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ProMix™ II General Operating Cycle

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Air Flow Switch Function

310633C

11

Air Flow Switch Function

Air or Air-assisted Airless Guns

The air flow switch detects air flow to the gun and sig-
nals the ProMix™ II controller when the gun is being
triggered. The switch functions with the flow meters to
ensure that the system components are functioning cor-
rectly.

For example, if a flow meter fails or clogs, pure resin or
catalyst could spray indefinitely if the ProMix™ II does
not detect the condition and intervene, which is why the
air flow switch is so important.

If the ProMix™ II controller detects through the air flow
switch signal that the gun is triggered, yet there is no
fluid flow through the meter, a Dose Time Alarm (page
54) occurs after 40 seconds and the system shuts down.

Operating Without Air Flow Switch

It is possible to operate the ProMix™ II without the air
flow switch, such as when a switch fails or when using
an airless gun.

Airless Gun

If using an airless gun or operating without the air flow
switch (not recommended), the dose time alarm will not
function. Instead, two minutes after a meter fails, the
system generates an Idle Time Warning and the dis-
pense valves turn off. What this means is:

•

It is possible to spray pure resin or catalyst for up to
2 minutes before the system shuts down.

•

Since the Idle Time Warning can occur during nor-
mal operation, you may not immediately realize that
a meter failed and may continue painting.

Idle Time Warning

This warning occurs if the ProMix™ II is set to Mix

,

and 2 minutes have elapsed since the system received
a flow meter pulse.

In applications using the air flow switch, triggering the
gun clears the warning and the operator can start spray-
ing again.

Without the air flow switch, triggering the gun does not
clear the alarm. To start spraying again, you must press

Mix

, then trigger the gun.

F

IG

. 2

Fluid Manifold Cutaway

H

D

C

A

F

E

G

J

K

L

M

Key:

A

Dispense Valve A

B

Dispense Valve B

C Flow Meter A
D Component A Supply Line
E

Air Purge Valve

F

Shutoff Valve A

G Flow Meter B
H Component B Supply Line
J

Solvent Purge Valve

K

Integrator

L

Static Mixer

M Fluid Supply to Gun

B

If a switch fails, replace it as soon as possible.

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Summary of Contents for ProMix II

Page 1: ...proportional mixing of plural component coatings See page 3 for model information including maximum working pressure and approvals Important Safety Instructions Read all warnings and instructions in this manual Save these instructions ...

Page 2: ...creen 34 Calibrate Screen 34 Advanced Screens 35 Operation 38 Pressure Relief Procedure 38 Trigger Lock 38 Start Up 39 Color Change 42 Printing Job Log 43 Shutdown 43 Purging 44 Purging Mixed Material 44 Using Color 0 45 Purging Fluid Supply System 46 Purging Sampling Valves and Tubes 48 Meter Calibration 49 Alarm Troubleshooting 51 ProMix II Alarms 51 ProMix II Warnings 55 Technical Data 56 Graco...

Page 3: ...mum Working Pressure Maximum working pressure rating is dependent on the A and B meter and color change option selected The pres sure rating is based on the rating of the lowest rated fluid manifold component Refer to the component pressure ratings below Example Model PM1140 has a maximum working pressure of 3000 psi 21 MPa 207 bar Check the ID plate on your EasyKey Display or fluid panel for its ...

Page 4: ... Meter 310696 Coriolis Flow Meter 310656 Color Change Kit 307731 Color Change Valve Assembly Low Pressure 307941 Color Change Valve Low Pressure 308291 Color Change Valve Assembly High Pressure 308977 Color Change Valve High Pressure 310695 Gun Flush Box 308818 Printer 310669 ProMix II Data Download Kit 310745 Gun Air Shutoff Kit Manual Language Manual Language 310633 English 310636 German 310634 ...

Page 5: ...Related Manuals 310633C 5 ...

Page 6: ...stallation in a Hazardous Location Class I Div I Group D T3 To help prevent fire and explosion Do not install equipment approved only for non hazardous location in a hazardous area See the ID label for the intrinsic safety rating for your model Do not substitute system components as this may impair intrinsic safety ELECTRIC SHOCK HAZARD Improper grounding setup or usage of the system can cause ele...

Page 7: ...fingers and other body parts Keep clear of moving parts Do not operate equipment with protective guards or covers removed Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure in this manual Disconnect power or air supply TOXIC FLUID OR FUMES HAZARD Toxic fluids or fumes can cause serious injury or death if splashed in th...

Page 8: ...EasyKey Display accepts 85 250 VAC 50 60 Hz line power and converts that power to accept able low voltage and optical signals used by other system components Smart Fluid Panel Includes air control solenoids pressure and flow switches fluid flow meters and the fluid manifold assembly to control and monitor fluid dispensing Fluid Manifold Fluid component assembly mounted on the Smart Fluid Panel It ...

Page 9: ...mart Fluid Panel Fluid Panel Power Supply Cable Used to provide power to the Smart Fluid Panel Operator Station Used by the operator for daily painting functions including choosing color initiating report printing reading clearing alarms and placing the system in Standby Mix or Purge mode It is typically mounted inside the booth or near the painter Gun Flush Box not shown Used to automatically flu...

Page 10: ...ses 5 The components are pre mixed in the integrator K then uniformly blended in the static mixer tube L 6 Components A and B are alternately fed into the integrator K as long as the gun is triggered 7 If the gun is not triggered for two minutes the sys tem switches to Idle mode which closes off the mix manifold dispense valves 8 When the gun is triggered again the ProMix II continues the process ...

Page 11: ...hout the air flow switch not recommended the dose time alarm will not function Instead two minutes after a meter fails the system generates an Idle Time Warning and the dis pense valves turn off What this means is It is possible to spray pure resin or catalyst for up to 2 minutes before the system shuts down Since the Idle Time Warning can occur during nor mal operation you may not immediately rea...

Page 12: ...n the text refer to icons on the equipment or keypad FIG 4 and FIG 5 page 14 show typical installations Contact your Graco distributor for actual system designs Be sure all accessories are adequately sized and pressure rated to meet system requirements For maintenance and safety you must have a shutoff valve between each fluid supply line and the ProMix II system A 100 mesh minimum fluid filter mu...

Page 13: ...Installation Typical Installation 310633C 13 FIG 3 J G F H C D E N A B P L M K Q R S S G H H T T TI4658A ...

Page 14: ...VAC Maximum Supply Voltage I S Power Cable Fiber Optic Communication Cable Pneumatic Interface I S Power and Communication Cable 1 Nonintrinsically safe terminals power rail must not be con nected to any device which uses or generates more than 250 VRMS or DC unless it has been determined that the voltage has been adequately isolated 2 The installation must meet the requirements of the National El...

Page 15: ... to 3800 cc min Fluid supply pressure tanks feed pumps or circulat ing systems can be used Materials can be transferred from their original con tainers or from a central paint recirculating line Contact your Graco distributor for additional information WARNING Do not install equipment approved only for non haz ardous location in a hazardous area See the identifi cation ID label FIG 6 on the EasyKe...

Page 16: ...nt height for the operator and so equipment is easily accessi ble for maintenance FIG 7 4 Drill mounting holes in the wall Install anchors as needed 5 Bolt equipment securely FIG 7 EasyKey Display Smart Fluid Panel Dimensions Operator Station 12 in 304 8 mm 12 75 in 323 9 mm 13 47 in 342 1 mm 14 in 355 6 mm 3 in 7 6 mm Depth 6 38 in 161 9 mm 26 5 in 673 1 mm 12 in 304 8 mm 16 5 in 419 1 mm 5 in 12...

Page 17: ...eed type shutoff valve L into the air filter inlet on the Smart Fluid Panel FIG 8 3 Connect a clean air supply line to the shutoff valve L This air line supplies air to operate the gun solenoids and dispense valves 4 lnstall a bleed type shutoff valve X into the air purge valve inlet on the Smart Fluid Panel FIG 8 5 Connect an air supply line to the shutoff valve X to supply air for the solvent an...

Page 18: ...hutoff valve See Gun Flush Box Manual 310695 CAUTION The ProMix II potlife timer will not function properly when used with multiple guns operating simultane ously To avoid having mixed material set in the equip ment carefully monitor potlife by some other means Install a bleed type air shutoff valve Z in the gun air supply line or at the gun air inlet AA FIG 10 FIG 11 WARNING If using a Graco elec...

Page 19: ...exceed the pressure rating of the lowest rated component Refer to the product ID Label Read Pro Mix II Models information page 3 WARNING To reduce the risk of injury including fluid injection you must install a shutoff valve T between each fluid supply line and the fluid manifold assembly FIG 12 Use the valves to shut off fluid during maintenance and service Paint Recirculating System The color ch...

Page 20: ...g page 23 Connect EasyKey Display to Smart Fluid Panel There are two 50 ft 15 2 m cables to route between the EasyKey Display and Smart Fluid Panel the Fluid Panel Power Cable A and the Fiber Optic Cable C 1 Connect the appropriate Fluid Panel Power Cable A end to the EasyKey Display connector FIG 14 2 Connect the other cable end to the Smart Fluid Panel connector B FIG 15 3 The Fiber Optic Cable ...

Page 21: ... 16 Connect Operator Station to Smart Fluid Panel The Operator Station cable F is factory wired into the Operator Station FIG 17 Do not disconnect the cable except to replace it Route the 50 ft 15 2 m cable to the Smart Fluid Panel and connect it to the Operator Station connector G FIG 15 Gun Flush Box Refer to the Gun Flush Box manual for installation and connection instructions Printer If using ...

Page 22: ...Graco HG6000 helical meter Route the signal cables through the Smart Fluid Panel holes J FIG 19 and into the enclosure through the strain reliefs GG FIG 20 Leave enough slack in the cable so the enclosure K can be raised for service See FIG 20 for electrical connections FIG 19 J FIG 20 K GG COMMON SIGNAL SHIELD COMMON SIGNAL SHIELD J3 1 2 3 4 5 6 7 8 CABLE CABLE FLOW METER A FLOW METER B Flow Mete...

Page 23: ... part no 222011 is available from Graco EasyKey Display For Intrinsic Safety Remove knock out FF from bottom of EasyKey Dis play enclosure FIG 21 Install a bulkhead strain relief Connect a ground wire to the ground block terminal W FIG 22 Route the wire through the strain relief and con nect it to a true earth ground Smart Fluid Panel Connect a ground wire from the Smart Fluid Panel ground lug EE ...

Page 24: ...ed hoses only Spray Gun Follow the grounding instructions in your gun manual Fluid Supply Container Follow local code Object Being Sprayed Follow local code All Solvent Pails Used When Purging Follow local code Use only conductive metal pails placed on a grounded surface Do not place the pail on a nonconductive surface such as paper or cardboard which interrupts the grounding continuity Maintain G...

Page 25: ...l ground wire connection point Fluid Panel ground wire True Earth Ground check your local code for requirements Operator Station ground wire connection point Operator Station ground wire Gun Flush Box ground wire connection point Gun Flush Box ground wire Ground wires for the EasyKey Display Smart Fluid Panel Operator Station and Gun Flush Box must all be connected to the same true earth ground Se...

Page 26: ...ainting functions including choosing color initiating report printing reading clearing alarms and placing the system in Standby Mix or Purge mode It is typically mounted inside the booth or near the painter The Operator Station consists of an LED display LED mode indicator and input keys FIG 27 Operation Modes Mix System mixes and dispenses material Standby Stops the system Purge Purges the system...

Page 27: ...lit while a color is in use Shuts off when or keys are pressed If a new color is entered the LED blinks while the color is loaded and turns solid after loading is complete A new color is selected by pressing or then pressing Error Clear Red LED stays lit when error occurs or blinks for a potlife alarm LED shuts off after alarm is cleared key is pushed Report Sends report to printer and resets A an...

Page 28: ...information related to setup and spray operations There is a screen saver option available in the Advanced Setup Screen 3 Pressing any key brings the display out of screen saver mode Audible Alarm Provided to alert the user when an alarm condition occurs It will sound intermittently for a Potlife Exceeded alarm and continuously for all other errors The alarm is cleared by pressing the Operator Sta...

Page 29: ...ad manual 310669 or ProMix II Ser vice manual 310653 for more information Ethernet Connection You can access data from the ProMix II on an office or industrial network or through the internet with the proper network configuration You will need an external module commonly called an Ethernet to Serial Converter that converts serial data RS 232 to ethernet Converters are available from electronics su...

Page 30: ...n cc or oz Total Job Volume A B is reset to zero each time the Report key is pressed on the Operator Station or after a color change or purge Animation When there is flow the gun appears to spray and the component A or B hose light up showing which component dispense valve is open Status Bar shows current alarm or operation mode Mix Standby Purge or Color change to Current Date and Time Security L...

Page 31: ...llowing keys to navigate within a screen and between screens and to save entered values If you forget the password you can reset the password to 0 using the ProMix II Data Download Kit 234668 FIG 30 Setup Mode Password Screen If a password is activated Setup Locked displays momentarily after exiting Setup mode and returning to the Run Screen FIG 31 FIG 32 Setup Mode Color Setup Screen Key Function...

Page 32: ...fficient time to spray or purge the mix material from the system Purge Time This setting is used during Purge mode and color change It can be set from 0 999 seconds in increments of 1 second See ProMix II Purge Sequence and ProMix II Color Change Sequence page 33 Fill Time This setting is used during color change to set the amount of time the system spends loading the new color It can be set from ...

Page 33: ...uence Purge Time Pa Ps Pa Ps Pa Ps Pa S1 A C2 A A B A B A B A B Legend S1 cc stack solvent valve C2 cc stack color 2 valve A Component A dispense valve B Component B dispense valve Pa Air purge valve Ps Solvent purge valve Ps final Solvent purge valve final solvent fill is 25 of purge time or 50 of purge time when color changing to 0 PS final Gun Trigger Purge Sequence Purge Time Pa Ps Pa Ps Pa Ps...

Page 34: ...Grand total cannot be reset There are no selectable settings on the Report Screen Calibrate Screen Use this screen to calibrate a meter Start start calibration Abort stop calibration Purge purge sampling valves after calibration See Meter Calibration page 49 for when and how to calibrate meter FIG 36 Setup Mode Report Screen The optional ProMix II Data Download Kit 234668 enables you to download a...

Page 35: ...smaller dose sizes However due to the uncertainty of the valve timing smaller dose sizes can generate more off ratio condi tions especially at high flow rates Repeated trial and adjustment may be necessary to find the optimal dose size and ratio tolerance Select from these 3 settings 25 cc default works well for most applica tions It is small enough for good integration while still avoiding nuisan...

Page 36: ...nits selected in Advanced Screen 1 Set from 0 999 cc or 0 33 ounces If you change the units this value updates to the new units Default is 350 cc 12 oz The volume of the ProMix II mix manifold integrator and static mixer is 100 cc To determine the volume of your fluid hose to the gun use the following information FIG 39 Setup Mode Advanced Screen 2 If you have a one color ProMix II system you can ...

Page 37: ... Enter current day Year Enter current year four digits Time Enter current time in hours 24 hour clock and minutes Seconds are not adjustable Password Is only used to enter Setup mode The default is 0 which means no password is required to enter setup Enter a number from 1 9999 if a password is desired Screen Saver Time Defines the number of minutes a screen can be inactive before the screen saver ...

Page 38: ...guard retaining nut or hose end coupling to relieve pressure gradually then loosen completely Clear hose or tip obstruction Trigger Lock Always engage the trigger lock when you stop spraying to prevent the gun from being triggered accidentally Read warnings page 6 WARNING Follow Pressure Relief Procedure when you stop spraying before changing spray tips and before cleaning checking or servicing eq...

Page 39: ...pense and purge valves packing nuts D to 25 in lbs 2 8 N m FIG 41 Repeat this torque weekly to extend valve life and avoid leakage Fluid supply valves open and pressure set Component A and B fluid supply pressures should be equal unless one component is more viscous and requires a higher pressure setting Solenoid pressure set 75 100 psi inlet air supply 0 5 0 7 MPa 5 2 7 bar Mix Manifold Valves FI...

Page 40: ...e Pro Mix II system Most applications require about 80 psi 552 kPa 5 5 bar air pressure to operate properly Do not use less than 75 psi 517 kPa 5 2 bar 10 Purge air from the fluid lines a Shut off air to the gun by clos ing the air regulator or shutoff valve for the gun atomizing air b Trigger the gun into a grounded metal pail c Press Mix on Operator Station d If the flow meters over run because ...

Page 41: ...wn on the EasyKey Run screen is for either component A or B depending on which dispense valve is open The fluid supply lines on the screen highlight to show which dis pense valve is open 1 Component A Dispensing Pressure adjustments of each component will vary with fluid viscosity Start with the same fluid pres sure for component A and B then adjust as needed CAUTION Do not use the first 4 5 oz 12...

Page 42: ...ion the color change sequence is complete 7 When you are ready to spray remove the gun from the gun flush box if used and close its door 8 Press Mix to start spraying Color Change for single color systems 1 Follow procedure for Purging Fluid Supply Sys tem page 46 2 Load the new color as instructed in Start Up page 39 3 Press Mix to start spraying WARNING If using an electrostatic gun shut off the...

Page 43: ...page 44 If your shutdown time WILL NOT exceed the potlife you do not need to purge the system but you must relieve system pressure Job 1 Color 3 Start Time 03 Feb 2004 12 07 48 End Time 03 Feb 2004 13 38 04 Target Ratio 2 5 1 Ave Ratio 2 51 1 Volume A 282 cc Volume B 112 cc Alarm NO ALARMS To print a Material Usage Report see page 35 The Job Log and other reports can be viewed or printed using the...

Page 44: ...g or an injection injury Generally a setting of 100 psi 0 7 MPa 7 bar is sufficient 5 If using a gun flush box place the gun into the box Press Purge key on the Operator Station The purge sequence automatically starts If the gun flush box is not used trig ger the gun into a grounded metal pail until the purge sequence is complete When done purging the Operator Station automat ically switches to St...

Page 45: ...LED blinks while Color 0 runs and turns solid after purge sequence is complete If the system is not completely clean you can repeat Color 0 by pressing Color 0 is typically used in multiple color systems to purge out material lines without loading a new color at the end of a shift to prevent hardening of cata lyzed material To setup Color 0 see page 32 Operator Station Screen LED WARNING If using ...

Page 46: ...ccess the solenoid valves 7 Purge component A side WARNING Follow Pressure Relief Procedure page 38 Engage trigger lock If you are using a high pressure gun remove spray tip and clean separately WARNING If using an electrostatic gun with a gun flush box shut off the electrostatics before placing the gun in the box Single color systems disconnect the compo nent A and B fluid supplies at the flow me...

Page 47: ...pail until clean solvent flows from the gun Method 2 Close B side fluid shutoff valve On the EasyKey Display press Setup key to access setup screens Press key to select the Calibrate screen Press key and select Purge from the drop down list Press Trigger the gun into a grounded metal pail The solvent valve s close auto matically after 2 minutes or when Abort is selected on the screen Open B side f...

Page 48: ...ling valves 10 Fully open both fluid shutoff valves 1A 1B 11 Follow Pressure Relief Procedure page 38 12 On a single color system reconnect component A fluid supply line to flow meter A WARNING Follow Pressure Relief Procedure page 38 3 Close both fluid shutoff valves 1A 1B and sam pling valves 2A 2B 1B 1A 2B 2A C 5A 7 Press key to select the Calibrate screen Press key and select Purge from the dr...

Page 49: ...removal of the valve stem while the manifold is pres surized If you cannot turn the valve stems manually relieve the system pressure then disassemble and clean the valve to remove the resistance K Factors on the Calibrate Screen are updated automatically after the calibration procedure is completed K Factor values on the screen are viewable only If needed you can manually edit the K Factors in Adv...

Page 50: ... after calibrating meters Use one of the following methods Follow the Purging Sampling Valves and Tubes procedure page 48 Place the sampling valve fluid tubes into a com patible cleaning fluid TSL or solvent or cap them 14 Before you begin production clear the system of solvent and prime it with material a Select Mix on the Operator Station b Trigger the gun into a grounded metal pail until mixed ...

Page 51: ...ess ing the Error Clear key on the Operator Station WARNING Follow Pressure Relief Procedure page 38 when you stop spraying before changing spray tips and before cleaning checking or servicing equipment Read warnings page 6 CAUTION Do not use the fluid in the line that was dispensed off ratio as it may not cure properly Operator Station E Code Red LED Description E Code Communication Error E1 Purg...

Page 52: ...r E2 Alarm Cause Solution ProMix II detects atomizing air flow to the gun dur ing Purge or Color Change sequence Verify that the gun air is shut off and atomizing air safety valve is connected and functioning In systems with a gun flush box operator selects to Purge or Color Change when the gun is not in the gun flush box In systems set up for Autodump page 36 Autodump is initiated when gun is not...

Page 53: ... down the initial fluid delivery rate until fluid hoses are loaded with material If the alarm occurred after you were spraying for some time the pressures from the fluid supplies could be unbalanced Adjust component A and B fluid supply regulator pressures until they are about equal If the pressures are already about equal verify that component A and B dispense valves are operating properly Slow a...

Page 54: ...install pressure regulators or a surge tank on the fluid inlets to the ProMix II to reduce the fluid supply pressure Contact your Graco distributor for information Slow actuation of component A or B valves See Ratio Alarm E4 page 53 third cause Running a high mix ratio and a high flow rate It may be necessary to restrict the flow rate through the component B dispense valve by adjusting its hex nut...

Page 55: ...n see Air Flow Switch Function page 11 In applications using the air flow switch trigger the gun to clear the warning and start spraying again If the alarm does not clear the air flow switch has failed and should be replaced Without the air flow switch triggering the gun does not clear the alarm To start spraying again press Mix then trigger the gun If the gun is dispensing when the alarm occurs t...

Page 56: ...waterborne paints polyurethanes epoxies acid catalyzed varnishes moisture sensitive isocyanates Viscosity range of fluid 20 5000 cps Fluid filtration 100 mesh minimum Fluid flow rate range G3000 Meter G3000HR Meter Coriolis Meter 75 3000 cc min 0 02 0 79 gal min 38 1500 cc min 0 01 0 40 gal min 20 3800 cc min 0 005 1 00 gal min External Power Supply Requirements 85 250 Vac 50 60 Hz 2 amps maximum ...

Page 57: ... 6 lbs 30 2 kg EasyKey Display 22 2 lbs 10 1 kg Smart Fluid Panel no meters 41 3 lbs 18 7 kg Operator Station 3 3 lbs 1 5 kg Optional Components G3000 G3000HR Flow Meter 6 lbs 2 7 kg each Coriolis Flow Meter 33 lbs 15 kg each Low Pressure Color Change Stack 6 color 3 0 lbs 1 4 kg High Pressure Color Change Stack 6 color 11 0 lbs 5 0 kg Gun Flush Box 22 lbs 9 6 kg ...

Page 58: ...anship 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 se...

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