses vibra tion to measure flow Custom Language A meth...

Page 13: ...the gun to resume operation Job Total a resettable value that shows the amount of material dispensed through the system for one job A job is complete when a color change or complete system flush occur...

Page 14: ...or change is initiated and the system automatically flushes the old color and loads a new color Sequential Dosing Components A and B dispense sequentially in the necessary volumes to attain the mix ra...

Page 15: ...asyKey EK Used to set up display operate and monitor the system The EasyKey accepts 85 250 VAC 50 60 Hz line power and converts that power to acceptable low voltage and optical signals used by other s...

Page 16: ...The K factor is user settable at lower flow rates use a lower K factor 1 8 in fluid passages set K factor to 020 or 061 3 8 in fluid passages set K factor to 061 or 0 119 Color Change Valves ACV and...

Page 17: ...erview 312776K 17 FIG 2 Manual System shown with G3000 Meters Color Catalyst Change One Gun Flush Box and Accessory Solvent Flow Meter TI29655a EK BC ST ACV CCM MS MA MB FM GFB BCV FO PS BCV acid mode...

Page 18: ...omponent 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...

Page 19: ...turns solid after load ing is complete LED blinks when purging Select a new recipe by pressing Up or Down keys then pressing Enter Alarm Reset Key and Indicator Red LED blinks when an alarm occurs Pre...

Page 20: ...to enter values in setup there are keys to navigate within a screen and between screens and to save entered values See Table 3 FIG 5 EasyKey Display and Keypad TI11630A Keypad LCD Display Navigation...

Page 21: ...has been ejected Graco Web Interface Port Used to communicate from a PC to Upgrade software View software version Download Job and alarm logs Material usage report Setup values can also upload Clear j...

Page 22: ...tarily display Estab lishing Communication If this display remains for more than one minute check that the fluid station circuit board is powered up LED is on and that the fiber optic cable is properl...

Page 23: ...Run Mode Screens 312776K 23 FIG 9 Run Screens Map TI12783a Press the Setup key to enter Setup mode...

Page 24: ...Two times are shown if there are two guns Status Bar shows current alarm or operation mode standby mix purge recipe change or the current alarm Current Flow Rate in cc min Animation when the gun is t...

Page 25: ...lly refer to material dispensed while in Mix fill mode after a color change or a purge opera tion This is likely not sprayed or atomized and is dis pensed to a purge container Solvent Totals and the R...

Page 26: ...The Alarm Level values may be adjusted using the advanced web interface See FIG 16 If the tank volume reaches the low level threshold the EasyKey screen will display the Tank Level Low alarm and promp...

Page 27: ...up Screens Map To access Advanced Setup Screens page 36 and Recipe Setup Screens page 40 To access System Configuration Screens page 30 TI12784a Press the Setup key to enter Setup mode Press the Setup...

Page 28: ...s plays momentarily after exiting Setup mode and return ing to the Status Screen A lock symbol appears on the Status Screen Set Up Home Screen This screen displays when you enter Setup mode From it yo...

Page 29: ...ected System can operate in 3K Manual Semi automatic or Automatic Mode XP XPORT V6 6 0 2 Example of XPORT network module software version Other versions are acceptable MC Micro Controller 1042 0198 Ex...

Page 30: ...TE See FIG 21 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 FIG 21...

Page 31: ...ct the desired display units cc liter default cc gallon Buzzer Alarms As the default the alarm buzzer is set to Potlife Only and will sound only for the Potlife Alarm E 2 Set to All Alarms to have the...

Page 32: ...udes an optional 3rd flush valve set to On Configure Screen 4 Dose Time Alarm Enter the dose time 1 to 99 seconds This is the amount of time allowed for a dose to occur before a dose time alarm occurs...

Page 33: ...ngs will duplicate those set tings established for the Gun Flush Box Each output has two different start times and durations defined on the Recipe Setup screen Flush and Fill Input is set to Recipe in...

Page 34: ...n 1 page 37 Advanced Setup Screen 2 3 and 5 are added See pages 37 39 If set to Recipe Color Catalyst Purge and Color Cata lyst Fill are added to Recipe Setup Screen 2 page 41 Recipe Setup Screen 3 4...

Page 35: ...Flow Rate Monitor If set to On Recipe Setup Screen 6 on page 43 is added enabling setting of high and low flow limits If set to Off flow rate monitoring is disabled and Rec ipe Setup Screen 6 on page...

Page 36: ...creens NOTE See FIG 32 for a map of the Advanced Setup Screens Detailed screen descriptions follow FIG 32 Advanced Setup Screens Map TI12786a Advanced Setup screens 2 3 4 and 5 appear depending on sel...

Page 37: ...eld only appears if the system includes a color change module and Flush and Fill Input is set to Global in Option Screen 1 page 34 Enter the fill time 0 to 99 seconds It refers to the time required to...

Page 38: ...9 seconds It refers to the amount of time that is required to load mixed material from the dose valves to the applica tor gun Advanced Setup Screen 4 This screen appears only if K factor Input is set...

Page 39: ...age 33 The I O board has four programmable outputs On Purge Delay time at the start of the purge cycle before the Spe cial Output turns on Length Duration for the Special Output to be active during th...

Page 40: ...Screens NOTE See FIG 38 for a map of the Recipe screens Detailed screen descriptions follow FIG 38 Recipe Screens Map TI12787a Recipe 0 Screens Recipe screens 3 4 5 6 and 7 appear depending on selecti...

Page 41: ...lve number 1 to 4 Recipe Setup Screen 2 Minimum Flush Volume This field only appears if Flush Volume Check is set to On in Option Screen 1 on page 34 Enter the mini mum flush volume 0 to 9999 cc Enter...

Page 42: ...set to On in Configure Screen 3 on page 32 Air Chop Time Enter the air chop time 0 0 to 99 9 seconds Solvent Chop Time 3rd Flush Valve Chop Time Enter the solvent or 3rd flush valve chop time 0 0 to...

Page 43: ...meter B K factor Solvent Meter This field only appears if Solvent Monitor in Configure Screen 5 page 33 is set to Meter Enter the k factor cc pulse for the solvent flow meter Recipe Setup Screen 6 Thi...

Page 44: ...s set to 3 GFB on 4 the Recipe 0 Screen 4 does not display the column of information for Special 4 That Output assumes the val ues assigned to GFB 1 On Purge Delay time at the start of the purge cycle...

Page 45: ...refers to the process of mix ing air and solvent or air and 3rd flush fluid together during the flush cycle to help clean the lines and reduce solvent usage Final Purge Source Select Air Solvent or 3r...

Page 46: ...4 This screen appears only if Flush and Fill Input is set to Recipe in Option Screen 1 page 34 and Special Out puts is set to 1 2 3 4 or 3 GFB on 4 in Configure Screen 5 page 33 The I O board has fou...

Page 47: ...er B Meter or Solvent Meter available if Solvent Monitor in Configure Screen 5 page 33 is set to Meter Start start calibration Abort stop calibration Purge purge sampling valves after calibration See...

Page 48: ...rating Cycle Sequential Dosing 1 The spray gun operator enters and loads the desired recipe The color change LED blinks while recipe is loading then turns solid when complete 2 The operator presses th...

Page 49: ...tinues the process where it left off NOTE Operation can be stopped at any time by pressing the Standby key or shutting off the main power switch Table 5 Sequential Dosing Operation Ratio 2 0 1 Dose 1...

Page 50: ...of system flow at higher mix ratios Component B Flow Ensure that the supply pump is sized to provide sufficient and uninterrupted flow Component A Pressure Ensure precise pressure regulation It is re...

Page 51: ...creen 4 Select DD option from the Dose Size drop down menu FIG 54 3 Selecting DD in System Configure Screen 4 makes the DD Setup mode available See FIG 55 To enable DD setup mode select On in the DD s...

Page 52: ...be possible to hold the desired mix ratio The system will generate an off ratio alarm and stop operation NOTE In multi flow rate systems it is recommended that you set up the system to run properly at...

Page 53: ...pressure Clean restrictor or use a larger size Verify B valve is opening properly FIG 59 Valve Adjustment E TI11581a Table 7 Mix Manifold Valve Settings Valve Setting Function Dose FIG 59 Hex nut E 1...

Page 54: ...possible Airless Gun It is not recommended to use an airless gun with the ProMix 2KS Two issues can arise from operating with out an air flow switch Without a gun trigger air flow switch input the Pr...

Page 55: ...ke sure that the Booth Control is in Standby mode Table 8 Pre Operation Checklist Checklist System grounded Verify all grounding connections were made See the Installation manual All connections tight...

Page 56: ...ich dose valve is open Watch the fluid flow rate displayed on the Status screen while the gun is fully open Verify that the flow rate of components A and B are within 10 of each other If the fluid flo...

Page 57: ...mps 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 pres sure See FIG 65 NOTE If a Dos...

Page 58: ...ough the dump valves 1 Complete all steps under Single Color Systems page 57 2 Shut off all color and catalyst supplies to the valve stacks 3 Press and hold the dump valve A solenoid override FIG 65 4...

Page 59: ...Valve B Solenoid Purge Valve A Solenoid Dose Valve B Solenoid Dose Valve A Solenoid Optional Solenoid Locations 1 Dose A Dose B Purge B Dump A 3rd Purge Dump B GFB 2 GFB 1 Power Fiber Optic CAN CAN J...

Page 60: ...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 Compone...

Page 61: ...avoid splashing or an injection injury Generally a setting of 100 psi 0 7 MPa 7 bar is sufficient 3 If using a gun flush box place the gun into the box and close the lid Press the Purge key on the Bo...

Page 62: ...or an extended period of time putting equipment into storage Some steps are not necessary for initial flushing as no material has been loaded into the system yet 1 Press the Standby key on the Booth C...

Page 63: ...ect Recipe 0 and press Enter to purge the component A side The color change LED blinks while Recipe 0 runs and turns solid after purge sequence is complete Purge component B side Press the manual over...

Page 64: ...solvent purge valve B side and color change solvent valves if used will open 7 To avoid splashing slowly open the sampling valves and dispense solvent until the valves and tubes are clean NOTE When pe...

Page 65: ...h The green Mix LED will light and the Recipe LED will blink The system will close the Dose Valves DVA DVB and open the Solvent Purge Valve SPV 4 The system will dispense solvent to push the mixed mat...

Page 66: ...nd Gun Flush Box must be configured as a Special Output See Configure Screen 5 on page 33 To enable Mix Fill Push select Mix Fill Push in the Auto Dump field See Option Screen 2 page 35 1 The system g...

Page 67: ...r A or B prime the system with material For a color catalyst change system make sure the color catalyst valve is open 2 Shut off all spray or dispense devices connected to the ProMix 3 Close both flui...

Page 68: ...l volume is the same or if for any reason you want to cancel the calibra tion procedure scroll to Abort on the Calibration Screen menu and press the Enter key 12 After the volume for A B or Solvent is...

Page 69: ...which figure to reference based on the recipe change and system con figuration The time sequences are detailed in the fol lowing paragraphs NOTE For software version 2 04 xxx and older the sys tem us...

Page 70: ...ll Time expires First Purge Select the First Purge Source air solvent or 3rd valve and First Purge Time For most applications air is selected The system purges the old material from the dose valves to...

Page 71: ...es Table 9 Color Change Chart Reference Starting Recipe Ending Recipe Change Type Dump A Exiting Fill Refer to Fig X Y Change Yes NA FIG 71 X Y Change No NA FIG 72 0 Y Fill Yes Yes FIG 73 0 Y Fill Yes...

Page 72: ...ange Input Start of Color Change Purge Active Output Fill Active Output End of Color Change Mix Ready Output Special Outputs Start of On Purge Start of On Fill Special Output 1 Length Length Special O...

Page 73: ...I O Color Change Input Start of Color Change Purge Active Output Fill Active Output End of Color Change Mix Ready Output Special Outputs Start of On Purge Start of On Fill Special Output 1 Length Len...

Page 74: ...put 2 Digital I O Color Change Input Start of Color Change Purge Active Output Fill Active Output End of Color Change Mix Ready Output Special Outputs Start of On Purge Start of On Fill Special Output...

Page 75: ...or Change Input Start of Color Change Purge Active Output Fill Active Output End of Color Change Mix Ready Output Special Outputs Start of On Purge Start of On Fill Special Output 1 Length Length Spec...

Page 76: ...ush Box Output 2 Digital I O Color Change Input Start of Color Change Purge Active Output Fill Active Output End of Color Change Mix Ready Output Special Outputs Start of On Purge Start of On Fill Spe...

Page 77: ...tal I O Color Change Input Start of Color Change Purge Active Output Fill Active Output End of Color Change Mix Ready Output Special Outputs Start of On Purge Start of On Fill Special Output 1 Length...

Page 78: ...of Color Change Purge Active Output End of Color Change Fill Active Output Mix Ready Output Special Outputs Start of On Purge Special Output 1 Length Special Output 2 Length Special Output 3 Length Sp...

Page 79: ...tart of Color Change Purge Active Output End of Color Change Fill Active Output Mix Ready Output Special Outputs Start of On Purge Special Output 1 Length Special Output 2 Length Special Output 3 Leng...

Page 80: ...ange Input Start of Color Change Purge Active Output End of Color Change Fill Active Output Mix Ready Output Special Outputs Start of On Purge Special Output 1 Length Special Output 2 Length Special O...

Page 81: ...I O Color Change Input Start of Color Change Purge Active Output End of Color Change Fill Active Output Mix Ready Output Special Outputs Start of On Purge Special Output 1 Length Special Output 2 Leng...

Page 82: ...10 alarms with date and time stamps To reset alarms see Table 11 Many alarms can be cleared by simply pressing the Alarm Reset key FIG 81 Booth Control TI11614A Display Recipe Indicator green Alarm In...

Page 83: ...r optic cable is cut or bent Verify that the cable has not been cut or bent at a radius smaller than 1 6 in 40 mm Dirty fiber optic cable ends Disconnect fiber optic cable ends and clean with a lint f...

Page 84: ...raying for some time the pressures from the fluid supplies could be unbalanced Adjust component A and B fluid supply regulator pres sures until they are about equal If the pressures are already about...

Page 85: ...aying for some time the pressures from the fluid supplies could be unbalanced Adjust component A and B fluid supply regulator pres sures until they are about equal If the pressures are already about e...

Page 86: ...on the circulating pumps and all the booth equipment such as fans and conveyors 3 Check if the ProMix 2KS is reading any fluid flow 4 If the ProMix 2KS shows there is fluid flow and there are no leaks...

Page 87: ...eter cap to expose sensor Pass a ferrous metal tool in front of the sensor If there is a meter or cable failure you will see a large dif ference between the amount of fluid dispensed and the flow mete...

Page 88: ...lution ProMix 2KS solvent flow switch is not activated while purging Verify that the gun is not shut off and that the solvent flow switch is activated while purge is taking place Minimum flush volume...

Page 89: ...ed The sticker on the color change board shows the software part number and version for example 15T270 1 01 If the version is older than 1 01 replace the board If all software versions and DIP switch...

Page 90: ...b interface E 17 POWER ON POWER OFF WARNING Cause Solution The power to the system has been cycled No action required See Event Log available through advanced web interface Voltage becoming too low du...

Page 91: ...the recipe data is incompatible with the current Autokey setting 2K or 3K This is possi ble if the Autokey is changed or an invalid configuration file is sent to the EasyKey Verify that the Autokey is...

Page 92: ...the system detects that fill volume is not achieved during mixed material fill time Check for restrictions or leaks in the fluid supply system Check if the fill volume is properly configured Adjust f...

Page 93: ...M Cause Solution System detects no meter pulses or system must detect at least 10cc of material from each side throughout the Color Catalyst fill time duration Check that meter cable is connected Clea...

Page 94: ...OSE OPEN 5 32TUBE DOSE B VALVE CLOSE OPEN 5 32TUBE 3 WAY SOLENOID 12VDC GFB 1 VALVE OPTIONAL 5 32TUBE A COLOR 1 COLOR 2 COLOR 3 COLOR 4 COLOR 5 COLOR 6 COLOR 7 COLOR 8 COLOR SOLVENT COLOR 9 COLOR 10 C...

Page 95: ...D RS485 NETWORK A WHT ORG RS485 NETWORK B ORG WHT RS485 NETWORK GROUND SHIELD FLOW CONTROL CAL BLK GUNTRIGGER WHT DIGITAL IN COMMON RED REMOTE STOP GRN ALARM RESET BRN ALARM OUTPUT BLU DIGITAL OUTPUT...

Page 96: ...AN H WHT CAN L BLU 3 2 5 4 1 BOOTH CONTROL BOARD 6 5 4 3 2 1 J14 BLACK RED BLACK RED BLACK RED AIR FLOW SWITCH 2 SOLVENT FLOW SWITCH GFB 1 PRESSURE SWITCH GFB 2 PRESSURE SWITCH PURGE B PURGE A NOT USE...

Page 97: ...L BLOCKS POWER ROCKER SWITCH L L N N 24 VDC OUTPUT HIGH VOLTAGE IN J4 24 VDC IN J1 GND L1 N J5 3 J5 2 J5 1 J5 IS POWER 12 VDC DISPLAY BOARD BLACK 18 AWG RED 18 AWG GRN YEL 16 AWG RED 16 AWG BROWN 16 A...

Page 98: ...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 Ratio Flow Rate cc min 50cc Dose 25cc Dose 10cc Dose NOTE Maximum system flow is 3800 cc...

Page 99: ...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 Ratio Flow Rate cc min 50cc Dose 25cc Dose 10cc Dose NOTE Maximum system flow is 3800 cc mi...

Page 100: ...Meter Performance Data G3000 on A Coriolis on B 100 312776K...

Page 101: ...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 f...

Page 102: ...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 WARRAN...

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