Graco PrecisionMix ii Datasheet

PRECISIONMIXII
3K System
For Proportional Mixing of Two and Three Component Coatings
Patent No. 5,368,059
Instructions – Parts List
GRACO INC.ąP.O. BOX 1441ąMINNEAPOLIS, MNą55440-1441
Copyright 2001, Graco Inc. is registered to I.S. EN ISO 9001
309107E
Read warnings and instructions.
See page 2 for the Table of Contents.

EEXia II A T3
ITS03ATEX21382
0359
II 2 G
Conforms to ANSI/UL
standard 2279
Class 1 Zone 0
AExia II A T4
110474
Certified to CAN/CSA
22.2 No. E79–11

2
Table of Contents
Warnings 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 2–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using this Manual 2–3. . . . . . . . . . . . . . . . . . . . . . . . .
Related Publications 2–4. . . . . . . . . . . . . . . . . . . . . .
How the PrecisionMix II 3K Works 2–6. . . . . . . . . .
Functional Diagrams 2–7. . . . . . . . . . . . . . . . . . .
Changing the Mixing Order 2–10. . . . . . . . . . . . . . . .
Flow Control Overview 2–12. . . . . . . . . . . . . . . . . . .
Flow Control Features 2–12. . . . . . . . . . . . . . . .
System Requirements 2–12. . . . . . . . . . . . . . . .
General Operation Sequence 2–12. . . . . . . . . .
One Gun Flow Control Using a Flow Meter
in the Mixed Material Line 2–13. . . . . . . . . .
Flow Control Components 2–14. . . . . . . . . . . . .
Flow Control Parameters 2–15. . . . . . . . . . . . . .
Using Recipes/Color Change 2–16. . . . . . . . . . . . . .
No Color Change 2–16. . . . . . . . . . . . . . . . . . . . .
Integrated Color Change 2–16. . . . . . . . . . . . . .
Integrated Color Change with Queue 2–17. . . .
Color Change Sequences 2–18. . . . . . . . . . . . .
Changing from One Color Change
Sequence to Another 2–19. . . . . . . . . . . . . .
Actual Valve Times 2–20. . . . . . . . . . . . . . . . . . .
Installation 3–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical Installation 3–3. . . . . . . . . . . . . . . . . . . . . . . .
Non-intrinsically Safe 3–4. . . . . . . . . . . . . . . . . .
Intrinsically Safe 3–5. . . . . . . . . . . . . . . . . . . . . .
Fluid Supply Requirements 3–6. . . . . . . . . . . . . . . . .
Mounting Components 3–7. . . . . . . . . . . . . . . . . . . .
For Wall Mounting 3–7. . . . . . . . . . . . . . . . . . . . .
Stand Mounting Kit 241501 3–9. . . . . . . . . . . . .
System Installation 3–10. . . . . . . . . . . . . . . . . . . . . . .
Install the Controller and User Interface 3–10.
Power Requirements 3–11. . . . . . . . . . . . . . . . .
Install the Fluid Panel with Fluid Meters 3–12.
Install the Air Control Kit 3–13. . . . . . . . . . . . . .
Install the Operator Station 3–13. . . . . . . . . . . .
Install the Color/Catalyst/Reducer
Change Valves and Solenoids 3–14. . . . . .
Install the Gun Flush Box and
Solenoid Box 3–16. . . . . . . . . . . . . . . . . . . . .
Install the Optional Flow Control 3–20. . . . . . . .
Fluid Connections 3–20. . . . . . . . . . . . . . . . . . . .
Pressure Test and Solvent Flush
the System 3–20. . . . . . . . . . . . . . . . . . . . . .
Digital Outputs 3–21. . . . . . . . . . . . . . . . . . . . . . .
Component Electrical Connections 3–22. . . . . . . . .
Controller Terminal Block 3–29. . . . . . . . . . . . . . . . .
Ground the System 3–30. . . . . . . . . . . . . . . . . . . . . .
Check the Resistance 3–31. . . . . . . . . . . . . . . . . . . .
Power-up Checklist 3–32. . . . . . . . . . . . . . . . . . . . . .
Checking Flow Control I/P Transducers 3–34.
Testing Flow Control External 4–20 mA Input
Signal 3–35. . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Test and Solvent Flush Procedure 3–36.
Test Color Valve Operation 3–36. . . . . . . . . . . .
Pressure Test Component A 3–36. . . . . . . . . . .
Pressure Test Component B and C 3–36. . . . .
Pressure Test the Solvent Lines 3–36. . . . . . . .
Operation 4–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Relief Procedure 4–3. . . . . . . . . . . . . . . . .
Operator Controls and Indicators 4–4. . . . . . . . . . . .
Operator Station 4–4. . . . . . . . . . . . . . . . . . . . . .
User Interface 4–6. . . . . . . . . . . . . . . . . . . . . . . .
Operating Checklist 4–7. . . . . . . . . . . . . . . . . . . . . . .
Mode Switch 4–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purging the Ratio Check Valves 4–8. . . . . . . . . . . . .
Purging the PrecisionMix II 3K System 4–10. . . . . .
Starting Production 4–12. . . . . . . . . . . . . . . . . . . . . . .
Stopping Production 4–14. . . . . . . . . . . . . . . . . . . . . .
Flow Control Operation 4–15. . . . . . . . . . . . . . . . . . .
Flow Control Tips 4–15. . . . . . . . . . . . . . . . . . . . . . . .
Integrated Color Change 4–16. . . . . . . . . . . . . . . . . .
Multiple Gun Flush Box Operation 4–16. . . . . . . . . .
Printer Reports 4–18. . . . . . . . . . . . . . . . . . . . . . . . . .
Run Mode Report 4–18. . . . . . . . . . . . . . . . . . . .
Recipe Report 4–19. . . . . . . . . . . . . . . . . . . . . . .
System Setup (Configuration) Report 4–20. . .
Job Totals Report 4–22. . . . . . . . . . . . . . . . . . . .
Batch Totals Report 4–22. . . . . . . . . . . . . . . . . .
Grand Totals Report 4–23. . . . . . . . . . . . . . . . . .
Alarm Report 4–23. . . . . . . . . . . . . . . . . . . . . . . .
Screen Map 5–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Run Monitor 6–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Home Screen 6–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Target/Actual 6–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Rate 6–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Potlife Timer 6–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Rate Setpoint 6–5. . . . . . . . . . . . . . . . . . . . . . . .
Enter New Setpoint 6–5. . . . . . . . . . . . . . . . . . . . . . .
Recipe Select 6–5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm History 6–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Integrated Color Change with Queue 6–7. . . . . . . .
Modify Queue Screen 6–8. . . . . . . . . . . . . . . . . . . . .
Totalizers 7–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Home Screen 7–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Select Recipe and Totalizer Screen 7–3. . . . . . . . . .
Job Totals 7–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Batch Totals 7–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grand Totals 7–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3
Table of Contents
System Configuration 8–1. . . . . . . . . . . . . . . . . . . . . . .
Home Screen 8–3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Password Screen 8–3. . . . . . . . . . . . . . . . . . . . . . . . .
Menu Screen 8–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Language 8–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Station Number 8–5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Units of Measurement 8–6. . . . . . . . . . . . . .
Recipes 8–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Potlife Timer 8–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Rate Limits 8–7. . . . . . . . . . . . . . . . . . . . . . . . . .
Solvent Meter 8–8. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purge Sequence: Valves 8–8. . . . . . . . . . . . . . . . . . .
Purge Sequence: Purge Alarms 8–9. . . . . . . . . . . .
Mixed Load Volumes 8–10. . . . . . . . . . . . . . . . . . . . .
Guns Setup 8–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mix/Purge 8–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Control 8–11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Integrator Volume 8–12. . . . . . . . . . . . . . . . . . . . . . . .
Integrated Color Change 8–12. . . . . . . . . . . . . . . . . .
Password Selection 8–12. . . . . . . . . . . . . . . . . . . . . .
Time and Date Set 8–13. . . . . . . . . . . . . . . . . . . . . . .
Display Setup 8–14. . . . . . . . . . . . . . . . . . . . . . . . . . .
Print Setup 8–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Flow Switch 8–15. . . . . . . . . . . . . . . . . . . . . . . . . .
Flow Control Setup 8–16. . . . . . . . . . . . . . . . . . . . . . .
Home Screen 8–16. . . . . . . . . . . . . . . . . . . . . . .
Password Screen 8–16. . . . . . . . . . . . . . . . . . . .
Menu Screen 8–16. . . . . . . . . . . . . . . . . . . . . . . .
Flow Control Options 8–17. . . . . . . . . . . . . . . . .
Flow Control Menu 8–17. . . . . . . . . . . . . . . . . . .
Source of Flow Control Data 8–18. . . . . . . . . . .
Flow Control Scaling 8–18. . . . . . . . . . . . . . . . . .
Flow Control Force Output 8–19. . . . . . . . . . . .
Flow Control Delay Time 8–19. . . . . . . . . . . . . .
Flow Control Meter Location 8–20. . . . . . . . . . .
Integrated Color Change Setup 8–21. . . . . . . . . . . .
Home Screen 8–21. . . . . . . . . . . . . . . . . . . . . . .
Password Screen 8–21. . . . . . . . . . . . . . . . . . . .
Menu Screen 8–21. . . . . . . . . . . . . . . . . . . . . . . .
Color Change Mode Screen 8–22. . . . . . . . . . .
Color Change Sequence 8–22. . . . . . . . . . . . . .
Color Change Graph Screen 8–23. . . . . . . . . . .
Purge and Mix Timer Values 8–23. . . . . . . . . . .
A Component Dump Timer Value 8–24. . . . . . .
A Component Solvent Timer Value 8–24. . . . .
B Component Dump Timer Value 8–25. . . . . . .
B Component Solvent Timer Value 8–25. . . . .
C Component Dump Timer Valve 8–26. . . . . . .
C Component Solvent Timer Valve 8–26. . . . .
Gun 1 Trigger Start/Duration Times 8–27. . . . .
Gun 2 Trigger Start/Duration Times 8–27. . . . .
Special 1, 2, 5, and 6
Trigger Start/Duration Times 8–28. . . . . . .
PrecisionMix II 3K Robotic Interface 8–29. . . . . . . .
Pressure Test and Solvent Flush
the System 8–29. . . . . . . . . . . . . . . . . . . . . .
PrecisionMix II 3K Robotic Applications 8–29.
Integrated Color Change 8–30. . . . . . . . . . . . . .
Non-integrated Color Change 8–31. . . . . . . . . .
Digital Inputs 8–32. . . . . . . . . . . . . . . . . . . . . . . .
Recipe Setup 9–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Home Screen 9–3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Password Screen 9–3. . . . . . . . . . . . . . . . . . . . . . . . .
Recipe Selection 9–4. . . . . . . . . . . . . . . . . . . . . . . . . .
Setup Menu with Integrated Color Change On
and Flow Control On 9–5. . . . . . . . . . . . . . . . . . .
Setup Menu with Integrated Color Change
and Flow Control Off 9–5. . . . . . . . . . . . . . . . . . .
Mix Ratio and Tolerance 9–6. . . . . . . . . . . . . . . . . . .
Color Change Sequence 9–7. . . . . . . . . . . . . . . . . . .
Purge Sequence 9–8. . . . . . . . . . . . . . . . . . . . . . . . . .
System Alarms with Flow Control On and
Hand Gun Selected 9–9. . . . . . . . . . . . . . . . . . . .
System Alarms with Flow Control On and
Automatic Gun Selected 9–10. . . . . . . . . . . . . .
System Alarms with Flow Control Off 9–10. . . . . . .
Meter Calibration Tests 9–11. . . . . . . . . . . . . . . . . . .
Component A Flow Meter Calibration 9–12. . . . . . .
Component B Flow Meter Calibration 9–13. . . . . . .
Component C Flow Meter Calibration 9–13. . . . . . .
Solvent Flow Meter Calibration 9–14. . . . . . . . . . . .
Mixed Material Calibration Screen 9–14. . . . . . . . . .
Gun 1 Meter Calibration 9–15. . . . . . . . . . . . . . . . . .
Setup Flow Control 9–16. . . . . . . . . . . . . . . . . . . . . . .
Gain Factor Graphs 9–17. . . . . . . . . . . . . . . . . . . . . .
Flow Meter Calibration Procedure 9–18. . . . . . . . . .
Selection 1, 2, 3, or 4: Calibrating the
Meters Individually 9–18. . . . . . . . . . . . . . . .
Selection 6: Calibrating the Gun 1 Meter 9–20
Selection 5: Mixed Material Calibration 9–21. .

4
Table of Contents
Troubleshooting 10–1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Revision Number 10–2. . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Reference 10–3. . . . . . . . . . . . . . . .
Alarm Troubleshooting 10–7. . . . . . . . . . . . . . . . . . . .
To Clear the Alarm and
Restart the System 10–7. . . . . . . . . . . . . . .
Ratio Low or Ratio High 10–8. . . . . . . . . . . . . . .
Dose Time A, B, or C 10–9. . . . . . . . . . . . . . . . .
Overdose A, B, or C 10–9. . . . . . . . . . . . . . . . . .
Flow Rate Alarms for a System without
Flow Control 10–10. . . . . . . . . . . . . . . . . . .
Flow Too Low 10–10. . . . . . . . . . . . . . . . . .
Flow Too High 10–10. . . . . . . . . . . . . . . . . .
Flow Rate Alarms for a System with
Flow Control 10–10. . . . . . . . . . . . . . . . . . .
Gun #1 High/Low Flow 10–10. . . . . . . . . .
Gun # 2 High/Low Flow 10–10. . . . . . . . . .
Pot Life Exceeded 10–10. . . . . . . . . . . . . . . . . .
Purge/Load Interlock Not Ready 10–11. . . . . . .
Invalid Recipe 10–11. . . . . . . . . . . . . . . . . . . . . .
I/O Change 10–11. . . . . . . . . . . . . . . . . . . . . . . . .
Purge Not Completed 10–11. . . . . . . . . . . . . . . .
Purge Time Out 10–11. . . . . . . . . . . . . . . . . . . . .
Display Battery Low 10–12. . . . . . . . . . . . . . . .
Control Battery Low 10–12. . . . . . . . . . . . . . . .
Memory Failure 10–12. . . . . . . . . . . . . . . . . . . .
Communications Error 10–12. . . . . . . . . . . . . .
Invalid Guns From Input/Output Alarm 10–12
Air Flow Switch Alarm 10–12. . . . . . . . . . . . . .
Defaults Loaded 10–12. . . . . . . . . . . . . . . . . . .
Software Revision Alarm 10–12. . . . . . . . . . . .
Configuration Module Alarm 10–12. . . . . . . . .
External Alarms 10–12. . . . . . . . . . . . . . . . . . . .
Warnings 10–13. . . . . . . . . . . . . . . . . . . . . . . . . .
Job Total Rollover 10–13. . . . . . . . . . . . . . . . . .
Batch Total Rollover 10–13. . . . . . . . . . . . . . . .
Grand Total Rollover 10–13. . . . . . . . . . . . . . . .
Calibrate A Meter 10–13. . . . . . . . . . . . . . . . . .
Calibrate B Meter 10–13. . . . . . . . . . . . . . . . . .
Calibrate C Meter 10–13. . . . . . . . . . . . . . . . . .
Solenoid Box Troubleshooting 10–14. . . . . . . . . . .
Gun Flush Box Troubleshooting 10–16. . . . . . . . . .
Operator Station
with Color Change Troubleshooting 10–17. . .
Service 11–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the User Interface Battery 11–3. . . . . . .
Replacing the Controller Battery 11–4. . . . . . . . . . .
Replacing Isolation Barrier Fuses 11–5. . . . . . . . . .
Replacing the User Interface 11–5. . . . . . . . . . . . . .
Replacing the Power Supply 11–6. . . . . . . . . . . . . . .
Changing the Power Supply Voltage 11–6. . . . . . . .
Replacing Power Supply Fuses 11–6. . . . . . . . . . . .
Servicing the Operator Station 11–7. . . . . . . . . . . . .
Replacing Control Modules 11–8. . . . . . . . . . . . . . . .
Replacing Control Submodules 11–9. . . . . . . . . . . .
Parts 12–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller with User Interface 12–3. . . . . . . . . . . . . .
Part No. 243540 12–3. . . . . . . . . . . . . . . . . . . . .
Part No. 243541 12–3. . . . . . . . . . . . . . . . . . . . .
Controller 12–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part No. 240834 12–4. . . . . . . . . . . . . . . . . . . . .
Flow Control 12–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
One Gun 12–6. . . . . . . . . . . . . . . . . . . . . . . . . . . .
One Gun with Flow Meter in
Mixed Material Line 12–6. . . . . . . . . . . . . . .
Communication Ports 12–8. . . . . . . . . . . . . . . . . . . .
Part No. 241379 12–8. . . . . . . . . . . . . . . . . . . . .
Part No. 241378 12–8. . . . . . . . . . . . . . . . . . . . .
Software Utilities Kit 12–8. . . . . . . . . . . . . . . . . . . . . .
Part No. 243546 12–8. . . . . . . . . . . . . . . . . . . . .
Fluid Panel 12–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non-Intrinsically Safe 12–9. . . . . . . . . . . . . . . . .
Intrinsically Safe 12–9. . . . . . . . . . . . . . . . . . . . .
Fluid Panel Module 12–10. . . . . . . . . . . . . . . . . . . .
Part No. 243493 12–10. . . . . . . . . . . . . . . . . . .
Solenoid Module 12–12. . . . . . . . . . . . . . . . . . . . . . .
Part No. 552184 12–12. . . . . . . . . . . . . . . . . . .
Part No. 552186 12–12. . . . . . . . . . . . . . . . . . .
Fluid Meters 12–13. . . . . . . . . . . . . . . . . . . . . . . . . .
Part No. 243512 12–13. . . . . . . . . . . . . . . . . . .
Part No. 243513 12–13. . . . . . . . . . . . . . . . . . .
Part No. 243515 12–14. . . . . . . . . . . . . . . . . . .
Air Supply Station 12–16. . . . . . . . . . . . . . . . . . . . . .
Part No. 570122 12–16. . . . . . . . . . . . . . . . . . .
Operator Station 12–17. . . . . . . . . . . . . . . . . . . . . . .
Part No. 240835 12–17. . . . . . . . . . . . . . . . . . .
Part No. 240877 12–18. . . . . . . . . . . . . . . . . . .
Low Pressure Color Change Module 12–19. . . . .
Part No. 241386 12–19. . . . . . . . . . . . . . . . . . .
Part No. 242025 12–19. . . . . . . . . . . . . . . . . . .
Part No. 241387 12–20. . . . . . . . . . . . . . . . . . .
Part No. 242026 12–20. . . . . . . . . . . . . . . . . . .
High Pressure Color Change Module 12–22. . . . .
Part No. 241499 12–22. . . . . . . . . . . . . . . . . . .
Part No. 241500 12–23. . . . . . . . . . . . . . . . . . .
Part No. 907347 12–25. . . . . . . . . . . . . . . . . . .
Color Change Valve Assemblies 12–26. . . . . . . . .
Low Pressure Color Change Valves 12–26. . .
High Pressure Color Change Valves 12–26. .
Valve Bracket Changing Procedure 12–27. . .

5
Table of Contents
Gun Flush Box 12–28. . . . . . . . . . . . . . . . . . . . . . . .
Part No. 241389 12–28. . . . . . . . . . . . . . . . . . .
Part No. 241394 12–28. . . . . . . . . . . . . . . . . . .
Gun Flush Solenoid Box 12–29. . . . . . . . . . . . . . . .
Part No. 115125 12–29. . . . . . . . . . . . . . . . . . . .
Gun Holders for Gun Flush Box 12–30. . . . . . . . . .
Cable Chart 12–31. . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote User Interface 12–32. . . . . . . . . . . . . . . . .
Part No. 240874 12–32. . . . . . . . . . . . . . . . . . .
Stand Mount 12–33. . . . . . . . . . . . . . . . . . . . . . . . . .
Part No. 241501 12–33. . . . . . . . . . . . . . . . . . .
Audio/Visual Alarm 12–33. . . . . . . . . . . . . . . . . . . . .
Part No. 241380 12–33. . . . . . . . . . . . . . . . . . .
Accessories 12–34. . . . . . . . . . . . . . . . . . . . . . . . . . .
Part No. 241647 Catalyst Change Kit 12–34.
Part No. 195048 Paint Shield 12–34. . . . . . . .
Part No. 195049 Paint Shield 12–34. . . . . . . .
Part No. 241263 Printer Kit 12–34. . . . . . . . . .
Printer Power Supply 12–34. . . . . . . . . . . . . . .
Part No. 514037 Printer Paper 12–34. . . . . . .
Manual Dump Valve Kits 12–35. . . . . . . . . . . .
2K Fluid Outlet Valves 12–35. . . . . . . . . . . . . .
Part No. 513052 Air Flow Switch 12–35. . . . .
Part No. 241962 Hydro-Softfeel
Material Application Kit 12–35. . . . . . . . . .
Cable Network PC AMR 12–35. . . . . . . . . . . . .
Catalyst Supply Modules 12–35. . . . . . . . . . . .
Utilities Software 13–1. . . . . . . . . . . . . . . . . . . . . . . . . . .
Utilities Overview 13–3. . . . . . . . . . . . . . . . . . . . . . . .
Connection Error 13–3. . . . . . . . . . . . . . . . . . . . . . . .
Mode Switch 13–3. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Backup PrecisionMix II 13–4. . . . . . . . . . . . . . . . . . .
Restore PrecisionMix II 13–7. . . . . . . . . . . . . . . . . . .
Update the Operating System 13–9. . . . . . . . . . . . .
Update PrecisionMix II Program 13–11. . . . . . . . . .
Connecting Utilities 13–12. . . . . . . . . . . . . . . . . . . .
Update User Interface Program 13–13. . . . . . . . . .
Reset PrecisionMix II Password 13–15. . . . . . . . .
Set PrecisionMix II Date and Time 13–16. . . . . . .
Open Graco Web Site 13–17. . . . . . . . . . . . . . . . . .
Edit Language 13–17. . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 14–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Standard Warranty 14–6. . . . . . . . . . . . . . . . . . .
Graco Phone Number 14–6. . . . . . . . . . . . . . . . . . . . . .

6

1–1Warnings
Warnings
1

1–2 Warnings

1–3Warnings
WARNING
FIRE, EXPLOSION, AND ELECTRIC SHOCK HAZARD
Improper grounding, poor air ventilation, open flames, or sparks can cause a hazardous condition and
result in fire or explosion and serious injury.
The PrecisionMix Controller must only be installed and serviced by a qualified electrician.
The PrecisionMix Controller is for use only in non-hazardous locations. The maximum applied relay
voltage shall not exceed +24 volts. Do not operate the controller in hazardous locations, as defined
in Article 500 of the National Electrical Code (USA).
Ground the equipment and the object being sprayed. See Ground the System on page 3–30.
Do not install non-intrinsically safe equipment in a hazardous area.
Provide fresh air ventilation to avoid the buildup of flammable vapors from solvent or the fluid being
sprayed.
Extinguish all the open flames or pilot lights in the spray area.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Do not turn on or off any light switch in the spray area while operating or if fumes are present.
Do not smoke in the spray area.
Do not operate a gasoline engine in the spray area.
If there is any static sparking while using the equipment, stop spraying immediately. Identify and
correct the problem.
Keep liquids away from the electrical components.
Disconnect electrical power at the main switch before servicing the equipment.
The battery inside the PrecisionMix Controller may explode if mishandled. Do not recharge or
disassemble the battery. Do not expose the battery to fire or heat. The battery is intended for use
at normal temperatures, where high temperature cycles are not expected to exceed 212F
(100C).
TOXIC FLUID HAZARD
Hazardous fluids or toxic fumes can cause serious injury or death if splashed in the eyes or on the
skin, swallowed, or inhaled.
Know the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Wear the appropriate protective clothing, gloves, eyewear, and respirator.

1–4 Warnings
WARNING
INJECTION HAZARD
Spray from the gun, hose leaks, or ruptured components can inject fluid into your body and cause
extremely serious injury, including the need for amputation. Splashing fluid in the eyes or on the skin
can also cause serious injury.
Fluid injected into the skin might look like just a cut, but it is a serious injury. Get immediate medi-
cal attention.
Do not point the spray gun at anyone or at any part of the body.
Do not put hand or fingers over the spray tip.
Do not stop or deflect fluid leaks with your hand, body, glove, or rag.
Follow the Pressure Relief Procedure on page 4–3 whenever you: are instructed to relieve pres-
sure; stop spraying; clean, check, or service the equipment; or install or clean the spray tip.
Tighten all the fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily. Replace worn, damaged, or loose parts immediately.
Permanently coupled hoses cannot be repaired; replace the entire hose.
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture, malfunction, or start unexpectedly and result
in serious injury.
This equipment is for professional use only.
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are uncertain about usage, call your Graco
distributor.
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
Check the equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated system component. See the
instruction manuals of the individual PrecisionMix components for their maximum working pres-
sures.
Route the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces. Do not
expose Graco hoses to temperatures above 180F (82C) or below –40F (–40C).
Do not use the hoses to pull the equipment.
Do not move pressurized equipment.
Use fluids or solvents that are compatible with the equipment wetted parts. See the Technical
Data section of all the equipment manuals. Read the fluid and solvent manufacturer’s warnings.
Comply with all applicable local, state and national fire, electrical and other safety regulations.

Overview 2–1
Overview
2

2–2 Overview

Overview 2–3
Using this Manual
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
Special Note Symbol
This symbol precedes information that should
be taken special note of.
Screen Navigation Symbol
This symbol precedes information that tells you
how to enter information and navigate through
the User Interface screens.
Text that appears in grey on the screens in these
instructions indicates lines that may or may not appear
on your display, depending on previous selections that
have been made.
Text that appears in a grey box indicates a selection
that is being recommended or explained in that sec-
tion of the instructions.
Manual Overview
The information is organized in the following way:
1. Warnings: Read this section for important safety
information.
2. Overview: This section provides information on
the instruction manuals and on PrecisionMix II 3K
Component ID and function.
3. Installation: This section provides information on
installing a configured PrecisionMix II 3K system.
After installation is complete, a startup checklist is
provided to verify the system is installed correctly
and ready to begin production. Portions of the
checklist will guide you to other procedures, such
as purging the system and configuring the soft-
ware, to prepare the system for production.
4. Operation: The Pressure Relief Procedure and
miscellaneous operation procedures are in this
section.
5. Screen Map: The screen map shows the general
layout of all the User Interface screens and pro-
vides the page number to go to for more detailed
information on each screen.
6. Run Monitor: This section covers the use of the
Run Monitor screens.
7. Totalizer: This section covers the use of the
Totalizer screens.
8. System Configuration: This section covers how
to use the System Configuration screens. These
screens are used to configure how the system will
operate. Integrated color change and flow control
are part of the system configuration.
9. Recipe Setup: This section covers how to use the
Recipe Setup screens to setup recipes.
10. Troubleshooting: This section provides informa-
tion on troubleshooting alarm conditions and some
system problems.
11. Parts: This section includes parts drawings and
lists for components of the PrecisionMix II 3K
system.

2–4 Overview
Related Publications
Form No. Description
308288 Fluid Manifold Manual
308778 G3000 Meter Manual
309148 Piston Meter Manual
309149 Magnetic Meter Manual
307731 LP Color Change Valve Assy. Manual
307941 LP Color Change Valve Manual
308977 HP Color Change Valve Assy. Manual
Form No. Description
308291 HP Color Change Valve Manual
309227 Gun Flush Box Manual
308818 Printer Manual
308292 Fluid Pressure Regulator
309138 System Electrical Schematic
309158 System Configurator Schematic
309234 Coriolis Meter Manual

Overview 2–5

2–6 Overview
How the PrecisionMix II 3K Works
Usage
The standard Graco PrecisionMix II 3K can blend most
two and three component epoxy or polyurethane
paints. The PrecisionMix is not for use with “quick-set-
ting” paints (those with a pot life of less than 15 min-
utes). For information on handling quick-setting paints
or abrasive fluids, contact your Graco distributor.
Fluid Supply
The system can be set up to mix components supplied
from pressure tanks or feed pumps. The materials can
be transferred from their original containers or from a
central paint recirculating line.
The standard PrecisionMix II 3K is designed to operate
an air spray or air-assisted system with a capacity of
up to 2000 cc/min.
Adaptive Overrun Correction
The actual volume of fluid dispensed each cycle can
vary slightly from the calculated target. However, the
controller monitors this variance and continuously
makes adjustments to keep the ratio of Component A
to Component B and the ratio of Component C to
Component B within the user specified tolerance.
Operating Cycle
The 3K fluid manifold consists of four separate fluid
supply lines for Component A, B, C, and the flushing
material. The Component A, B, and C supply lines
have the following parts to individually control the flow
of the three materials. Refer to Fig. 2.2.
Fluid filters (DA, DB, DC)
Check valves (EA, EB, EC)
Flow meters (FA, FB, FC)
Dispense valves (GA, GB, GC)
The dispense valves control the entry of the compo-
nents into the integrator chambers. The flow meters
monitor the exact fluid volumes being dispensed and
send electrical pulses to the controller. The controller
monitors these pulses and signals the solenoids to turn
the dispense valves on or off accordingly (based on
the target volumes calculated by the controller).
Other inputs and outputs are provided to control the
purging process, signal an alarm, and interface with
the operator. Refer to Fig. 3.21, page 3–29.
The order in which the three components are mixed
depends on the characteristics of the materials being
used. In the standard configuration, Component A is
mixed with Component C first, then the blend of A and
C is mixed with Component B. The instructions in this
manual correspond with this mixing order.
To convert the PrecisionMix II 3K to a configuration
where Component A is mixed with Component B
before Component C is added, refer to Changing the
Mixing Order, on page 2–10.
The following is a typical ratio cycle:
Figures 2.2, 2.3, and 2.4 show the flow of fluid through
component lines A, B, and C during this cycle.
1. To begin operation, the operator enters the desired
ratio and other parameters through the User
Interface (BB) and turns the operator switch (AA)
to MIX .
AA BB
Fig. 2.1
2. When the operator triggers the spray gun, the
controller sends a signal to activate the solenoid
valve for the component A dispense valve (GA).
See Fig. 2.2.
3. The component A dispense valve (GA) opens and
Component A begins to flow into the first integrator
chamber (L). When the correct quantity is dis-
pensed (based on the calculated target value), the
component A dispense valve closes. See Fig. 2.2.

Overview 2–7
How the PrecisionMix II 3K Works
Functional Diagram – Component A Dispense
Fig. 2.2
KEY for Figs. 2.2, 2.3, and 2.4
Component A
A Supply Line, Component A
DAFluid Filter, Component A ,
100 mesh minimum
EACheck Valve, Component A
FAFlow Meter, Component A
GADispense Valve, Component A
HAPurge Valve (usually air), Component A
JAFluid Shut-off Valve, Component A
KARatio Check Valve, Component A
Component C
C Supply Line, Component C
DCFluid Filter, Component C,
100 mesh minimum
ECCheck Valve, Component C
FCFlow Meter, Component C
GCDispense Valve, Component C
HCPurge Valve (usually solvent),
Component C
JCFluid Shut-off Valve, Component C
KCRatio Check Valve, Component C
Component B
B Supply Line, Component B
DBFluid Filter, Component B,
100 mesh minimum
EBCheck Valve, Component B
FBFlow Meter, Component B
GBDispense Valve, Component B
HBPurge Valve (usually solvent),
Component B
JBFluid Shut-off Valve, Component B
KBRatio Check Valve, Component B
Other
L First Integrator
M First Static Mixer
N Second Integrator
P Second Static Mixer
Q Fluid Meter
R Fluid Supply to Gun
A
JA
KA
C
M
R
B
L
NQ
P
FA
EA
DA
GA
HA
KC
HC
GC
DC
EC
FC
JC
KB
HB
GB
DB
EB
FB
JB
Component A Component BComponent C
TI0085B

2–8 Overview
How the PrecisionMix II 3K Works
Functional Diagram – Component B Dispense
Fig. 2.3
M
R
L
NQ
P
A
JA
KA
CB
FA
EA
DA
GA
HA
KC
HC
GC
DC
EC
FC
JC
KB
HB
GB
DB
EB
FB
JB
Component A Component BComponent C
TI0087B
4. The controller sends a signal to activate the sole-
noid valve for the component B dispense valve
(GB). See Fig. 2.3.
5. The component B dispense valve (GB) opens and
Component B flows into the second integrator
chamber (N). The fluid is lined up proportionately
with the previously-dispensed Component A and C
dose. The component B dispense valve closes
when the target volume for Component B is
reached. See Fig. 2.3.

Overview 2–9
How the PrecisionMix II 3K Works
Functional Diagram – Component C Dispense
Fig. 2.4
M
R
L
NQ
P
A
JA
KA
CB
FA
EA
DA
GA
HA
KC
HC
GC
DC
EC
FC
JC
KB
HB
GB
DB
EB
FB
JB
Component A Component BComponent C
TI0086B
6. The component C dispense valve (GC) opens and
Component C flows into the first integrator cham-
ber. The fluid is lined up proportionately with
Components A and B. The component C dispense
valve closes when the target volume for Compo-
nent C is reached. See Fig. 2.4.
7. Components A and C flow into a static mixer (M),
where they are mixed. The mixture then flows into
the second integrator chamber (N). See Fig. 2.4.
8. The three components are given a homogeneous
blending as they pass through a second static
mixer tube (P).
9. The three components continue to be alternately
fed into the integrators as long as the gun is trig-
gered. Output from the mixer tube to the spray gun
may be controlled by a fluid pressure regulator (Q).
After the trigger is released, if the gun is not trig-
gered again within four minutes, the system will go
to an idle mode, which closes off the mix manifold.
When the gun is triggered again, the system will
continue the process where it left off. Operation
can be stopped at any time by energizing the
standby input or shutting off the main power
switch.

2–10 Overview
Changing the Mixing Order
The order in which the three components are mixed
depends on the characteristics of the materials being
used. In the standard configuration, Component A is
mixed with Component C first, then the blend of A and
C is mixed with Component B. The instructions in this
manual correspond with this mixing order.
To convert the PrecisionMix II 3K to a configuration
where Component A is mixed with Component B
before Component C is added, perform the following
steps.
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 4–3.
1. Flush the system and relief the pressure.
2. Refer to Fig. 2.5. Unscrew the nut of the Compo-
nent C tube (T) from the nipple at the dispense
valve (V).
3. Remove the screws (S) and take the Component
C meter (U), bracket, and tube off the fluid panel.
4. Unscrew the nut of the Component B tube (W)
from the nipple at the dispense valve (Y).
5. Remove the screws (S) and take the Component
B meter (Z), bracket, and tube off the fluid panel.
6. Turn the tubes of both meters 180so the nuts
face in the opposite direction.
7. Reinstall the Component B and C meters, in the
opposite locations.
8. Refer to Fig. 2.6. Disconnect the red air lines (R)
from the elbows at the Component B and C dis-
pense valves and reconnect them to the opposite
dispense valve. Switch the green air lines (G) in
the same way.
9. Refer to Fig. 2.6. Disconnect the red air lines (R)
from the elbows at the Component B and C purge
valves and reconnect them to the opposite purge
valve. Switch the green air lines (G) in the same
way.
10. Using Part No. 196303 Label, relabel dispense
valve B to C and dispense valve C to B.
11. Reverse the wires on terminals 4271 and 4291.
Refer to Fig. 3.21, page 3–29.
Fig. 2.5
TI0223
T
S
S
V
U
WY
Z
U
ZS
S
V
T
W
Y
Affix Label B Here
Affix Label C Here
Disassembly Reassembly