Graco TI12552a Installation Instructions Manual
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Graco TI12552a Installation Instructions Manual

Graco TI12552a Installation Instructions Manual

Plural component proportioner
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Installation
ProMix
Plural Component Proportioner
Automatic system for proportional mixing of plural component coatings, with Wall Mount
Fluid Station or RoboMix Fluid Station. For professional use only.
Approved for use in explosive atmospheres (except the EasyKey).
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
Automatic System with Wall Mount Fluid Station
®
2KS
See pages 4-7 for model information, including maxi-
mum working pressure. Equipment approval labels are
on page 3. Some components shown are not included
with all systems.
Automatic System with RoboMix Fluid Station
TI12553a
0359
312778G
EN
TI12552a
II 2 G

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  • Page 1 Read all warnings and instructions in this on page 3. Some components shown are not included manual. Save these instructions. with all systems. Automatic System with RoboMix Fluid Station Automatic System with Wall Mount Fluid Station TI12552a TI12553a 0359 II 2 G...

  • Page 2: Table Of Contents

    Air Supply ....... . 22 Graco Standard Warranty ....56 Requirements .

  • Page 3: Related Manuals

    15V825 Discrete I/O Board Kit PART NO. SERIES SERIAL MFG. YR. MAX AIR WPR Intrinsically safe equipment for Class I, Div 1, Group D, T3 GRACO INC. Ta = -20°C to 50°C P.O. Box 1441 15V256 Automatic FM08ATEX0073 Install per 289833 II 2 G...

  • Page 4: System Configuration And Part Numbers

    System Configuration and Part Numbers System Configuration and Part Numbers Wall Mount Fluid Station Configurator Key The configured part number for your equipment is printed on the equipment identification labels. See F for location of the identification labels. The part number includes one digit from each of the following six categories, depending on the configuration of your system.
  • Page 5 System Configuration and Part Numbers Hazardous Location Approval Models using a G3000, G3000HR, G3000A, or intrinsically safe Coriolis meter for both A and B meters are approved for installation in a Hazardous Location - Class I, Div I, Group D, T3 or Zone I Group IIA T3. Maximum Working Pressure Maximum working pressure rating is dependent on the fluid component options selected.

  • Page 6: Robomix Fluid Station Configurator Key

    System Configuration and Part Numbers RoboMix Fluid Station Configurator Key The configured part number for your equipment is printed on the equipment identification labels. See F for location of the identification labels. The part number includes one digit from each of the following six categories, depending on the configuration of your system.
  • Page 7 System Configuration and Part Numbers Hazardous Location Approval Models using a G250 or G250HR for both A and B meters are approved for installation in a Hazardous Location - Class I, Div I, Group D, T3 or Zone I Group IIA T3. Maximum Working Pressure Maximum working pressure rating for RoboMix Systems is 190 psi (1.31 MPa, 13.1 bar).
  • Page 8 System Configuration and Part Numbers 312778G...

  • Page 9: Accessories

    26A099 7 Color/1 Catalyst Change Kit 26A100 12 Color/1 Catalyst Change Kit NOTE: This is not a complete list of available accesso- ries and kits. Refer to the Graco website for more infor- mation about accessories available for use with this product.

  • Page 10: Warnings

    Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama- tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
  • Page 11 Warnings WARNING SKIN INJECTION HAZARD High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. • Tighten all fluid connections before operating the equipment.

  • Page 12: Important Two-Component Material Information

    Important Two-Component Material Information Important Two-Component Material Information Material Self-ignition Isocyanates (ISO) are catalysts used in two component materials. Isocyanate Conditions Some materials may become self-igniting if applied too thick. Read material manufacturer’s warnings and Safety Data Sheet (SDS). Spraying or dispensing materials that contain Keep Components A and B isocyanates creates potentially harmful mists, vapors, and atomized particulates.

  • Page 13: Moisture Sensitivity Of Isocyanates

    Important Two-Component Material Information Moisture Sensitivity of NOTE: The amount of film formation and rate of crystal- lization varies depending on the blend of ISO, the Isocyanates humidity, and the temperature. Exposure to moisture (such as humidity) will cause ISO Changing Materials to partially cure;...

  • Page 14: Important Acid Catalyst Information

    Important Acid Catalyst Information Important Acid Catalyst Information The 2KS Plural Component Proportioner is designed for acid catalysts (“acid”) currently used in two-component, wood-finishing materials. Current acids in use (with pH levels as low as 1) are more corrosive than earlier acids. More corrosion-resistant wetted materials of construction are required, and must be used without substitution, to withstand the increased corrosive properties of these acids.

  • Page 15: Component Identification And Definition

    Component Identification and Definition Component Identification and Definition See Table 1, and F . 3 for the wall mount system components and F . 4 for the RoboMix system components. Air Controls/ Filter BCV - acid model See the ProMix 2KS Repair-Parts manual for optional cable lengths.
  • Page 16 Component Identification and Definition Table 1: Component Descriptions Component Description Used to set up, display, operate, and monitor the system. The EasyKey accepts 85-250 EasyKey (EK) VAC, 50/60 Hz line power and converts that power to acceptable low voltage and optical signals used by other system components.
  • Page 17 Component Identification and Definition Table 1: Component Descriptions Component Description The following optional flow meters are available from Graco: Flow Meters (MA, MB, MS) • G3000 is a general purpose gear meter typically used in flow ranges of 75-3800 cc/min. (0.02–1.0 gal/min.), pressures up to 4000 psi (28 MPa, 276 bar), and viscosi- ties of 20–3000 centipoise.
  • Page 18 Component Identification and Definition Air Controls/ Filters Purge Air RoboMix Control Air See the ProMix 2KS Repair-Parts manual for optional cable lengths. TI12552a . 4. RoboMix System shown with Color/Catalyst Change and Flow Control 312778G...
  • Page 19 Component Identification and Definition Air Logic In Cable Path B Supply (1/4 npt) A Supply (1/4 npt) Ground Screw Air Purge TI12511a Solvent Supply (1/4 npt) A Dump Out B Dump Out Cover is removed for clarity TI12579a . 5: Details of RoboMix Fluid Station 312778G...

  • Page 20: Location

    8. For ATEX installations, interconnecting cabling specified is Type A cable in accordance with EN 60079-14. Optional Cables Optional CAN cables and fiber optic cables are available from Graco. See the ProMix 2KS Repair-Parts manual for available part numbers and lengths. 312778G...
  • Page 21 3’ CAN WARNING: Substitution of components Coriolis Meter Options, DMT 00 ATEX E 074 X (No exceptions): Network may impair intrinsic safety. For installation, Cable Size Graco P/N Endress+Hauser P/N maintenance or operation instructions, see instruction manual. 1/8” 15T633* 80A-04-A-SVW-9-A-N-A-B-B-A-S 3/8”...

  • Page 22: General Information

    • Air hoses: use grounded hoses that are correctly shows the basic components of an automatic Robo- sized for your system. Mix system. Contact your Graco distributor for actual system designs. • Be sure all accessories are adequately sized and pressure-rated to meet system requirements.
  • Page 23 (APV) and check valve (CV) fail. atomizing and turbine air to the gun. Contact your Graco distributor for information on air shutoff valves Do not shorten the 25 ft (7.6 m), 1/4 in. (6 mm) OD for electrostatic applications.

  • Page 24: Fluid Supply

    If necessary, install pressure regulators or a surge racies. tank on the ProMix fluid inlets to reduce pulsation. Con- tact your Graco distributor for additional information. 4. Connect the gun fluid supply line between the fluid manifold static mixer outlet and the gun fluid inlet.
  • Page 25 Fluid Supply TI12556b Key: Component A Meter SVB Component B Shutoff Valve DVA Component A Dose Valve Solvent Meter (accessory) RVA Component A Sampling Valve SPV Solvent Purge Valve SVA Component A Shutoff Valve APV Air Purge Valve Component B Meter Static Mixer DVB Component B Dose Valve Fluid Integrator...

  • Page 26: Setup The Fluid Manifold For Dynamic Dosing

    Fluid Supply Setup the Fluid Manifold for Dynamic Dosing If you will be operating using dynamic dosing, the fluid 5. See F . 13. Remove the remaining parts from the manifold must be setup properly for your application. restrictor housing (H). Retain the plug (J) and base Order the 15U955 Injection Kit (accessory).
  • Page 27 Fluid Supply 10. Install the two setscrews and o-rings (L3*). Install 13. Tune the fluid pressure and flow as explained in the the long setscrew (S) at the front of the housing, for ProMix 2KS Operation Manual. ease of access. NOTE: When using dynamic dosing it is very important 11.

  • Page 28: Solvent Meter Accessory

    The ProMix 2KS Solvent Push feature requires installa- 2. Connect a solvent supply line (SS) from the outlet of tion of the accessory solvent meter (MS). Order Graco the solvent meter (MS) to the inlet of the solvent Part No. 280555 S3000 Solvent Meter Kit. See manual purge valve (SPV).

  • Page 29: Flow Control

    Flow Control Flow Control The intrinsically safe flow regulator (FC) is required to 2. Connect a fluid inlet line from the static mixer tube at use flow control in your system. the fluid station to the 1/8 npt(f) inlet of the flow reg- ulator (FC).

  • Page 30: Electrical

    Electrical Electrical Requirements 3. Ground the EasyKey to a true earth ground. See Grounding, page 36. All electrical wiring must be completed by a qualified electrician and comply with all local codes and regula- tions. Enclose all cables routed in the spray booth and high traffic areas in conduit to prevent damage from paint, solvent, and traffic.

  • Page 31: Connect Easykey To Fluid Station Control

    Relief Port Audible Alarm Main Power Access Port TI12638a Ground Screw I/S Power Graco Web Discrete I/O Cable TI12657a Interface Connector Ports . 18. EasyKey Connections and AC Power Switch Connect EasyKey to Fluid black cable connectors to the matching connectors on the EasyKey circuit board.

  • Page 32: Fluid Station Control Board Switch Settings

    Electrical Fluid Station Control Board Switch Settings On the 2KS fluid station control board, set switch S1 to ON (down) or OFF (up), as shown in F . 20. (Fiber Optic Output - blue) (Fiber Optic Input - black) (Power Input) (Color Change Module) Set Switch S1...

  • Page 33: Connect Color Change Module

    Electrical Connect Color Change Module To install the color change module(s), see manual Set switches S3-S6 on the color change board(s) as 312787. shown in Table 2 and F . 21, depending on the number of color change boards and color change modules being Connect a 5-pin electrical cable from the labeled con- used in your system.
  • Page 34 Electrical Switch S3-S6 Positions TI13661a . 21. Color Change Board Switches S3-S6 312778G...
  • Page 35 Electrical WIRING DIAGRAM +12VDC COLOR 8 (21) COLOR 9 (22) +12VDC +12VDC COLOR 10 (23) COLOR 7 (20) +12VDC +12VDC COLOR 11 (24) COLOR 6 (19) +12VDC +12VDC COLOR 12 (25) COLOR 5 (18) +12VDC +12VDC CATALYST 4 (26) COLOR 4 (17) +12VDC +12VDC COLOR 3 (16)

  • Page 36: Grounding

    1 ohm, a different ground site may ground screw to a true earth ground. A ground wire and be required. Do not operate the system until the problem clamp, part no. 223547, is available from Graco. F . 23. is corrected.
  • Page 37 Electrical TI13897a . 23: Grounding 312778G...

  • Page 38: Install Automatic Upgrade Kit 15V256

    Install Automatic Upgrade Kit 15V256 Install Automatic Upgrade Kit 15V256 Install the Auto Key Board Use this kit to upgrade a ProMix 2KS manual system to an automatic system. 1. Shut off ProMix 2KS power (0 position). F . 24. Also shut off power at main circuit breaker.

  • Page 39: Install The Discrete I/O Board

    Install Automatic Upgrade Kit 15V256 Install the Discrete I/O Board Install the Discrete I/O board (1) in the position shown in . 26, using the four board supports (2) supplied in the kit. See F . 27 for board orientation. Install the I/O Terminal Strips 1.
  • Page 40 Install Automatic Upgrade Kit 15V256 Multiple Station TI12923a Integration Control J9 (Power Input/Alarm) J10 (Inputs/Outputs) (Remote I/O) J5 (Inputs/Outputs) J1 (Graphic Display) J4 (Membrane Ribbon Cable) Remove Screw J3 (Auto Key J8 (F.O. Out - blue) J7 (F.O. In - black) Board Plug-in) TI12924a .
  • Page 41 Install Automatic Upgrade Kit 15V256 I/O Terminal Strip Detail Pin 1 RS485 Integration A RS485 Integration B RS485 Integration Ground RS485 Network A RS485 Network B RS485 Network Ground Flow Control Calibrate Pin 1 Gun Trigger INPUTS Digital Common Remote Stop Alarm Reset General Alarm Digital Common...
  • Page 42 Install Automatic Upgrade Kit 15V256 Digital Output Common/Power Flow Rate Alarm Output Flow Calibrate Active Fill Active Mix Ready Output LED D1 Mix Active Output (green) Purge/Recipe Change Active Output Digital Output Common/Power Recipe Change Input Recipe Bit 5 Input Recipe Bit 4 Input Recipe Bit 3 Input Recipe Bit 2 Input...

  • Page 43: Schematic Diagrams

    Schematic Diagrams Schematic Diagrams System Pneumatic Schematic COLOR COLOR VALVE CHANGE STACKS CONTROL AIR EXHAUST MUFFLER MANIFOLD COLOR 1 COLOR 2 12 VDC COLOR 3 DOSE A COLOR 4 VALVE 4-WAY SOLENOID COLOR 5 COLOR 6 COLOR 7 COLOR 8 12 VDC COLOR SOLVENT DOSE B...

  • Page 44: System Electrical Schematic

    Schematic Diagrams System Electrical Schematic NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS system. Some compo- nents shown are not included with all systems. Non-Hazardous Area NON-HAZARDOUS AREA LINE OPERATOR INTERFACE FILTER DC OK 85-250 VAC POWER +24 VDC TERMINAL...
  • Page 45 Schematic Diagrams System Electrical Schematic NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS system. Some compo- nents shown are not included with all systems. Hazardous Area HAZARDOUS AREA FLUID PANEL CONTROL BOX 3X CABLE FLUID PWR (RED) PANEL COM (BLACK)

  • Page 46: Dimensions And Mounting Hole Layouts

    Dimensions and Mounting Hole Layouts Dimensions and Mounting Hole Layouts Wall Mount Fluid Station Mounting plate only shown, for clarity TI14134a TI11894b NOTE: Height is shown from top of panel to fluid shutoff valves, and does not include the effect of variable fluid integrator heights.
  • Page 47 Dimensions and Mounting Hole Layouts EasyKey Air Supply Control TI11895a TI11891a RoboMix Fluid Station TI13658a TI14133a Flow Control Module TI13659a TI14135a 312778G...

  • Page 48: Dynamic Dosing Restrictor Selection Graphs

    Dynamic Dosing Restrictor Selection Graphs Dynamic Dosing Restrictor Selection Graphs Use the graphs on pages 49- 53 as a guide to determine the correct restrictor size for your desired flow and mate- Table 3: Restrictor Sizes rial viscosity. Table 3 lists the available restrictor sizes. Size Code Orifice Size Part No.
  • Page 49 Dynamic Dosing Restrictor Selection Graphs (bar, MPa) 4000 (276, 27.6) 3500 (241, 24.1) #2 Restrictor #3 Restrictor 3000 #4 Restrictor (207, 20.7) #7 Restrictor 2500 (172, 17.2) 2000 (138, 13.8) 1500 (103, 10.3) 1000 (69, 6.9) See Detail View Below (34, 3.4) 1000 1500...
  • Page 50 Dynamic Dosing Restrictor Selection Graphs (bar, MPa) 1400 (97, 9.7) 1200 (83, 8.3) #2 Restrictor #3 Restrictor 1000 #4 Restrictor (69, 6.9) #7 Restrictor (55, 5.5) (41, 4.1) (28, 2.8) See Detail View Below 14, 1.4) 1000 1500 2000 2500 3000 3500 4000...
  • Page 51 Dynamic Dosing Restrictor Selection Graphs (bar, MPa) (55, 5.5) (48, 4.8) #2 Restrictor #3 Restrictor #4 Restrictor (41, 4.1) #7 Restrictor (34, 3.4) (28, 2.8) (21, 2.1) (14, 1.4) See Detail View Below (7, 0.7) 1000 1500 2000 2500 3000 3500 4000 Flow Rate (cc/min)
  • Page 52 Dynamic Dosing Restrictor Selection Graphs (bar, MPa) (21, 2.1) (17.2, 1.72) #2 Restrictor #3 Restrictor #4 Restrictor #7 Restrictor (14, 1.4) 10.3, 1.03) (7.0, 0.7) See Detail View Below (3.4, 0.34) 1000 1500 2000 2500 3000 3500 4000 Flow Rate (cc/min) Detail View (7, 0.7) (5.2, 0.52)
  • Page 53 Dynamic Dosing Restrictor Selection Graphs (bar, MPa) (14, 1.4 (12.4, 1.2 #2 Restrictor (11, 1.1) #3 Restrictor #4 Restrictor 9.7, 0.9) #7 Restrictor 8.3, 0.8) (7, 0.7) (5.5, 0.55) (4.1, 0.41) (2.8, 0.28) See Detail View Below (1.4, 0.14) 1000 1500 2000 2500...
  • Page 54 Dynamic Dosing Restrictor Selection Graphs 312778G...

  • Page 55: Technical Data

    Air filtration for air logic and purge air (Graco-supplied)......5 micron (minimum) filtration required; clean and dry air Air filtration for atomizing air (user-supplied) .

  • Page 56: Graco Standard Warranty

    With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective.

This manual is also suitable for:

Promix 2ksTi12553a

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