Pump-Based Plural Component Proportioner

EN

Related Manuals

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

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 (resin) and component B (isocyanate) parts.

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 vis- cosity. If used, this partially cured ISO will reduce perfor- mance and the life of all wetted parts.

NOTE: The amount of film formation and rate of crystal- lization 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 con- taminated from the other side.

???Always lubricate threaded parts with ISO pump oil or grease when reassembling.

Changing Materials

???When changing materials, flush the equipment mul- tiple times to ensure it is thoroughly clean.

???Always clean the fluid inlet strainers after flushing.

???Check with your material manufacturer for chemical compatibility.

Dose Size - the amount of resin (A) and catalyst (B) that is dispensed into an integrator.

Dose Time Alarm - the amount of time that is allowed for a dose to occur before an alarm occurs.

Dynamic Dosing - Component A dispenses constantly. Component B dispenses intermittently in the necessary volume to attain the mix ratio.

Grand Total - a non-resettable value that shows the total amount of material dispensed through the system.

Intrinsically Safe (IS) - refers to the ability to locate cer- tain components in a hazardous location.

Idle - if the gun is not triggered for 2 minutes the system enters Idle mode. Trigger the gun to resume operation.

Batch Total - a resettable value that shows the amount of material dispensed through the system for one batch. A batch is complete when the user resets the batch counter to zero.

Mix - when cross-linking of the resin (A) and catalyst (B) occurs.

Overdose Alarm - when either the resin (A) or catalyst

(B) component dispenses too much material and the system cannot compensate for the additional material.

Potlife Time - the amount of time before a material becomes unsprayable.

Potlife Volume - the amount of material that is required to move through the mix manifold, hose, and applicator before the potlife timer is reset.

Pump Calibration Factor - the amount of material dis- pensed per inch of pump travel.

Purge - when all mixed material is flushed from the sys- tem.

Purge Time - the amount of time required to flush all mixed material from the system.

Ratio Tolerance - the settable percent of acceptable variance that the system will allow before a ratio alarm occurs.

Standby - refers to the status of the system.

Overview

Usage

The ProMix 2KE is an electronic two-component paint proportioner. It can blend most two-component paints. It is not for use with quick-setting paints (those with a pot life of less than 5 minutes).

???Has dynamic dosing capabilities. It dispenses mate- rial A, monitors fluid flow, and dispenses material B in doses to cause the mixture to stay on ratio.

???Can proportion at ratios from 0.1:1 to 30.0:1.

???Will display the last 50 errors with date, time, and event. The optional USB upgrade kit will log 500 errors and up to 2000 jobs.

???For systems with one gun, an optional Gun Flush Box provides an automated flushing system for a manual spray gun.

Do not substitute or modify system components as this may impair intrinsic safety. For installation, maintenance, or operation instructions, read instruction manuals. Do not install equipment approved only for non-hazardous location in a hazardous location. See the identification label for the intrinsic safety rating for your model.

1.The installation must meet the requirements of the National Electric Code, NFPA 70, Article 504 Resp., Article 505, and ANSI/ISA 12.06.01.

2.Multiple earthing of components is allowed only if high integrity equipotential system realized between the points of bonding.

3.For ATEX, install per EN 60079-14 and applicable local and national codes.

Installation

FIG. 2. Non-Hazardous Location Installation

USER INTERFACE

MODULE

Display Module

1.Use the screws provided to mount the bracket for the Display Module on the front of the Control Box or on the wall, as you prefer.

2.Snap the Display Module

3.Connect one end of the CAN cable (provided) to J6 on the Display Module (either port).

ti16604a

J6

4.The other end of the cable

comes from the factory connected as shown, depending on the configuration of your system:

Installation

Air Supply

Requirements

???Compressed air supply pressure: 75-100 psi (517-700 kPa, 5.2-7 bar).

???Air hoses: use grounded hoses that are correctly sized for your system.

Trapped air can cause a pump or dispense valve to cycle unexpectedly, which could result in serious injury from splashing or moving parts. Use bleed-type shutoff valves.

???Wall Power Systems with USB Module:

Connect the CAN cable to P3 on the USB Mod- ule.

???Wall Power Systems without USB Module:

Connect CAN cable to J8 on the Advanced Fluid Control Module.

P3

ti16580a

J8

If using a Graco electrostatic PRO??? Gun, a shutoff valve must be installed in the gun air line to shutoff the atomizing and turbine air to the gun. Contact your Graco distributor for information on air shutoff valves for electrostatic applications.

???Air line filter: a 10 micron or better air filter is rec- ommended to filter oil and water out of the air supply and help avoid paint contamination and clogged solenoids.

Air Connections

See the System Pneumatic Schematic on page 66 (hazardous location) or page 67 (non-hazardous loca- tion).

1.Tighten all ProMix 2KE system air and fluid line con- nections as they may have loosened during ship- ment.

2.Connect the main air supply line to the main air inlet. This air line supplies the solenoids, valves, and pumps. See FIG. 3.

Main Air

Inlet

ti15708a

FIG. 3. Air Supply Inlet

3.For each gun in the system, connect a separate clean air supply line to the air inlet of the air flow switch. This air supplies gun atomizing air. The air flow switch detects air flow to the gun and signals the controller when the gun is being triggered.

Fluid Supply

Requirements

???Do not exceed the pressure rating of the lowest rated component. See the identification label.

???To reduce the risk of injury, including fluid injection, you must install a shutoff valve between each fluid supply line and the mix manifold. Use the valves to shut off fluid during maintenance and service.

ProMix 2KE models are available to operate airless (high pressure, 50 cc pumps only), air spray, or air-assisted systems with a capacity of up to 3800 cc/min.

???Fluid supply pressure tanks, feed pumps, or circu- lating systems can be used.

???Materials can be transferred from their original con- tainers or from a central paint recirculating line.

NOTE: The fluid supply must be free of pressure spikes, which are commonly caused by pump stroke change- over. If necessary, install pressure regulators or a surge tank on the ProMix 2KE fluid inlets to reduce pulsation. Contact your Graco distributor for additional information.

Atomizing air outlets

Atomizing air inlets

Solenoid air inlet

Fluid Connections

1.See FIG. 5, page 15. Connect the solvent supply line to the 1/4 npt(f) solvent valve inlets (SVA and SVB).

2.Connect the component A supply line(s) to the com- ponent A dose valve inlet (DVA).

NOTE: Paint Recirculating System Only

???If you are recirculating paint, use the standard inlet on Dose Valve A or Dose Valve B. Remove the plug directly opposite it on the dose valve for the recircu- lation outlet. See FIG. 5.

3.Connect the component B line to the component B dose valve inlet (DVB).

ti15709a

Component

Inlet

ti16754a

SVA

DVA

PA

Key:

PA Component A Pump

DVA Component A Dose Valve

SVA Solvent Valve A

FIG. 5. Fluid Connections

Installation

Solvent inlet

Remove plug; recirculation outlet.

ti16755a

SVB

DVB

GFB1-A

ATOM-1

ATOM-2

A2

B Side

A1

A3

2G

2R

1R

1G

A5

A Side ti16765a

A5

See Manual 312784 for full setup instructions for a gun flush box.

A6

A Side

A3

A Side

ti16772a

4G

4R

3R

3G

A4

A4

A7

Installation

Electrical

Power Connection (non-IS units only)

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

Enclose all cables routed in the spray booth and high traffic areas in conduit to prevent damage from paint, solvent, and traffic.

The ProMix 2KE operates with 85-250 VAC, 50/60 Hz input power, with a maximum of 2 amp current draw. The power supply circuit must be protected with a 15 amp maximum circuit breaker.

Not included with system:

???Power supply cord compatible to your local power configuration. Wire gauge size must be 8-14 AWG.

???The input power access port is 22.4 mm (0.88 in.) in diameter. It accepts a bulkhead strain relief fitting or conduit.

1.Verify that electrical power at the main panel is shut off. Open Control Box cover.

2.Connect electrical cord to the terminal block as shown in FIG. 6.

3.Close the Control Box. Restore power.

4.Follow instructions in Grounding, page 19.

Line

Ground

Neutral

ti16391a

FIG. 6. Control Box Electrical Connection

TERMINAL

BLOCK

L N GRND

LN

SWITCH

ROCKER

21

FIG. 7. Electrical Schematic

Grounding

The equipment must be grounded. Grounding reduces the risk of static and electric shock by providing an escape wire for the electrical current due to static build up or in the event of a short circuit.

Connect the ProMix 2KE ground wire to the ground screw. Connect the clamp to a true earth ground. If wall power is used to power controls, ground electrical con- nection according to local codes.

AC

Power

Ground

Screw

TI15712a

FIG. 8. Ground Screw and Power Switch

Gun Flush Box

Connect a ground wire from the Gun Flush Box ground lug to a true earth ground.

Feed Pumps or Pressure Pots

Connect a ground wire and clamp from a true earth ground to the pumps or pots. See pump or pressure pot manual.

Installation

Air and Fluid Hoses

Use grounded hoses only.

Spray Gun

Follow the grounding instructions in your gun manual.

???Non-Electrostatic: Ground the spray gun through connection to a Graco-approved grounded fluid sup- ply hose.

???Electrostatic: Ground the spray gun through con- nection to a Graco-approved grounded air supply hose. Connect the air hose ground wire to a true earth ground.

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/con- tainers placed on a grounded surface. Do not place the pail/container on a nonconductive surface, such as paper or cardboard, which interrupts the grounding con- tinuity.

Check Resistance

To ensure proper grounding, resistance between components and true earth ground must be less than 1 ohm.

2

local code for requirements.

5

6

10 Power cable, Display Module/Control Box

3

4

9

7

8

ti16467a

Display

Shows graphical and text information related to setup and spray operations. The screen backlight is factory set to remain on. The user may set a number of minutes the screen can be inactive before the backlight dims. See Configure 3 (Screen 20), page 44. Press any key to restore.

NOTE: The Display Module and bracket can be removed from the cover of the electrical box and mounted remotely, if preferred.

Keys are used to input numerical data, enter setup screens, navigate within a screen, scroll through screens, and select setup values.

NOTICE

To prevent damage to the soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.

KeyFunction

Setup: Press to enter or exit

Setup mode.

Enter: Press to choose a field to update, to make a selection, or to save a selection or value.

Left/Right Arrows: Use to move from screen to screen.

Up/Down Arrows: Use to move among fields on a screen, items on a dropdown menu, or digits in a settable field.

Error Reset: Use to clear alarm so cause can be fixed. Also use to cancel a data entry field.

Standby: Stops the current operation and puts the system into standby.

Soft keys: Press to select the specific screen or operation shown on the display directly above each key.

General Icons

I

Icon Description

Pump

Meter

Dose Valve

Solvent Valve

Air Filter

Fluid Filter

Gun Flush Box

Park Pumps

Flush Time

Spray Gun States

I

Icon Description

Mix

Mix Spray

In Flush Box

Purge

Purge in Flush Box

Standby

Idle

Locked

Screen Shortcuts

I

Icon Description

Home

Spray

Alarm Log

Run Pumps

System Configuration

Recipes

Maintenance

Calibrate

Hose Length

Hose Diameter

Ratio

Potlife

Length

Volume

Pressure

Air Flow Switch

Flow Rate High/Low

Job Number

User Number

Operation Modes

I

Icon Description

Standby

Mix

Purge

Color Change

Dispense A

Dispense B

Batch

Calibrate

Forced

Park

Locked

Softkeys

I

Icon Description

Mix/Spray

Standby

Purge

Reset Counter

Start

Stop/Standby

Run Mode

The run mode has three screen sections that control the mixing operations.

Mix (Screens 2-4, 38)

???Spray (Screen 2) controls most mixing opera- tions.

???Batch (Screen 3) controls dispense of a set vol- ume.

???Totals (Screen 4) displays grand and batch totals for materials A and B.

???Job Number (Screen 38) displays job number and user number

Error Log (Screens 5-14)

???10 screens, 5 errors per page.

???Displays date, time, and error.

Pump Control (Screen 15)

???Manually start or stop a pump.

???Park pumps for brief shutdowns.

Setup Mode

The setup mode has four screen sections that allow an authorized user to choose the exact settings needed for the system:

Configure (Screens 18-21)

???Configure 1 (Screen 18) controls system type (pump or meter), gun flush box enable, and number of guns (1 or 2).

???Configure 2 (Screen 19) controls hose length and diameter for one or two guns, flow rate region setting, and air flow switch enable or disable.

???Configure 3 (Screen 20) controls language (for optional USB Module), date format, date, time, password setting, and backlight timer.

???Configure 4 (Screen 21) controls units for dis- tance, volume and pressure.

Recipe (Screens 28 and 29)

???Recipe 1-1 (Screen 28) and 1-2 (Screen 29) control Material 1/Color 1 parameters and flush.

Maintenance (Screens 24-26)

???Maintenance 1 (Screen 24) controls mainte- nance timer actual and target for Pump A, Pump B, Solvent Valve A, and Solvent Valve B.

???Maintenance 2 (Screen 25) controls dose valves A and B maintenance timers, actual and target.

???Maintenance 3 (Screen 26) controls fluid and air filter maintenance timers, actual and target.

Calibration (Screens 22 and 23)

???Calibration 1 (Screen 22) controls pump factors for Pump A and Pump B.

???Calibration 2 (Screen 23) allows the user to per- form a calibration.

Troubleshooting

The troubleshooting mode has three screen sections that allow an authorized user to troubleshoot system operation. See FIG. 14, page 28.

System Inputs (Screen 35)

Membrane Test (Screen 36)

System Outputs and Manual Activation (Screen 37)

Basic Operation

Pre-Operation Tasks

Go through the Pre-Operation Checklist in Table 1.

Table 1: Pre-Operation Checklist

???Checklist System grounded

Verify all grounding connections were made. See

Grounding, page 19.

All connections tight and correct

Verify all electrical, fluid, air, and system connec- tions are tight and installed according to the man- ual instructions.

Fluid supply containers filled

Check component A and B and solvent supply containers.

Dose valves set

Check that dose valves are set correctly. Start with the settings recommended in Valve Set- tings, page 35, then adjust as needed.

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)

Power On

1.IS Systems (Alternator Power Supply): Set pump air regulators to minimum setting. Open main air valve to start air-powered alternator. Main air pres- sure is displayed on gauge.

Basic Operation

Non-IS Systems (Wall Power Supplied): Turn the

AC Power Switch ON (I = ON, 0 = OFF).

I = ON

TI16336a

FIG. 15. Power Switch

2.Graco logo will display after five seconds, followed by Run Mix Spray (Screen 2).

FIG. 16. Run Mix Spray (Screen 2)

Initial System Setup

1.Change optional setup selections to desired param- eters, as described in Configure 1-4 (Screens 18-21), page 43.

2.Set recipe and flush information as described in

Recipe 1-1 (Screen 28) and Recipe 1-2 (Screen 29), page 44.

3.Set maintenance timers for pumps, valves, fluid fil- ters and air filters, as described in Maintenance 1-3 (Screens 24-26), page 45.

Prime the System

NOTE: See Run Mode Details, pages 39-41, for further screen information, if needed.

1.Adjust the main air pressure. Most applications require about 80 psi (552 kPa, 5.5 bar) air pressure to operate properly. Do not use less than 75 psi (517 kPa, 5.2 bar).

2.If this is the first time starting up the system, or if lines may contain air, purge as instructed in Purg- ing, page 32. The equipment was tested with light- weight oil, which should be flushed out to avoid contaminating your material.

3.From Run Home (Screen 1), press . Make sure that the system is in Standby mode.

Standby

4.Press to show the dropdown menu.

5.Press to highlight Pump A, then press .

6.Put Pump A into supply pail.

7.Adjust air pressure to component A

pump for your application. Use lowest pressure possible.

NOTE: Do not exceed the maximum rated working pres- sure shown on the system identification label or the low- est rated component in the system.

8.Open the fluid supply valve to the pump.

NOTE: If using an electrostatic gun, shut off the electrostatics before spraying.

9.If using a gun flush box, place the gun in the box

and close the lid. Press . The pump will run 12 cycles.

If the gun flush box is not used, trig- ger the gun into a grounded metal pail until the system returns to Standby.

10.Press to stop the pump before 12 cycles are completed. If the pump is not fully primed after 12 cycles, press again.

11.Repeat for Pump B.

Pump Calibration

NOTE: See Calibration 1 and 2 (Screens 22 and 23), page 46, for further screen information, if needed.

Calibrate the pump:

???The first time the system is operated.

???Whenever new materials are used in the system, especially if the materials have viscosities that differ significantly.

???At least once per month as part of regular mainte- nance.

???Whenever a pump is serviced or replaced.

NOTE:

???Pump factors on Calibration 1 (Screen 22) are updated automatically after the calibration pro- cedure is completed. You also may manually edit them if desired.

???All values on this screen are in cc or cc/in., regardless of the units set in Configure 4 (Screen 21).

???During each calibration the dispense valve will close during an up stroke and a down stroke (in either order). This test is to verify that the pump ball checks are seating properly and not leak- ing. If leaking occurs, the system will alarm after the calibration for that particular valve.

1.Before calibrating pump A or B, prime the system with material. See Prime the System, page 30.

2.If the display is on a Run Mode screen, press to access setup screens.

3.Press to display Calibration1 (Screen 22). Pump calibration factors are shown for Pump A and Pump B.

4.Press to move to Calibration 2 (Screen 23).

5.Press to highlight the pump you wish to cali- brate. Press . An X displays in the box.

6.Press to start the calibration on the checked pump (A or B). Press to cancel the calibration.

7.Trigger gun into a graduated cylinder. Dispense a minimum of 200-300cc of material.

NOTE: Stop triggering the gun when desired amount is

reached. Do not press , as it will cancel the calibra- tion.

8.The volume that the ProMix measured displays on the Display Module.

Volume measured by system displays here.

Enter dispensed volume here.

FIG. 17. Dispensed Volume Comparison

9.Compare the amount on the Display Module to the amount in the graduated cylinder.

NOTE: For maximum accuracy, use a gravimetric (mass) method to determine the actual volumes dis- pensed.

???If the screen and actual volumes are different, press

to highlight the dispense volume field. Press

. Press to move between digits. Press

to change a digit. Press when field is correct.

NOTE: If the value is substantially different, repeat the calibration process until the dispensed volume and mea- sured volume match.

10.After the volume for A or B is entered, the ProMix 2KE controller calculates the new pump factor and shows it on Calibration 1 (Screen 22) and Calibra- tion 2 (Screen 23).

11.Before you begin production, clear the system of solvent and prime it with material.

a.Go to Mix mode.

b.Trigger the gun into a grounded metal pail until mixed material flows from the gun nozzle.

If the fluid flow rate is too low: increase air pres- sure to component A and B fluid supplies or increase the regulated fluid pressure of mixed material.

If the fluid flow rate is too high: reduce the air pressure to component A and B fluid supplies, close the dose valves further, or decrease the reg- ulated fluid pressure of mixed material.

4.Turn on atomizing air to the gun. Check the spray pattern as instructed in your spray gun manual.

loaded, the system returns to Standby. Press again to spray the loaded recipe.

3.Adjust the flow rate. The fluid flow rate shown on the Display Module screen is for either component A or B, depending on which dose valve is open.

Flow

rate

Purging

NOTE: See Run Mode Details, pages 39-41, for further screen information, if needed.

There are 2 purging procedures in this manual:

???Purging Mixed Material

???Purging Fluid Supply System

Use the criteria listed for each procedure to determine which procedure to use.

Purging Mixed Material

There are times when you only want to purge the fluid manifold, such as:

???end of potlife

???breaks in spraying that exceed the potlife

???overnight shutdown or end of shift

???before servicing the fluid manifold assembly, hose or gun.

1.Press on Run Mix Spray (Screen 2) or from any screen to put the system in Standby.

2.Trigger the gun to relieve pressure.

3.If you are using a high pressure gun, engage the trigger lock. Remove spray tip and clean tip sepa- rately.

4.If using an electrostatic gun shut off the electrostat- ics before flushing the gun.

5.Set the solvent supply pressure regulator at a pres- sure high enough to completely purge the system in a reasonable amount of time but low enough to avoid splashing or an injection injury. Generally, a setting of 100 psi (0.7 MPa, 7 bar) is sufficient.

6.If using a gun flush box, place the gun into the box and close the lid.

7.Press on Run Mix Spray (Screen 2). 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 com- plete.

When done purging, the system automatically switches to Standby mode.

8.If the system is not completely clean, repeat step 6.

NOTE: If necessary, adjust purge sequence times so only one cycle is required.

Basic Operation

9.Trigger the gun to relieve pressure. Engage trigger lock.

10.If spray tip was removed, reinstall it.

11.Adjust the solvent supply regulator back to its nor- mal operating pressure.

NOTE: The system remains full of solvent.

NOTE: If your system uses 2 guns, you must trigger both guns simultaneously during a purge to purge both guns and lines. Verify that clean solvent flows from each gun. If not, repeat purge or clear clog/blockage in sys- tem.

Purging Fluid Supply System

Follow this procedure before:

???the first time material is loaded into equipment

???servicing

???shutting down equipment for an extended period of time

???putting equipment into storage

1.Press on Run Mix Spray (Screen 2) or from any screen to put the system in Standby.

2.Trigger the gun to relieve pressure.

3.If you are using a high pressure gun, engage the trigger lock. Remove spray tip and clean tip sepa- rately.

4.If using an electrostatic gun, shut off the electrostat- ics before flushing the gun.

5.Disconnect the component A and B fluid supplies at the pump inlets, and connect solvent supply lines.

6.Adjust the solvent fluid supply pressure. Use the lowest possible pressure to avoid splashing.

7.Remove the Control Box cover to access the sole- noid valves. See FIG. 19.

8.Purge as follows:

???Purge component A side. Press the manual override on the Dose Valve A solenoid valve and trigger the gun into a grounded metal pail.

???Purge component B side. Press the manual override on the Dose Valve B solenoid valve and trigger the gun into a grounded metal pail until clean solvent flows from the gun.

9.Reinstall the Control Box cover.

10.Shut off the solvent fluid supply.

11.Disconnect the solvent supply lines and reconnect the component A and B fluid supplies.

NOTE: The system remains full of solvent.

Pressure Relief Procedure

Basic Operation

Power down and power back up again to clear the lock and put the new settings into effect. The lock ensures that the selection was intended and prevents the user from attempting to operate with incorrect settings.

To reduce the risk of skin injection, relieve pressure when you stop spraying, before changing spray tips, and before cleaning, checking, or servicing equipment.

NOTE: The following procedure relieves all fluid and air pressure in the ProMix 2KE system.

1.Press on Run Mix Spray (Screen 2) or from any screen to put the system in Standby.

2.Follow procedure for Purging Fluid Supply Sys- tem, page 33, if desired or necessary.

3.Shut off air supply to A and B pumps and solvent supply pumps.

4.With the gun triggered, push the manual override on the A and B dose and solvent valve solenoids to relieve pressure. See FIG. 19. Verify that fluid pres- sure is reduced to 0.

5.Reinstall the Control Box cover.

Valve Settings

Dose valves and purge valves are factory set with the hex nut 1-1/4 turns out from fully closed. This setting limits maximum fluid flow rate into integrator and mini- mizes valve response time. To open dose or purge valves (for high viscosity materials), turn hex nut (E) counterclockwise. To close dose or purge valves (for low viscosity materials), turn clockwise. See FIG. 21.

E

TI11581a

FIG. 21. Valve Adjustment

Lock Mode

NOTE: Do not change system type, number of guns, hose length or hose diameter when material is loaded in the system. Change these inputs only if system hard- ware is changed.

If you change one of these inputs, the system locks so that you cannot spray or mix. If you have changed to a meter system, the system also locks if you change the dosing type or the number of colors. The lock icons dis- play.

Shutdown

1.Follow Purging, on page 32.

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

3.Non-IS Systems: Shut off ProMix 2KE power (0 position).

USB Logs

Job Log 1

See example in FIG. 22. The job log records total vol- umes for each job that the system performs, up to 2000. It records the date, time, user number, job number, total A volume, total B volume, and mix ratio. Job total vol- umes are in cubic centimeters. A log entry is made when a new job is initiated, which occurs when batch totals are cleared, or when the job number is incre- mented from Run Job Number (Screen 38). Job infor- mation is displayed on the Display Module only through use of the optional USB Module.

NOTE: User Number, Ratio, and Alarm 1-5 are dis- played as of 2KE System Software version 1.03.001 (USB Cube Software version 1.10.001).

Error Log 2

See example in FIG. 23. The error log records all errors generated by the system, up to 500. It records the date, time, error number, error code, and error type for each error that occurs. Without the USB, the user can access the 50 most recent errors via the Display Module.

NOTE: For both the Job Log and the Error Log, when the log is full, new data automatically overwrites old data. When data in either log is downloaded via the USB, it remains in the module until it is overwritten.

FIG. 23. Sample Error Log

Setup

The only setup required is to select the language in which you want to view the downloaded data. (Screens are icon-based and do not change.) Navigate to Config- ure 3 (Screen 20). Select your language from the lan- guage dropdown.

Language dropdown menu

Download Procedure

Remove proportioner from hazardous location before inserting, downloading, or removing the USB flash drive.

1.Press on Run Mix Spray (Screen 2) or from any screen to place the system in Standby.

NOTE: The system will not operate with a USB flash drive in the port. If you insert the flash drive while spray- ing, the system will stop and an alarm error will occur.

2.Insert USB flash drive into USB port. Use only Graco-recommended USB flash drives; see Rec- ommended USB Flash Drives, page 38.

3.Data download begins automatically. An LED on the flash drive blinks until the download is complete.

NOTE: If you use a flash drive that does not have an LED, open the Control Box. An LED near the USB mod- ule flashes until the download is complete.

4. Remove flash drive from USB port.

To help prevent fire and explosion, never leave the USB flash drive in the USB port.

USB Port

TI15712a

FIG. 25. USB Port

5. Insert USB flash drive into USB port of computer.

6.The USB flash drive window automatically opens. If it does not, open USB flash drive from within Win- dows?? Explorer.

7.Open Graco folder.

8.Open sprayer folder. If downloading data from more than one sprayer, there will be more than one sprayer folder. Each sprayer folder is labeled with the corresponding USB serial number.

9.Open DOWNLOAD folder.

10.Open folder labeled with the highest number. The highest number indicates the most recent data download.

11.Open log file. Log files open in Microsoft?? Excel?? by default. However, they can also be opened in any text editor or Microsoft?? Word.

NOTE:

All USB logs are saved in Unicode (UTF-16) format. If opening the log file in Microsoft Word, select Unicode encoding.

Recommended USB Flash

Drives

It is recommended that users use the 4GB USB flash drive (16A004) available for purchase separately from Graco. If preferred, users may use one of the following 4 GB or less USB flash drives (not available from Graco).

???Crucial Gizmo!??? 4GB USB flash drive (model JDO4GB-730)

???Transcend JetFlash?? V30 4GB USB flash drive (model TS4GJFV30)

???OCZ Diesel??? 4GB USB flash drive (model

OCZUSBDSL4G)

Run Mode Details

Run Mix Spray (Screen 2)

Run Mix Spray (Screen 2) displays at startup or if is selected from Run Home (Screen 1). Use the Mix Spray screen to control most mixing operations.

Potlife for each gun

FIG. 26. Run Mix Spray (Screen 2)

???Press to toggle between Run Mix Spray (Screen 2), Run Mix Batch (Screen 3), Run Mix Totals (Screen 4), and Run Job Number (Screen 38).

???Press to access Run Home (Screen 1).

Run Home (Screen 1)

Screen number

FIG. 27. Run Home (Screen 1)

???Press a soft key button to select one of the main

Run Mode screen sections: Mix , Errors , or Pump Control .

???Press to enter the Setup screens.

Run Mix Batch (Screen 3)

Run Mix Batch (Screen 3) displays if is selected from the Run Mix Spray Screen. Use the Mix Batch screen to dispense set volumes. Target volume can be set from 1 to 9999 cc.

Target ratio

Actual ratio

Target volume

Actual volume

FIG. 28. Run Mix Batch (Screen 3)

???Press to set the target dispense volume. Use

to change each digit, then to move

to the next digit. Press when finished.

???Press to toggle between Run Mix Spray (Screen 2), Run Mix Batch (Screen 3), Run Mix Totals (Screen 4), and Run Job Number (Screen 38).

Run Mix Totals (Screen 4)

Run Mix Totals (Screen 4) displays if is selected from the Run Mix Batch Screen. Use this screen to view grand and batch totals for material A and material B, and to clear batch totals if desired.

Run Job Number (Screen 38)

Run Job Number (Screen 38) displays if is selected from the Run Mix Totals Screen. Use this screen to view and increment the job number as well as view and assign a 9-digit user number to the job.

Batch total

Grand total

FIG. 29. Run Mix Totals (Screen 4)

???Press to clear all batch totals. A verification screen appears. Use to highlight and press on the to clear the batch totals, or on the to return to Run Totals (Screen 4) without clearing.

FIG. 30. Confirm Clear Batch Totals

???Press to toggle between Run Mix Spray (Screen 2), Run Mix Batch (Screen 3), Run Mix Totals (Screen 4), and Run Job Number (Screen 38).

Job number

User number

Home

FIG. 31. Run Job Number (Screen 38)

???Press to set the user number. Use to change each digit, then to move to the next digit. Press when finished.

???Press increment the job number.

???Press to toggle between Run Mix Spray (Screen 2), Run Mix Batch (Screen 3), Run Mix Totals (Screen 4), and Run Job Number (Screen 38).

Run Log Errors (Screens 5-14)

Run Log Errors (Screens 5-14) display if is selected from Run Home (Screen 1). It displays the last 50 errors in the log. (Screen 5 displays errors 1-5; Screen 6 displays errors 6-10, etc.).

Error codes

Error Icons

FIG. 32. Run Log Errors (Screen 5)

???Use to view the next page. See FIG. 54, page 50, for an explanation of the different error icons. See Table 3, page 52, for an explanation of the different error codes.

Setup Mode Details

Press on any screen to enter the Setup screens. If the system has a password lock, Password (Screen 16) displays. If the system is not locked (password is set to 0000), Setup Home (Screen 17) displays.

Password (Screen 16)

From any Run screen, press to access the pass- word screen. The Password Screen displays if a pass- word has been set. Set the password to 0000 to prevent Password (Screen 16) from displaying. See Configure 3 (Screen 20), page 44, to set or change the password.

FIG. 34. Password (Screen 16)

???Press to enter the password (0000 to 9999). Press to move between digits. Press

to change a digit. Press when field is correct. Setup Home (Screen 17) displays.

???Press to toggle between Run Mode and Setup Mode.

???Select to display Run Home (Screen 1). Enter- ing an incorrect password also displays Run Home (Screen 1).

Setup Home (Screen 17)

Setup Home (Screen 17) displays if is selected on any screen and the system is not locked, or when a cor- rect password is entered on the Password Screen. The Setup Home screen displays the software versions of the boards in the Display Module, Advanced Fluid Con- trol Module, and the USB Module (if applicable).

Software Version:

Display Module

Fluid Control Module

USB Module

Configure Recipe Maintenance Calibration

FIG. 35. Setup Home (Screen 17)

???Press a soft key button to select one of the four Setup Mode screen sections:

Configure , Recipe , Maintenance , or Calibration .

???Press to toggle between Run Mode and Setup Mode.

Configure 1 (Screen 18) displays if is selected on Setup Home (Screen 17). This screen allows users to set up the system type (pump or meter) and number of guns (1 or 2).

NOTE: If 1 gun is selected, users can enable a gun flush box (???=yes; X=no). The gun flush box option is avail- able only for 1-gun systems.

For all pump systems, the type of dosing is dynamic, and the number of colors is 1. See Dynamic DosingDy- namic Dosing, page 48, for more information.

Gun flush box

System

type

Number of guns

Home

FIG. 36. Configure 1 (Screen 18)

???Press to highlight the desired field. Press

to display the dropdown menu for that field.

Press to choose from the menu options and

to set. Press to move to the next field.

???Press to move through Configure 2 (Screen 19), Configure 3 (Screen 20), and Configure 4 (Screen 21).

NOTE: If you change system type (pump to meter) or number of guns, a verification screen appears. Use

to highlight and press on the to make the

change, or on the to return to Configure 1 (Screen 18) without making a change. If a change is made, the system locks so that you cannot spray or mix. Power down and power back up again to clear the lock and put the new settings into effect. The lock ensures that the selection was intended, and prevents the user from attempting to operate with incorrect settings.

FIG. 37. Confirm Change of System Type

Configure 2 (Screen 19) allows users to set for each gun the hose length (0.1 to 45.7 m, 0.3 to 150 ft) and hose diameter (0.1 to 1 inch). The system uses this informa- tion to calculate pot life volume. The pot life volume tells the system how much material must be moved to trigger a reset of the pot life timer. It also tells the system the volume needed to fill during a load sequence.

Users also can configure the flow rate region and the air flow switch. The flow rate region (High/Low) determines the sensitivity of the overdose alarm:

???Select the High setting if your flow rate is 250 cc/min or higher. The High setting has a 100cc over- dose volume.

???Select the Low setting if your flow rate is less than 250 cc/min. The Low setting has a 50 cc over- dose volume.

The air flow switch can be disabled here for airless applications. Select to enable or to disable.

A change in any of these fields will trigger the lock. See NOTE in previous paragraph.

FIG. 38. Configure 2 (Screen 19)

Configure 3 (Screen 20) allows users to set preferred language (for optional USB Module), date format, date, time, password (0000 to 9999), and number of minutes (0 to 99) of inactivity required before the backlight turns off. Configure 4 (Screen 21) allows users to set pre- ferred units for distance, volume, and pressure.

Setup Mode Details

USB log language

Date

format

Password

Date

Backlight

timer

Time

Configure 3

FIG. 39. Configure 3 (Screen 20) and Configure 4 (Screen 21)

Recipe 1-1 (Screen 28)

Recipe 1-2 (Screen 29)

Note about Settings of 0: If a Flush time is set to 0,

that valve will not flush.

Recipe 1-2 (Screen 29) includes timers for first, second and third flush:

???First flush: Always an A side purge, using the A side flush material from the A purge valve.

???Second flush: Always a B side purge, using the B side flush material from the B purge valve.

???Third flush: User settable to run the A purge valve or the B purge valve for any required additional flush, as selected in the dropdown for the third flush source (A or B).

All flush times are settable from 0 to 240 seconds. Set flush time to 0 seconds to skip a flush in the sequence. For example, to skip the first flush (A side purge), enter 0 seconds. The system goes immediately to the second flush, followed by the third flush as user defined.

thirde of 0flushsecondswith thetoskipA purgea flushvalve.Forforexample,30 secondsenter. 0 seconds for A, 30 seconds for B, 30 seconds for the third flush time, and select A for the third flush source. The system will skip the first A flush, go directly to the second flush with the B purge valve for 30 seconds followed by the

Note about Settings of 0: If Ratio is set to 0, the sys- tem will dispense the A material only. If Potlife Time is set to 0, the potlife alarm is disabled.

Recipe 1-1 (Screen 28) displays if is selected on Setup Home (Screen 17). The Recipe Screens allow the user to set up the basic recipe. Recipe 1-1 (Screen 28) includes the ratio of Material A to Material B (0 to 30), ratio tolerance (1 to 99 percent), and potlife time (0 to

First flush time (A purge)

Recipe number

Second flush time (B purge)

Third flush time (uses material set in next field)

Third flush source

Home

240 minutes).

Recipe

numberPotlife timer

Ratio

Ratio tolerance

Home

FIG. 40. Recipe 1-1 (Screen 28)

FIG. 41. Recipe 1-2 (Screen 29)

???Press to highlight the desired field and press

to select. Press to move between dig- its. Press to change a digit. Press when field is correct.

???Press to toggle between the Recipe screens.

???Press to return to Setup Home (Screen 17).

Maintenance 1-3 (Screens 24-26)

Maintenance 1 (Screen 24) displays if is selected on Setup Home (Screen 17). The Maintenance Screens display actual and target maintenance timers for pumps and solvent valves (Maintenance 1, Screen 24), dose valves (Maintenance 2, Screen 25), and fluid filters and air filters (Maintenance 3, Screen 26). Maintenance tim- ers for pumps and valves are settable from 0 to 9999999. Timers for filters are settable from 0 to 9999 days.

Solvent valves

Pumps

Maintenance actual and target

Maintenance 1

Clear Home

Totals

Dose valves

Maintenance 2

Air filter

Fluid

Maintenance 3

FIG. 42. Setup Maintenance 1-3 (Screens 24-26)

???Press to move through the three mainte- nance screens.

???Press to clear the maintenance total that is highlighted. A verification screen appears. Use

to highlight and press on the to clear the batch totals. No other button press will clear the

totals. Press on the to return to the active Maintenance Screen without clearing.

Maintenance Recommendations

The following table shows recommended starting values for maintenance. Maintenance needs will vary based on individual applications and material differences.

Calibration 1 and 2 (Screens 22 and 23)

NOTE: See Pump Calibration, page 31, for detailed instructions.

Calibration 1 (Screen 22) displays if is selected on Setup Home (Screen 17). This screen displays the pump factor for Pump A and Pump B. The factor is the pump displacement per inch. The system starts at the default factor for the pump size chosen on Configure 1 (Screen 18, page 43). Factor values update automati- cally as needed based on calibration results from Cali- bration 2 (Screen 23). Factor values also can be set on this screen, from 5 to 50 cc/in.

Pump B

Factor

Pump A

Factor

Home

FIG. 43. Calibration 1 (Screen 22)

Press to display Calibration 2 (Screen 23). This screen allows the user to perform a calibration. It dis- plays Pump A and Pump B factors, the target dispense volume, the actual dispense volume (0 to 9999 cc), and the material to dispense.

FIG. 44. Calibration 2 (Screen 23)

???Press to highlight the pump you wish to cali- brate. Press . An X displays in the box.

???Press to start the calibration on the highlighted pump (A or B). Press to cancel the calibration.

NOTE: If you press but calibration does not begin, check to be sure that you have selected Pump A or Pump B.

???Press to highlight the actual dispense vol- ume field. Press to set the volume (from 0 to

9999 cc). Press to move between digits. Press to change a digit. Press when field is correct.

???Use to toggle between Calibration 1 (Screen 22) and Calibration 2 (Screen 23).

Troubleshooting (Screens 35-37)

Screens for testing system controls can be accessed by setting the password to 9909. See Configure 3 (Screen 20), page 44, to set or change the password.

After setting the password to 9909, press to exit

Setup. Press to reenter Setup. Setup Home (Screen 17) displays, with troubleshooting screen options.

Troubleshooting screen options appear here.

FIG. 45. Setup Home with Troubleshooting

Troubleshooting System Inputs (Screen 35)

From Setup Home (Screen 17) with Troubleshooting

active, press to display Troubleshooting System Inputs (Screen 35). An X displays in the box to indicate if Pump B is up or down, if Pump A is up or down, if Air Flow Switch 1 or 2 is on, and if the gun is in the Gun Flush Box. This screen also displays the pressure of Pump A and Pump B. The fields relating to meter func- tion can be ignored.

Gun in Gun

Flush Box

FIG. 46. Troubleshooting System Inputs (Screen 35)

???Press , then again to move to Trouble-

shooting System Outputs (Screen 37). Press to move to the Membrane Test (Screen 36).

Troubleshooting System Outputs (Screen 37)

From Setup Home (Screen 17) with Troubleshooting

active, press to display Troubleshooting System Outputs (Screen 37). An X displays in the box to show an electrical state of On for the dose valves B and A1 (A2 and A3 are used only for meter systems), solvent valves (B and A), the gun flush box, and the alarm.

Press to start Forced Mode. A second set of check

boxes displays. Use to highlight an output to test. Manually actuate the valve, alarm, or gun trigger corresponding to the highlighted box. For properly work- ing components, an X will display in the second box

upon actuation. Press to exit Forced Mode. Moving to any other screen also will exit Forced Mode.

Gun

Trigger

Alarm

Start

Forced

Mode

Membrane Test (Screen 36)

From Setup Home (Screen 17) with Troubleshooting active, press , then again. Membrane Test (Screen 36) displays. You could also press , then

again. This screen allows an authorized user to test the buttons on the Display Module membrane. When in this screen, all buttons lose their predefined functions, and the soft keys are not defined. When a properly working button is pressed, an X appears in the box.

FIG. 47. Membrane Test (Screen 36)

???Press three times to return to Setup Home (Screen 17). Direct access to any other screen is not possible.

Stop

Forced

Mode

FIG. 48. Troubleshooting Screen Outputs (Screen 37)

Setup Mode Details

Dynamic Dosing

In typical operation (ratios 1:1 and above), component A dispenses constantly. Component B dispenses intermit- tently in the necessary volume to attain the mix ratio.

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.

A restrictor injects component B into a continuous stream of component A. The software controls the dura- tion and frequency of each injection. See FIG. 52 for a schematic diagram of the process.

Dynamic Dosing System Parameters

The following parameters affect dynamic dosing perfor- mance:

???Component A Flow: Ensure that the supply pump is sized to provide sufficient and uninterrupted flow. Note that component A provides majority of system flow at higher mix ratios.

???Component B Flow: Ensure that the supply pump is sized to provide sufficient and uninterrupted flow.

???Component A Pressure: Ensure precise pressure regulation. It is recommended that the component A pressure be 5-15% lower than the component B pressure.

???Component B Pressure: Ensure precise pressure regulation. It is recommended that the component B pressure be 5-15% higher than the component A pressure.

NOTE: When using dynamic dosing it is very important to maintain a constant, well-regulated fluid supply. To obtain proper pressure control and minimize pump pul- sation, install a fluid regulator on the A and B supply lines upstream of the meters.

Select a Component B Restrictor Size

If you cannot maintain the desired flow and spraying ratio, you may need to select a different restrictor. Use the charts on pages 61 to 65 to select an appropriate restrictor size based on the desired flow and mix ratio.

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 Ratio High error.

If component B pressure is too low, it will not be injected in sufficient volume. The valve will stay open too long, causing a Ratio Low error.

Selecting the correct component B restrictor size and balancing the A/B pressures will keep the system in the proper pressure range, resulting in a consistent mix ratio.

FIG. 50 shows the A to B pressure balance, read at the proportioner inlet. It is recommended that the compo- nent B pressure be 5-15% higher than the component A pressure to keep the system in the control range, hold the proper mix ratio, and obtain properly mixed material. If pressures are not balanced (???B Pressure Too High??? or ???B Pressure Too Low???), it may not be possible to hold the desired mix ratio. The system will generate an off ratio alarm and stop operation.

NOTE: In multi-flow rate systems, it is recommended that you set up the system to run properly at the highest flow rate, to ensure adequate fluid supply across the flow rate range.

In dynamic dosing, component A dose valve is con- stantly on. Component B dose valve will cycle on and off; one cycle every 0.5 ??? 1.0 seconds indicates proper balance.

Monitor system performance by watching the pressure readings for each pump on Run Pump Control (Screen 15).

FIG. 49. Monitor Pump Pressures

Warning messages also provide information on system performance. Adjust pressures accordingly. See Table 2 on page 49.

BPressure Too High

B Pressure

Too Low

B Pressure

Too High

B Pressure

Too Low

FIG. 50. A/B Control Range with Properly Sized Restrictor

NOTE: If the restrictor is too small, it may be necessary to supply more differential pressure than is available in your system.

FIG. 51. A/B Control Range with Too Large a Restrictor

System Errors

System Errors

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 buzzer sounds.

???Status bar on the Display Module shows the alarm code.

???Alarm is saved in the date/time stamped log.

Error Code Indicator

FIG. 53. Display Module Alarm Codes

System Advisory/Record Codes

TABLE 3 lists the advisory and record codes. Advisories and records do not stop operation or sound an alarm. If an advisory occurs, the Status bar on the Display Mod- ule shows the advisory icon and code. System records do not display on the Status bar. Both advisories and records are saved in the date/time stamped log, which can be viewed on the display or saved to a flash drive using optional USB port.

Record - no icon

Alarm icon

Advisory icon

FIG. 54. Error Log Icons

To Clear Error and Restart

NOTE: When an error occurs be sure to determine the error code before resetting it. If you forget which code occurred, use Run Log Errors (Screens 5-14), page 40, to view the last 50 errors, with date and time stamps.

To reset alarms, see Table 3, and Alarm Troubleshoot- ing, page 53. Many errors can be cleared by simply

pressing .

Air Flow Switch (AFS) Function

Air or Air-assisted Guns

The air flow switch (AFS) detects air flow to the gun and signals the ProMix 2KE controller when the gun is trig- gered. The gun icon on the Display Module shows spray when the AFS is activated.

If a pump fails, pure resin or catalyst could spray indefi- nitely if the ProMix 2KE does not detect the condition and intervene, which is why the AFS is so important.

If the ProMix 2KE detects through the AFS signal that the gun is triggered, yet one or both of the pumps are not running, a Dose Time Alarm (QTA1 or QTB1) occurs after 40 seconds and the system goes into Standby.

NOTE: Systems with a 45:1 pump ratio are designed for use with an airless gun. These systems contain no air flow switch and are set up so that they do not trigger a System Idle Warning.

NOTE: For airless applications with other pump ratios, the air flow switch can be disabled on Configure 2 (Screen 19).

System Errors

Error Codes

Table 3: System Alarm/Advisory/Record Codes

Alarm Codes - Alarm sounds, system stops, icon dis- plays until problem is solved and alarm is cleared.

Table 3: System Alarm/Advisory/Record Codes

Advisory Codes - No alarm, system continues operat- ing, icon displays on active screen until cleared

Record Codes - No alarm, system continues operating, no icon displays on active screen.

Use the graphs on pages 61- 65 as a guide to determine the correct restrictor size for your desired flow and mate- rial viscosity. Table 4 lists the available restrictor sizes.

Example:

Application: air spray system with a 5:1 mix ratio

Fluid Supply: 1:1 pumps at 100 psi (7 bar, 0.7 MPa)

Flow Rate: 300 cc/min at the gun

Select the Restrictor Size: choose either the 0.040 or 0.070 orifice, to ensure that the pressure differen- tial is not more than 10-20 psi (0.7-1.4 bar, 0.07-0.14 MPa), provided the fluid viscosities are similar to those tested.

???If the viscosity of component B is lower than the vis- cosity of the chart used for selection you may need to use a smaller restrictor or decrease the pressure differential.

???If the viscosity of component B is higher than the viscosity of the chart used for selection you may need to use a larger restrictor or increase the pres- sure differential.

???In systems using an air-assisted gun, if the fluid pressure of component A is higher than the compo- nent A pressure from the charts you may need to use a larger restrictor or increase the pressure dif- ferential.

Table 4: Restrictor Sizes

*These restrictors are included in Injection Kit 15U955.

???These restrictors are optional sizes, not included in the Injection Kit.

Differential Pressure between A and B

psi (bar, MPa)

4000 (276, 27.6)

2500 (172, 17.2)

2000 (138, 13.8)

1500 (103, 10.3)

1000 (69, 6.9)

500 (34, 3.4)

0

Flow Rate (cc/min)

Detail View

Differential Pressure between A and B

800 (55, 5.5)

600 (41, 4.1)

400 (28, 2.8)

200 14, 1.4)

Differential Pressure between A and B

500 (34, 3.4)

400 (28, 2.8)

300 (21, 2.1)

200 (14, 1.4)

100 (7, 0.7)

0

Flow Rate (cc/min)

Detail View

200 (14, 1.4)

150 (10, 1.0)

100 (7, 0.7)

50 (3.4, 0.34)

0

0

Key

#2 Restrictor

#3 Restrictor

#4 Restrictor

#7 Restrictor

Differential Pressure between A and B

120 8.3, 0.8)

100 (7, 0.7)

80 (5.5, 0.55)

60 (4.1, 0.41)

40 (2.8, 0.28)

20 (1.4, 0.14)

0

Flow Rate (cc/min)

Detail View

40 (2.8, 0.28)

30 (2.1, 0.21)

20 (1.4, 0.14)

10 (0.7, 0.07)

0

66

PUMPS SYSTEMS ONLY

AIR SUPPLY

ALTERNATOR

AIR REG.

18 PSI (.12 MPa,

1.2 BAR)

AIR

INPUT

PUMPS SYSTEMS ONLY

RELIEF VALVE 20 PSI (.12 MPa, 1.2 BAR)

1/2" O.D. x 60" LONG TUBE

TURBINE/POWER SUPPLY

3A0868G

Location Hazardous-Non

GAUGE

AIR REGULATOR

PUMP A PILOT

GAUGE

AIR REGULATOR

RELIEF VALVE

85/110 PSI (.58/.76GAUGE MPa, 5.8/7.6 BAR)

3/4" AIR FILTER

AUTO DRAIN 20 MICRON

AIR

INPUT

PUMPS SYSTEMS ONLY

PUMP B PILOT

3/8" TUBE

TO MANIFOLD

3/8" AIR REG.

AUTO DRAIN

5 MICRON

100 PSI (.7 MPa, 7 BAR)

3/4" BALL VALVE

BLEED TYPE

Schematic Pneumatic

Schematics

Schematics

Hazardous Location Electrical Schematic

GROUND

TERMINAL

J7

1UNUSED

2UNUSED

3UNUSED

4UNUSED

5UNUSED

SOLENOID/METER CABLE HARNESS

1

2

3

4

"A" PRESSURE

TRANSDUCER

CABLE SWITCH REED

SENSOR/ LINEAR

UNUSED

ALARM (+)

COMMON

PURGE A (+)

DOSE A1 (+)

+12 VDC

FLOW METER A SIG

COMMON

DOSE A2 (+)

DOSE A3 (+)

+5 VDC

AI (-)

COMMON AI (+)

SHIELD

LINEAR SENS "A" SIG.

UNUSED

REED SWITCH_BTM (DOWN)

REED SWITCH_TOP (UP)

REED SWITCH_COM LINEAR SENS "A" +5 VDC

LINEAR SENS "A" COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

FLUID

J4CONTROL

1

2MODULE

3

4

5

J12

1

2

3

4

5

J2

1

2

3

4

5

J14

1

2

3

4

5

6

7

8

J25

1

2

3

4

J25

1

2

3

4

J5

1UNUSED

2AFS #1 (+)

3COMMON

4PURGE B (+)

5DOSE B (+)

J13

1+12 VDC

2FLOW METER B SIG

3COMMON

4GFB INPUT/AFS #2 (+)

5GFB OUTPUT

4AI (+)

5SHIELD

J15

1LINEAR SENS "B" SIG.

2UNUSED

3REED SWITCH_BTM (DOWN)

4REED SWITCH_TOP (UP)

5REED SWITCH_COM

6LINEAR SENS "B" +5 VDC

7LINEAR SENS "B" COM

8UNUSED

J11

1UNUSED

2UNUSED

3UNUSED

4UNUSED

HARNESS CABLE SOLENOID/METER

5

6

7

8

9

10

11

12

13

14

1

2

3

4

5

6

7

8

9

10

11

12

13

14

"A" REED

SWITCH

"B" REED

SWITCH

"B" LINEAR

SENSORFERRITE

Schematics

Non-Hazardous Location Electrical Schematic

GROUND

TERMINAL

SOLENOID/METER CABLE HARNESS

1

2

3

4

5

6

7

8

9

10

11

12

13

14

1

2

3

4

5

6

7

8

9

10

11

12

13

14

"A" PRESSURE

TRANSDUCER

CABLE SWITCH REED

CAN_L

+V_CAN V_CAN_RTN CAN_H

SHIELD

UNUSED

ALARM (+)

COMMON

PURGE A (+)

DOSE A1 (+)

+12 VDC

FLOW METER A SIG

COMMON

DOSE A2 (+)

DOSE A3 (+)

+5 VDC

AI (-)

COMMON AI (+)

SHIELD

LINEAR SENS "A" SIG.

UNUSED

REED SWITCH_BTM (DOWN)

REED SWITCH_TOP (UP)

REED SWITCH_COM LINEAR SENS "A" +5 VDC

LINEAR SENS "A" COM

UNUSED

1

2

3

4

5

J12

1

2

3

4

5

J2

1

2

3

4

5

J14

1

2

3

4

5

6

7

8

J25

1

2

3

4

J25

1

2

3

4

"A" REED

SWITCH

"A" LINEAR

SENSOR

J7

1CAN_L

2+V_CAN

3V_CAN_RTN

4CAN_H

5SHIELD

J5

1UNUSED

2AFS #1 (+)

3COMMON

4PURGE B (+)

J13

1+12 VDC

2FLOW METER B SIG

3COMMON

4GFB INPUT/AFS #2 (+)

5GFB OUTPUT

J3

1+5 VDC

2AI (-)

3COMMON

4AI (+)

5SHIELD

J15

1LINEAR SENS "B" SIG.

2UNUSED

3REED SWITCH_BTM (DOWN)

4REED SWITCH_TOP (UP)

5REED SWITCH_COM

6LINEAR SENS "B" +5 VDC

7LINEAR SENS "B" COM

8UNUSED

J11

1UNUSED

2UNUSED

3UNUSED

4UNUSED

J11

1UNUSED

2UNUSED

3UNUSED

4UNUSED

"B" REED

SWITCH

"B" LINEAR

SENSOR

"B" PRESSURE

TRANSDUCER

REED SWITCH CABLE

LINEAR SENSOR/

HARNESS CABLE SOLENOID/METER