Graco 312776F User Manual
Operation
ProMix
®
2KS
312776F
Plural Component Proportioner
Manual system for proportional mixing of plural component coatings.
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.
See page 4 for model information, including maximum working
pressure. Equipment approval labels are on page 3. Some
components shown are not included with all systems.
EN
#53
TI12504a
II 2 G0359
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Equipment Approvals . . . . . . . . . . . . . . . . . . . . . . . 3
System Configuration and Part Numbers . . . . . . . 4
Configurator Key . . . . . . . . . . . . . . . . . . . . . . . . . 4
Standard Features . . . . . . . . . . . . . . . . . . . . . . . 5
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Important Two-Component Material Information . 9
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 9
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 9
Keep Components A and B Separate . . . . . . . . . 9
Moisture Sensitivity of Isocyanates . . . . . . . . . . . 9
Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 9
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . 10
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Component Identification and Definition . . . . . . 13
Booth Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
EasyKey Display and Keypad . . . . . . . . . . . . . . . 18
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
AC Power Switch . . . . . . . . . . . . . . . . . . . . . . . 19
I/S Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Audible Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Graco Web Interface Port . . . . . . . . . . . . . . . . . 19
Ethernet Connection . . . . . . . . . . . . . . . . . . . . . 19
Run Mode Screens . . . . . . . . . . . . . . . . . . . . . . . . 20
Splash Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Totals Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Reset Total Screen . . . . . . . . . . . . . . . . . . . . . . 23
Reset Solvent Screen . . . . . . . . . . . . . . . . . . . . 23
Alarms Screens . . . . . . . . . . . . . . . . . . . . . . . . . 24
Level Control Screen . . . . . . . . . . . . . . . . . . . . 24
Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Password Screen . . . . . . . . . . . . . . . . . . . . . . . 26
Set Up Home Screen . . . . . . . . . . . . . . . . . . . . 26
System Configuration Screens . . . . . . . . . . . . . 28
Option Screens . . . . . . . . . . . . . . . . . . . . . . . . . 32
Advanced Setup Screens . . . . . . . . . . . . . . . . . 34
Recipe Setup Screens . . . . . . . . . . . . . . . . . . . 38
Recipe 0 Screens . . . . . . . . . . . . . . . . . . . . . . . 43
Calibration Screen . . . . . . . . . . . . . . . . . . . . . . 45
System Operation . . . . . . . . . . . . . . . . . . . . . . . . . 46
Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . 46
Sequential Dosing . . . . . . . . . . . . . . . . . . . . . . . 46
Dynamic Dosing . . . . . . . . . . . . . . . . . . . . . . . . 46
Recipe (Color) Change . . . . . . . . . . . . . . . . . . . 46
Solvent Push . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Mix Fill Push . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
General Operating Cycle, Sequential Dosing . . 46
General Operating Cycle, Dynamic Dosing . . . . 48
Mix Manifold Valve Settings . . . . . . . . . . . . . . . 51
Air Flow Switch (AFS) Function . . . . . . . . . . . . . 52
Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Pressure Relief Procedure . . . . . . . . . . . . . . . . 55
Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Solvent Push Feature . . . . . . . . . . . . . . . . . . . . 63
Mix Fill Push Feature . . . . . . . . . . . . . . . . . . . . . 64
Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Color Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Color Change Procedures . . . . . . . . . . . . . . . . . 67
Color Change Sequences . . . . . . . . . . . . . . . . . 67
Alarms and Warnings . . . . . . . . . . . . . . . . . . . . . . 80
System Alarms . . . . . . . . . . . . . . . . . . . . . . . . . 80
System Warnings . . . . . . . . . . . . . . . . . . . . . . . 80
Alarm Troubleshooting . . . . . . . . . . . . . . . . . . . . . 81
Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . 92
System Pneumatic Schematic . . . . . . . . . . . . . . 92
System Electrical Schematic . . . . . . . . . . . . . . . 93
EasyKey Electrical Schematic . . . . . . . . . . . . . . 95
Meter Performance Data (G3000 on A and B) . . . 96
Meter Performance Data (G3000 on A, Coriolis on B)
97
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Graco Standard Warranty . . . . . . . . . . . . . . . . . . 100
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 100
2 312776F
Related Manuals
Related Manuals
Component Manuals in English
Manual Description
312775 ProMix 2KS Manual System Installation
312777 ProMix 2KS Manual System Repair-Parts
312781 Fluid Mix Manifold
312782 Dispense Valve
312783 Color Change Valve Stacks
312787 Color Change Module Kit
312784 Gun Flush Box Kits
310745 Gun Air Shutoff Kit
312786 Dump Valve and Third Purge Valve Kits
312785 Network Communication Kits
308778 G3000/G3000HR Flow Meter
313599 Coriolis Flow Meter
313290 Floor Stand Kit
313542 Beacon Kit
313386 Basic Web Interface/Advanced Web Inter-
face
406799 15V256 Automatic System Upgrade Kit
406800 15V825 Discrete I/O Board Kit
Equipment Approvals
Equipment approvals appear on the following labels
which are attached to the Fluid Station and EasyKey
See F
IG. 1 on page 4 for label locations.
EasyKey and Fluid Station Label
ATEX Certificate is listed here
Fluid Station Label
™
.
®
PART NO. SERIES SERIAL MFG. YR.
CUS
Artwork No. 293538
ProMix 2KS
Intrinsically safe equipment
for Class I, Div 1, Group D, T3
Ta = -20°C to 50°C
Install per 289833
ATEX Certificate is listed here
EasyKey Label
®
ProMix 2KS
PART NO.
SERIES NO. MFG. YR.
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
CUS
Intrinsically safe connections
for Class I, Div 1, Group D
Ta = -20°C to 50°C
Install per 289833
Um: 250 V
FLUID PANEL
MAX AIR WPR
FM08ATEX0073
II 2 G
Ex ia IIA T3
.7 7
MPa bar PSI
100
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
TI13581a
POWER REQUIREMENTS
VOLTS
AMPS
85-250 ~
2 AMPS MAX
50/60 Hz
II (2) G
[Ex ia] IIA
FM08ATEX0072
TI13582a
Artwork No. 293467
ATEX Certificate is listed here
312776F 3
System Configuration and Part Numbers
System Configuration and Part Numbers
Configurator Key
The configured part number for your equipment is printed on the equipment identification labels. See FIG. 1
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.
Manual
System Control and Display A and B Meter Color Valves Catalyst Valves Applicator Handling
M D = EasyKey with LCD
Display
0 = No Meters
1 = G3000 (A and B)
2 = G3000HR (A and
B)
3 = 1/8 in. Coriolis (A)
and G3000 (B)
4 = G3000 (A) and 1/8
in. Coriolis (B)
5 = 1/8 in. Coriolis (A)
and G3000HR (B)
6 = G3000HR (A) and
1/8 in. Coriolis (B)
7 = 1/8 in. Coriolis (A
and B)
0 = No Valves
(single color)
1 = Two Valves
(low pressure)
2 = Four Valves
(low pressure)
3 = Seven Valves
(low pressure)
4 = Twelve Valves
(low pressure)
5 = Two Valves
(high pressure)
6 = Four Valves
(high pressure)
0 = No Valves
(single catalyst)
1 = Two Valves
(low pressure)
2 = Four Valves
(low pressure)
3 = Two Valves
(high pressure)
1 = One Air Flow
Switch Kit
2 = Two Air Flow
Switch Kits
3 = One Gun Flush Box
Kit
4 = Two Gun Flush Box
Kits
Label Location
on EasyKey
TI12418aTI12423a
Configured Part Number
Label Location
on Fluid Station
Maximum Fluid
Working Pressure
is listed here
FIG. 1: Identification Label
4 312776F
System Configuration and Part Numbers
Hazardous Location Approval
Models using a G3000, G3000HR, 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. The pressure rating is
based on the rating of the lowest rated fluid component. Refer to the component pressure ratings below.
Example: Model MD2531 has a maximum working pressure of 3000 psi (21 MPa, 210 bar).
Check the identification label on the EasyKey or fluid station for the system maximum working pressure.
See F
IG. 1.
ProMix Fluid Components Maximum Working Pressure
Base System (no meters [option 0], no color/catalyst change [option 0]). . . . . . . 4000 psi (27.58 MPa, 275.8 bar)
Meter Option 1 and 2 (G3000 or G3000HR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000 psi (27.58 MPa, 275.8 bar)
Meter Option 3, 4, 5, 6, and 7 (one or two Coriolis Meters) . . . . . . . . . . . . . . . . . 2300 psi (15.86 MPa, 158.6 bar)
Color Change Option 1, 2, 3 and 4 and
Catalyst Change Option 1 and 2 (low pressure valves) . . . . . . . . . . . . . . . . . . . . . . . 300 psi (2.07 MPa, 20.6 bar)
Color Change Option 5 and 6 and
Catalyst Change Option 3 (high pressure valves) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 psi (21 MPa, 210 bar)
Flow Meter Fluid Flow Rate Range
G3000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-3800 cc/min. (0.02-1.0 gal./min.)
G3000HR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-1900 cc/min. (0.01-0.50 gal./min.)
Coriolis Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3800 cc/min. (0.005-1.00 gal./min.)
S3000 Solvent Meter (accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-1900 cc/min. (0.01-0.50 gal./min.)
Standard Features
Feature
EasyKey with LCD
Fiber Optic and Power Cables, 50 ft (15.25 m)
Wall Mount Fluid Station, 50 cc Integrator and Static Mixer
B Side Dump Valve, if multiple catalyst valves
Booth Control
Basic Web Interface
312776F 5
Accessories
Accessories
Accessory
Gun Flush Box Gun Insert Selection
15V354 Third Purge Valve Kit
15V536 Solvent Flow Switch Kit
15V213 Power Cable, 100 ft (30.5 m)
15G710 Fiber Optic Cable, 100 ft (30.5 m)
15U955 Injection Kit for Dynamic Dosing
15V034 10 cc Integrator Kit
15V033 25 cc Integrator Kit
15V021 50 cc Integrator Kit
24B618 100 cc Integrator Kit
15W034 Strobe Light Alarm Indicator Kit
15V337 Advanced Web Interface
15V256 Automatic Mode Upgrade Kit
16D329 S3000 Solvent Flow Meter Kit
15V825 Discrete I/O Integration Board Kit
NOTE: This is not a complete list of available accessories and kits. Refer to the Graco website for more information about accessories available for use with this
product.
6 312776F
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation 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.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause
electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
INTRINSIC SAFETY
Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe equipment
will create a hazardous condition and can cause fire, explosion, or electric shock. Follow local
regulations and the following safety requirements.
• Only models with a G3000, G250, G3000HR, G250HR, or intrinsically safe Coriolis meter are
approved for installation in a Hazardous Location - Class I, Div I, Group D, T3 or Zone I Group IIA
T3.
• Do not install equipment approved only for a non-hazardous location in a hazardous area. See the
ID label for the intrinsic safety rating of your model.
• Do not substitute or modify system components as this may impair intrinsic safety.
312776F 7
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.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
•Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS forms from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
• Always wear chemically impermeable gloves when spraying or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
8 312776F
Important Two-Component Material Information
Important Two-Component Material Information
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
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 viscosity. If used, this partially cured ISO will reduce performance and the life of all wetted parts.
NOTE: The amount of film formation and rate of crystallization 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 contaminated from the other side.
• Always lubricate threaded parts with ISO pump oil
or grease when reassembling.
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 (isocyanate) and component B (resin)
parts.
312776F 9
Changing Materials
• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.
• Always clean the fluid inlet strainers after flushing.
• Check with your material manufacturer for chemical
compatibility.
• Most materials use ISO on the A side, but some use
ISO on the B side.
Glossary of Terms
Glossary of Terms
Advanced Web Interface (AWI) - This allows remote
ProMix backup and restore, configuration, logging, and
software update options.
Air Chop - the process of mixing air and solvent
together during the flush cycle to help clean the lines
and reduce solvent usage.
Air Chop Time- duration of each activation of the air
purge valve during a chop sequence. User settable from
0.0-99.9 seconds.
Analog - relating to, or being a device in which data are
represented by continuously variable, measurable,
physical quantities, such as length, width, voltage, or
pressure.
B Purge After Chop - Optional 2-second B solvent
valve activation after the Chop sequence. This is used
to separate the chop material and the Final Purge material to prevent unwanted mixing.
Basic Web Interface (BWI) - This allows remote ProMix backup and restore, logging, and software update
options.
Bootloader - The utility program that handles initial system startup re-programming of the main ProMix application.
Chop Time- refers to the total length of the chop
sequence during a purge. User settable from 0-999 seconds.
Coriolis Meter - a non-intrusive flow meter often used in
low flow applications or with light viscosity, shear sensitive, or acid catalyzed materials. This meter uses vibration to measure flow.
Custom Language - A method to load a translation file
into the ProMix to display languages other than those
built into the system. Only Unicode characters through
codespace 0x00FF are supported.
Digital Input and Output - a description of data which
is transmitted as a sequence of discrete symbols, most
commonly this means binary data represented using
electronic or electromagnetic signals.
Discrete I/O - refers to data that constitutes a separate
entity and has direct communication to another control.
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. More than
30 pulses from the flow meter of the active dose valve
are needed while the Gun Trigger is on to prevent the
alarm.
Dynamic Dosing - Component A dispenses constantly.
Component B dispenses intermittently in the necessary
volume to attain the mix ratio.
Ethernet - a method for directly connecting a computer
to a network or equipment in the same physical location.
Closed Loop Flow Control - refers to the process
when the flow rate is adjusted automatically to maintain
a constant flow.
Color/Catalyst Purge - refers to the time required to
flush the lines from the color or catalyst change module
to the mix manifold during a color or catalyst change.
Color/Catalyst Fill - refers to the time required to fill the
lines from the color or catalyst change module to the mix
manifold.
Command Holdoff - The amount of time that flow rate
learning is not allowed after the set point is changed to
allow the flow rate to stabilize.
10 312776F
ExtSP - External Set Point selection for PLC input of the
flow rate set point while operating in Flow Control Override mode.
Fiber Optic Communication - the use of light to transmit communication signals. Blue is the transmitter, and
black is the receiver. This must be cross-connected
between the EasyKey and the Fluid Panel for communication to work. The Fiber Optic cable has a blue band to
indicate the proper connection.
Final Purge Source- source of the media used in the
final purge cycle. User settable to air purge valve, solvent purge valve, or 3rd purge valve.
Final Purge Time- duration of the final purge cycle.
User settable from 0-999 seconds.
Glossary of Terms
First Purge Source- source of the media used in the
first purge cycle. User settable to air purge valve, solvent purge valve, or 3rd purge valve
First Purge Time- duration of the first purge cycle. User
settable from 0-999 seconds.
Flow Control Resolution - a settable value that allows
the flow control system to maximize its performance.
The value is based on maximum desired flow rates.
Flow Rate Analog Signal - the type of communication
signal that can be used on the ProControl module.
Flow Rate Tolerance - the settable percent of acceptable variance that the system will allow before a flow
rate warning occurs.
Flow Set Point - a predefined flow rate target.
Flush Volume Check - system monitors flush volume.
E-11 Alarm occurs if minimum volume is not achieved.
Minimum flush volume is user settable (0-999 cc).
Global - indicates that values on the screen apply to all
recipes, 1 through 60.
K-factor - a value that refers to the amount of material
that passes through a meter. The assigned value refers
to an amount of material per pulse.
Kd - refers to the amount the fluid flow system attempts
to not overshoot the target set point.
Ki - refers to the degree fluid flow over shoots its set
point.
Kp - refers to the speed in which the fluid flow reaches
its set point.
Learn Strength - How much and how quickly to apply
the difference in the flow rate set point compared to the
measured flow rate when updating the flow control data
table.
Manual Mode - when the proportioning or flow control
system is controlling the inputs without any input from
an outside control.
Minimum Material Fill Volume - system monitors
material fill volume. E-21 Alarm occurs if minimum volume is not achieved. Minimum material fill volume is
user settable (0-9999 cc).
Grand Total - a non-resettable value that shows the
total amount of material dispensed through the system.
GT-Off Drive Time - The amount of time to regulate the
fluid pressure based on the flow rate set point after the
gun trigger is closed.
GT-Off Target Rise - The additional time to regulate the
fluid pressure based on the flow rate set point after the
gun trigger is closed.
Gun Trigger Holdoff - The amount of time that flow rate
learning is not allowed after the gun trigger is opened to
allow the flow rate to stabilize.
Gun Trigger Input Signal - used to manage ratio
assurance dose times and flow control processes.
Intrinsically Safe (IS) - refers to the ability to locate certain 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.
Job Total - a resettable value that shows the amount of
material dispensed through the system for one job. A job
is complete when a color change or complete system
flush occurs.
Mix - when cross-linking of the resin (A) and catalyst (B)
occurs.
Mix Fill Push - An option for the Autodump selection to
automatically clear the Potlife alarm if the gun is in the
Gun Flush Box by running new mixed material through
the gun.
Mix Input Signal- refers to system mode status where
system begins a dose sequence each time the mix signal is made “High”.
Mixed Material Fill Time - the amount of time that is
required to load mixed material from the dose valves to
the applicator/gun.
Modbus/TCP - a type of communication protocol used
to communicate Digital I/O signals over an ethernet.
Network Station - a means to identify a particular individual proportioning or flow control system.
One-Point Learning - Flow Control table calibration
method using learned points above a specified flow rate
to interpolate the table at low flow rates with short gun
trigger times.
312776F 11
Glossary of Terms
Overdose (A, B, C) Alarm - when either the resin (A),
or catalyst (B), or reducer (C) 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.
Purge - when all mixed material is flushed from the system.
Purge Drive - The voltage drive during the Purge
sequence, maximum of 3300 mV. The response curve
of the V/P regulator is not linear, so it may be necessary
to test the response using Manual Override mode.
Purge Time - the amount of time required to flush all
mixed material from the system.
Purge Volume Alarm - E-11 Alarm occurs if minimum
flush volume is not achieved.
Third Purge Valve - refers to the use of three purge
valves used to flush some waterborne materials. The
valves are used to flush with water, air and solvent.
V/P - refers to the voltage to pressure device in the flow
control module.
Valve Holdoff Maximum - The maximum amount of
time that flow rate learning is not allowed after a dose
valve cycles. The system may internally use a time less
than is based on the stability of the fluid meter pulse
stream.
Ratio Tolerance - the settable percent of acceptable
variance that the system will allow before a ratio alarm
occurs.
Sequential Color Change - the process when a color
change is initiated and the system automatically flushes
the old color and loads a new color.
Sequential Dosing - Components A and B dispense
sequentially in the necessary volumes to attain the mix
ratio.
Solvent/3rd Purge Valve Chop Time- duration of each
activation of the solvent or 3rd purge valve during a
chop sequence. User settable from 0.0-99.9 seconds.
Solvent Fill - the time required to fill the mixed material
line with solvent.
Solvent Push - enables the user to save some mixed
material by pushing it out to the gun with solvent.
Requires an accessory solvent meter.
Standby - refers to the status of the system.
System Idle - This warning occurs if the ProMix is set to
Mix, and 2 minutes have elapsed since the system
received a flow meter pulse.
12 312776F
Overview
Overview
Usage
The Graco ProMix 2KS is an electronic two-component paint proportioner. It can blend most two-component solvent
and waterborne epoxy, polyurethane, and acid-catalyzed paints. It is not for use with “quick-setting” paints (those
with a potlife of less than 15 minutes).
• Can proportion at ratios from 0.1:1 to 50:1 in 0.1
increments with the wall mount fluid station.
• Has user selectable ratio assurance and can maintain up to +/-1% accuracy, depending on materials
and operating conditions.
• Models are available to operate air spray or
air-assisted systems with a capacity of up to 3800
cc/min.
• Color change options are available for low pressure
(300 psi [2.1 MPa, 21 bar]) air spray and high pressure (3000 psi [21 MPa, 210 bar]) systems with up
to 30 color change valves and up to 4 catalyst
change valves.
NOTE: Optional accessories are available for in
field installation to achieve 30 colors.
Component Identification and Definition
See Table 1, FIG. 2, and FIG. 3 for the system components.
Table 1: Component Descriptions
Component Description
EasyKey (EK)
Booth Control (BC)
Fluid Station (ST)
Fluid Manifold (FM)
Used to set up, display, operate, and monitor the system. The EasyKey accepts 85-250
VAC, 50/60 Hz line power and converts that power to acceptable low voltage and optical
signals used by other system components.
Used by the operator for daily painting functions including: choosing recipes, initiating job
complete, reading/clearing alarms, and placing the system in Standby, Mix, or Purge
mode. It is typically mounted inside the booth or near the painter.
Includes air control solenoids, flow switches, and mountings for the fluid flow meters and
the fluid manifold assembly. Its control board manages all proportioning functions.
• Pneumatically Operated Dose Valves for component A and B
• Purge Valves for solvent and air purge
• Sampling Valves for calibrating the flow meters and performing ratio checks
• Shutoff Valves for component A and B to close their fluid passages to the mix mani-
fold, to allow for accurate calibration and ratio checks
• Mix Manifold, which includes the fluid integrator and static mixer.
Fluid Integrator is the chamber where component A and B align at the
selected ratio and begin to mix.
Static Mixer has 24 elements to uniformly blend the materials downstream
of the fluid integrator.
312776F 13
Overview
Table 1: Component Descriptions
Component Description
Flow Meters (MA,
MB, MS)
Color Change
Valves (ACV) and
Color Change
Module (CCM)
Three optional flow meters are available from Graco:
• 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 viscosities of 20–3000 centipoise. The K-factor is approximately 0.119 cc/pulse.
• G3000HR is a high resolution version of the G3000 meter. It is typically used in flow
ranges of 38–1900 cc/min. (0.01–0.5 gal/min.), pressures up to 4000 psi (28 MPa,
276 bar). and viscosities of 20–3000 centipoise. The K-factor is approximately 0.061
cc/pulse.
• S3000 is a gear meter used for solvents in flow ranges of 38-1900 cc/min. (0.01–0.50
gal/min.), pressures up to 3000 psi (21 MPa, 210 bar), and viscosities of 20–50 centipoise. The K-factor is approximately 0.021 cc/pulse. Required to use the Solvent
Push feature.
• Coriolis is a specialty meter capable of a wide range of flow rates and viscosities.
This meter is available with 1/8 in. or 3/8 in. diameter fluid passages. For detailed
information on the Coriolis meter, see manual 313599.
The K-factor is user-settable; at lower flow rates use a lower K-factor.
1/8 in. fluid passages: set K-factor to .020 or .061.
3/8 in. fluid passages: set K-factor to .061 or 0.119.
An optional component. It is available as a color change valve stack for either low or high
pressure with up to 30 color change valves. Each stack includes one additional valve for
solvent to clean the fluid line between color changes.
Catalyst Change
Valves (BCV)
Dual Fiber Optic
Cable (FO)
Fluid Station Power
Supply Cable (PS)
Applicator
Handling: use Air
Flow Switch (AFS)
or Gun Flush Box
(GFB)
An optional component. It is available as a catalyst change valve stack for either low or
high pressure with up to 4 catalyst change valves. Each stack includes one additional
valve for solvent to clean the fluid line between catalyst changes.
Used to communicate between the EasyKey and Wall Mount Fluid Station.
Used to provide power to the Wall Mount Fluid Station.
Air Flow Switch: The air flow switch detects air flow to the gun and signals the ProMix
controller when the gun is being triggered. The switch functions with the flow meters to
ensure that the system components are functioning correctly. See page 52 for further
information.
Gun Flush Box: The gun flush box kit provides an automated flushing system for manual
spray guns, and includes an air flow switch.
14 312776F
Overview
EK
FO
ACV
PS
ST
CCM
BC
BCV
MS
MA
MB
FM
GFB
FIG. 2. Manual System, shown with G3000 Meters, Color/Catalyst Change, One Gun Flush Box, and
Accessory Solvent Flow Meter
TI12504a
312776F 15
Overview
MA
AT
APV
FIG. 3. Wall Mount Fluid Station
RVA
DVA
SVA SVB
FI
DVB
SM
MB
MS
RVB
SPV
TI12556b
Key:
MA Component A Meter
DVA Component A Dose Valve
RVA Component A Sampling Valve
SVA Component A Shutoff Valve
MB Component B Meter
DVB Component B Dose Valve
RVB Component B Sampling Valve
SVB Component B Shutoff Valve
MS Solvent Meter (accessory)
SPV Solvent Purge Valve
APV Air Purge Valve
SM Static Mixer
FI Fluid Integrator
AT Air Purge Valve Air Supply Tube
16 312776F
Booth Control
Booth Control
Used by the operator for daily painting functions including: changing recipes, signalling job complete, reading/clearing alarms, and placing the system in Standby,
Mix, or Purge mode. It is typically mounted inside the
booth or near the painter.
Table 2: Booth Control Key and Indicator Functions
(see F
IG. 4)
Key/Indicator Definition and Function
Display • Displays recipe number in Run
mode.
• If an alarm occurs, displays the
alarm code (E1 to E28) and red
Alarm indicator blinks.
• Recipe number displays after
alarm is reset.
• If Solvent Push is on, display alternately shows dashes and the percentage remaining (see page 63).
Recipe
Indicator
• Green LED stays lit while a recipe
is in use.
• LED shuts off when Up or
Down keys are pressed or if an
alarm occurs.
• LED blinks while a new recipe is
loading and turns solid after loading is complete.
• LED blinks when purging.
• Select a new recipe by pressing
Table 2: Booth Control Key and Indicator Functions
(see F
IG. 4)
Key/Indicator Definition and Function
Up Key Scrolls recipe numbers up.
Down Key Scrolls recipe numbers down.
Mix Mode Key • Starts Mix mode.
• Green LED remains lit while in Mix
mode or in Idle mode.
• Press and hold for 5 seconds to
turn on the Solvent Push feature.
Standby
Mode Key
• Starts Standby mode.
• Green LED remains lit while in
Standby mode.
Purge Mode
Key
• Starts Purge mode.
• Green LED remains lit while in
Purge mode.
Alarm Indicator (red)
Display
Up
or Down keys, then
pressing Enter .
Alarm Reset
Key and
Indicator
• Red LED blinks when an alarm
occurs.
• Press key to reset alarm. LED
shuts off after alarm is reset.
Job Complete
Key and
Indicator
• Signals that job is complete, and
resets A and B totalizers.
• Green LED blinks once after key is
pressed.
Enter Key Enters selected recipe and starts color
Recipe Indicator (green)
change sequence.
312776F 17
F
IG. 4. Booth Control (see Table 2)
TI11614A
EasyKey Display and Keypad
EasyKey Display and Keypad
LCD Display
F
IG. 5. EasyKey Display and Keypad
Keypad
TI11630A
Navigation Keys Alarm Reset Key
Display
Shows graphical and text information related to setup
and spray operations. Back light will turn off after 10
minutes without any key press. Press any key to turn
back on.
NOTE: Pressing a key to turn on the display back light
will also perform the function of that key. If you are
unsure whether that key will impact your current operation, use the setup or navigation keys to turn on the display back light.
Keypad
Used to input numerical data, enter setup screens, scroll
through screens, and select setup values.
In addition to the numbered keys on the EasyKey keypad, which are used to enter values in setup, there are
keys to navigate within a screen and between screens,
and to save entered values. See Table 3.
Table 3: EasyKey Keypad Functions (see FIG. 5)
Key Function
Setup: press to enter or exit Setup mode.
Enter: if cursor is in menu box, press Enter
key to view menu. Press Enter to save a
value either keyed in from the numerical
keypad or selected from a menu.
Up Arrow: move to previous field or menu
item, or to previous screen within a group.
Down Arrow: move to next field or menu
item, or to next screen within a group.
Left Arrow: move to previous screen group.
Right Arrow: move to next screen group.
Alarm Reset: resets all active alarms.
If the display becomes unresponsive,
pressing this key 4 times in succession will
re-initialize the display.
18 312776F
Relief Port
Audible AlarmFiber Optic Strain
Main Power
Access Port
EasyKey Display and Keypad
AC
Power
Ground Screw
F
IG. 6. EasyKey Connections and AC Power Switch
I/S Power Discrete I/O Cable
Graco Web
Interface
Connector Ports
AC Power Switch
Turns system AC power on or off.
I/S Power
Power circuit to Fluid Station.
Audible Alarm
Alerts the user when an alarm occurs. Available settings
for selecting which alarms will cause an audible alarm
are explained in Configure Screen 1, page 29.
Clear the audible alarm by pressing the Alarm Reset
TI12638a TI12657a
Graco Web Interface Port
Used to communicate from a PC to:
Upgrade software
View software version
Download
• Job and alarm logs
• Material usage report
• Setup values (can also upload)
Clear job, alarm, and material usage reports
Upload a custom language to view on
screen
Restore factory defaults
Restore setup password
See manual 313386 for more information.
key.
Ethernet Connection
Even after the Alarm Reset key is pressed, the Potlife
Exceeded alarm message will remain displayed until a
sufficient amount of mixed material has been dispensed
to ensure that the expired material has been ejected.
312776F 19
You can access data on an office or industrial network
through the internet with the proper configuration. See
manual 313386 for more information.
Run Mode Screens
Run Mode Screens
NOTE: See FIG. 9 for a map of the Run screens.
Detailed screen descriptions follow.
Splash Screen
At power up, the Graco logo and software revision will
display for approximately 5 seconds, followed by the
Status Screen (see page 22).
F
IG. 7. Splash Screen
The Splash screen will also momentarily display “Establishing Communication.” If this display remains for more
than one minute, check that the fluid station circuit board
is powered up (LED is on) and that the fiber optic cable
is properly connected (see installation manual).
NOTE: If the software version of the fluid plate does not
match the version of the EasyKey, the EasyKey will
update the fluid plate, and the fluid plate programming
screen will appear until the update is completed.
F
IG. 8. Fluid Plate Programming Screen
20 312776F
Run Mode Screens
Press the Setup key to
enter Setup mode.
TI12783a
FIG. 9. Run Screens Map
312776F 21
Run Mode Screens
Status Screen
•Use the Up or Down keys to scroll through the
Run screens.
• Press the Setup key to enter the Setup screens
from the Status screen.
• The other keys have no function in this Status
screen.
1
2
3
4
5
10
8
7
9
6
4
Potlife Timer: shows remaining potlife time in min-
utes. Two times are shown if there are two guns.
5
Status Bar: shows current alarm or operation mode
(standby, mix, purge, recipe change, or the current
alarm).
6
Current Flow Rate: in cc/min.
7
Animation: when the gun is triggered, the gun
appears to spray and the component A or B hose
lights up, showing which component dose valve is
open.
8
Current Date and Time
9
Screen Number and Scroll Arrows: displays the
current screen number and the total number of
screens in a group. The Up and Down arrows on the
right edge of the screen indicate the scroll feature.
The total number of screens in some groups may
vary depending on system configuration selections.
F
IG. 10. Status Screen
Key to F
1
2
3
IG. 10:
Active Recipe: shows the active recipe.
NOTE: At power up the system defaults to Recipe
61, which is not a valid recipe number.
Target Ratio: for the active recipe. The ratio can be
from 0.0:1–50.0:1, in 0.1 increments.
Actual Ratio: in hundredths, calculated after each
dose of A and B.
10
Lock Symbol: indicates that Setup screens are
password protected. See page 26.
22 312776F
Run Mode Screens
Totals Screen
F
IG. 11. Totals Screen
This screen shows the job totals, fill totals, grand totals,
and job number. Use the tabs to reset job totals (Job
Complete), reset solvent totals (Rst Solvent), or go to
Level Control Screen, page 24.
The job totals generally refer to material dispensed
while in Mix mode. This is likely atomized and sprayed
material with the gun trigger “On”.
Reset Total Screen
FIG. 12. Reset Total Screen
If job is reset, job number will increment by one for
default.
Reset Solvent Screen
The fill totals generally refer to material dispensed while
in Mix-fill mode after a color change or a purge operation. This is likely not sprayed or atomized, and is dispensed to a purge container.
Solvent Totals and the Rst Solvent tab only appear if
“Meter” is selected under Solvent Monitor in Configure
Screen 5 on page 31.
NOTE: Grand totals are not resettable.
IG. 13. Reset Solvent Total Screen
F
The screen will ask if you want to reset solvent total.
Select Yes or No.
312776F 23
Run Mode Screens
Alarms Screens
F
IG. 14. Alarms Screen
Two screens show the last 10 alarms. Use the Up or
Down
See Table 10 on page 80 for a list of alarm codes.
keys to scroll between the two screens.
Level Control Screen
occur after 25% of the remaining volume is mixed.
Refill tank volume to clear the alarm.
FIG. 16. Tank Level Low Screen (Tank A Shown)
IG. 15. Level Control Screen
F
This screen shows the current volume for each fluid.
Adjust the current volumes on this screen, or use the tab
to go to Usage (Totals Screen, page 23). The Alarm
Level values may be adjusted using the advanced web
interface.
See F
IG. 16. If the tank volume reaches the low-level
threshold, the EasyKey screen will display the Tank
Level Low alarm and prompt the user to do one of the
following:
1. Refill tank volume to clear the alarm.
2. Resume mixing by selecting “Spray 25% of Remainder.” If this selection is chosen, a second alarm will
24 312776F
Setup Mode
Setup Mode
Press the Setup key to enter Setup mode.
Press the Setup key to
enter Setup mode.
NOTE: See F
IG. 17 for a map of the Setup screens.
Detailed screen descriptions follow.
This screen appears only if a
password is activated.
To access Advanced Setup Screens, page 34
and Recipe Setup Screens, page 38.
To access System Configuration
Screens, page 28.
Press the Setup key to exit
Setup mode and return to the Status
FIG. 17. Setup Screens Map
screen.
This screen appears momentarily
if a password is activated.
TI12784a
312776F 25
Setup Mode
Password Screen
If a password has been activated (see Configure
Screen 1, page 29), the Password screen will appear.
You must enter the password to access the Set Up
Home Screen. Entering the wrong password returns the
display to the Status Screen.
NOTE: If you forget the password, you can reset the
password (to 0), using the ProMix 2KS Web Interface
(see manual 313386).
F
IG. 18. Password Screen
NOTE: If a password is activated, Setup Locked dis-
plays momentarily after exiting Setup mode and return-
ing to the Status Screen. A lock symbol appears
Set Up Home Screen
FIG. 20. Set Up Home Screen
This screen displays when you enter Setup mode. From
it you can go to Recipe and Advanced Setup Screens
(pages 34-42) or System Configuration Screens
(pages 28-31). Press the Enter key to go to the
selected screen set.
The screen also displays software versions and internet
addresses of various components. The values shown in
F
IG. 20 are only examples and may vary on your screen.
See Table 4 for further information.
on the Status Screen.
F
IG. 19. Setup Locked Screen
26 312776F
Setup Mode
Table 4: Component Software Versions
Display (may
vary from
Component
examples shown) Description
EK (EasyKey) 3.01.001 EasyKey software version.
FP (Fluid Plate) 3.01.001 Fluid Plate software version.
BC (Booth Control) -.- Booth Control not installed, not detected, or not operational.
1.XX Booth Control software version 1.00 or 1.01.
2.XX Booth Control software version 2.XX.
C1/C2 (Color Change
Modules 1 and 2)
-.- Color Change Module 1/2 not installed, not detected, or not
operational.
1.XX Color Change Module software version 1.00 or 1.01.
2.XX Color Change Module software version 2.XX.
AK (Autokey) No Key No AutoKey installed or detected. System operates in 2K
Manual Mode only
2K-Auto 2K AutoKey detected. System can operate in 2K Manual,
Semi-automatic, or Automatic Mode.
3K-Auto 3K AutoKey detected. System can operate in 3K Manual,
Semi-automatic, or Automatic Mode.
XP (XPORT) V6.6.0.2 Example of XPORT network module software version. Other
versions are acceptable.
MC (Micro Controller) 1042.0198 Example of fluid plate micro controller version. Other versions
are acceptable.
Axx By Cz A30 B4 Cx Color Change board valve configuration. This shows the num-
ber of valves available for each of the components. This is set
by the configuration switches on the color change boards
connected to the system.
Code Description
- Component not available with this machine configura-
tion.
x Component not used with this machine configuration.
1 Component available but no change stack.
4-30 Component available with change stack.
Number of valves flushed with a solvent valve.
IP (Internet Address) 192.168.178.3 Example of the address EasyKey is set to for basic and
advanced web interface reporting.
MAC (MAC address) 00204AAD1810 Example of internet MAC address. Each EasyKey will have a
different value in this format.
312776F 27
Setup Mode
System Configuration Screens
NOTE: See FIG. 21 for a map of the System Configuration Screens. Detailed screen descriptions follow.
NOTE: Each screen displays the current screen number
and the total number of screens in the group.
TI12785a
F
IG. 21. System Configuration and Option Screens Map
28 312776F
Setup Mode
Configure Screen 1
F
IG. 22. Configure Screen 1
Language
Defines the language of the screen text. Select English
(default), Spanish, French, German, Italian, Dutch, Japanese (Kanji), Korean, Chinese (Simplified), and Custom.
NOTE: Refer to document 313386 for instructions on
using the Custom Language feature to modify the
screens to support undefined languages.
Password
The password is only used to enter Setup mode. The
default is 0, which means no password is required to
enter Setup. If a password is desired, enter a number
from 1 to 9999.
Screen Timeout
Select the desired screen timeout in minutes (0-99). 5 is
the default.
Configure Screen 2
FIG. 23. Configure Screen 2
Month
Enter current month.
Day
Enter current day.
Year
Enter current year (four digits).
Time
NOTE: Be sure to write down the password and keep it
in a secure location.
Display Units
Select the desired display units:
• cc/liter (default)
•cc/gallon
Buzzer Alarms
As the default, the alarm buzzer is set to “Potlife Only”
and will sound only for the Potlife Alarm (E-2).
Set to “All Alarms” to have the buzzer sound for any
alarm.
Set to “All Except Potlife” to have the buzzer sound for
any alarm except a Potlife Alarm (E2). This option is not
recommended unless another active method of handling
the Potlife Alarm is implemented.
312776F 29
Enter current time in hours (24 hour clock), minutes, and
seconds. Seconds are not adjustable.
Date Format
Select MM-DD-YYYY, DD-MM-YYYY, or
YYYY-MM-DD.
Setup Mode
Configure Screen 3
F
IG. 24. Configure Screen 3
1K/2K/3K
Set this value to indicate the system performance level
designation. Selecting a value other than the installed
system level will result in restricted functionality.
Run Mode
NOTE: If an Autokey is installed, additional selections of
Semi-Automatic and Automatic are available.
Indicates that this is a Manual system.
Dump Valve A
This field only appears if the color change option is
detected from the cc board. Select “On” if an optional
Dump Valve A is installed and desired to be used.
Dump Valve B
This field only appears if the catalyst change option is
detected from the cc board, meaning that dump valve B
is present. On is the only setting.
3rd Flush Valve
Off is default. If the system includes an optional 3rd
flush valve, set to On.
Configure Screen 4
FIG. 25. Configure Screen 4
Dose Time Alarm
Enter the dose time (1 to 99 seconds). This is the
amount of time allowed for a dose to occur before a
dose time alarm occurs.
Dose Size
Select the total dose size (cc) from the pulldown menu:
100, 50, 25, 10, or select DD to turn on dynamic dosing
(see page 48).
Example:
For a total dose size of 50 cc and a ratio of 4.0:1, the
component A dose size is 40 cc and component B dose
size is 10 cc.
NOTE: Increase the dose size in applications with
higher flow rates or wider ratios. Decrease the dose size
for a better mix under low flow conditions.
Number of Guns
Enter the number of spray guns (1 or 2).
Gun Flush Box
Enter the number of gun flush boxes (Off, 1, or 2).
NOTE: For color change and flushing purposes, it is recommended that two GFBs are installed when using a
2-gun system.
DD Setup Mode
See Fig. 26 and Fig. 27 on page 31.
30 312776F
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