Graco 3A0868G User Manual

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Operation

ProMix

2KE

3A0868G

Pump-Based Plural Component Proportioner

Self-contained, electronic two-component paint proportioner. For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See pages 3-4 for model information, including maximum working pressure and approvals.

ti15696a

Contents

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Important Two-Component Material Information . 8

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 8

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 8

Keep Components A and B Separate . . . . . . . . . 8

Moisture Sensitivity of Isocyanates . . . . . . . . . . . 8

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 8

Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Component Identification and Definition . . . . . . 10

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

General Information . . . . . . . . . . . . . . . . . . . . . 10

Intrinsically Safe Installation Requirements . . . 11

Display Module . . . . . . . . . . . . . . . . . . . . . . . . . 13

Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Fluid Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Tubing Chart and Diagrams . . . . . . . . . . . . . . . 16

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Icon Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Screen Summary . . . . . . . . . . . . . . . . . . . . . . . 23

Ranges for User Inputs . . . . . . . . . . . . . . . . . . . 24

Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Pre-Operation Tasks . . . . . . . . . . . . . . . . . . . . . 29

Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Initial System Setup . . . . . . . . . . . . . . . . . . . . . 29

Prime the System . . . . . . . . . . . . . . . . . . . . . . . 30

Pump Calibration . . . . . . . . . . . . . . . . . . . . . . . 31

Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Pressure Relief Procedure . . . . . . . . . . . . . . . . 35

Lock Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Valve Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Use of Optional USB Module . . . . . . . . . . . . . . . . 36

USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Download Procedure . . . . . . . . . . . . . . . . . . . . 38

Recommended USB Flash Drives . . . . . . . . . . 38

Run Mode Details . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Run Mix Spray (Screen 2) . . . . . . . . . . . . . . . . . 39

Run Home (Screen 1) . . . . . . . . . . . . . . . . . . . . 39

Run Mix Batch (Screen 3) . . . . . . . . . . . . . . . . . 39

Run Mix Totals (Screen 4) . . . . . . . . . . . . . . . . . 40

Run Job Number (Screen 38) . . . . . . . . . . . . . . 40

Run Log Errors (Screens 5-14) . . . . . . . . . . . . . 40

Run Pump Control (Screen 15) . . . . . . . . . . . . . 41

Setup Mode Details . . . . . . . . . . . . . . . . . . . . . . . . 42

Password (Screen 16) . . . . . . . . . . . . . . . . . . . . 42

Setup Home (Screen 17) . . . . . . . . . . . . . . . . . . 42

Configure 1-4 (Screens 18-21) . . . . . . . . . . . . . 43

Recipe 1-1 (Screen 28) . . . . . . . . . . . . . . . . . . . 44

Recipe 1-2 (Screen 29) . . . . . . . . . . . . . . . . . . . 44

Maintenance 1-3 (Screens 24-26) . . . . . . . . . . . 45

Maintenance Recommendations . . . . . . . . . . . . 45

Calibration 1 and 2 (Screens 22 and 23) . . . . . . 46

Troubleshooting (Screens 35-37) . . . . . . . . . . . 46

Dynamic Dosing . . . . . . . . . . . . . . . . . . . . . . . . 48

System Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

System Alarms . . . . . . . . . . . . . . . . . . . . . . . . . 50

System Advisory/Record Codes . . . . . . . . . . . . 50

To Clear Error and Restart . . . . . . . . . . . . . . . . 50

Air Flow Switch (AFS) Function . . . . . . . . . . . . . 50

System Idle Warning (IDLE) . . . . . . . . . . . . . . . 51

Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Alarm Troubleshooting . . . . . . . . . . . . . . . . . . . 53

Dynamic Dosing Restrictor Selection Graphs . . 60

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Dimensions and Mounting . . . . . . . . . . . . . . . . . . 72

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 74

2 3A0868G

Models

ProMix 2KE systems are not approved for use in hazardous locations unless the base model, all accessories, all kits, and all wiring meet local, state, and national codes.

Approved for Hazardous Location

Class 1, Div 1, Group D (North America); Class 1, Zones 1 and 2 (Europe)

Maximum

Working Pressure

Part No. Series Ratio Pumps

psi (MPa, bar)

24F102 A 3:1 Merkur, A and B 300 (2.1, 21) 24F103 A 23:1 Merkur, A and B 2300 (15.8, 158) 24F104 A 30:1 Merkur, A and B 3000 (20.6, 206) 24F105 A 45:1 Merkur, A and B 4500 (31.0, 310)

24F106 A 3:1

24F107 A 23:1

24F108 A 35:1

Merkur A, Merkur Bellows B

300 (2.1, 21)

2300 (15.8, 158)

3500 (24.1, 241)

24F109 A 3:1 Merkur, A and B 300 (2.1, 21) 24F110 A 23:1 Merkur, A and B 2300 (15.8, 158) 24F111 A 30:1 Merkur, A and B 3000 (20.6, 206) 24F112 A 45:1 Merkur, A and B 4500 (31.0, 310)

24F113 A 3:1

24F114 A 23:1

24F115 A 35:1

Merkur A, Merkur Bellows B

300 (2.1, 21)

2300 (15.8, 158)

3500 (24.1, 241)

USB Port

II 2 G Ex ia px IIA T3 Ta = 0°C to 54°C FM10 ATEX 0025 X

#53

Intrinsically safe and purged equipment for Class I, Division 1, Group D, T3 Ta = 0°C to 54°C

✔ ✔ ✔ ✔

See Special Conditions for Safe Use in

✔

Warnings, page 5.

0359

✔

Models

Approvals*

* ProMix 2KE hazardous location equipment manufactured in the United States, with serial number beginning with

A or 01, has ATEX, FM, and CE approvals, as noted. Equipment manufactured in Belgium, with serial number beginning with M or 38, has ATEX and CE approvals, as noted.

See page 4 for models approved for non-hazardous locations.

3A0868G 3

Models

Models (continued)

Approved for Non-Hazardous Location

Maximum Working

Part

No.

24F088 A 3:1 Merkur, A and B 300 (2.1, 21)

24F089 A 23:1 Merkur, A and B 2300 (15.8, 158)

24F090 A 30:1 Merkur, A and B 3000 (20.6, 206)

24F091 A 45:1 Merkur, A and B 4500 (31.0, 310)

24F092 A 3:1

24F093 A 23:1

24F094 A 35:1

24F095 A 3:1 Merkur, A and B 300 (2.1, 21) 24F096 A 23:1 Merkur, A and B 2300 (15.8, 158) 24F097 A 30:1 Merkur, A and B 3000 (20.6, 206) 24F098 A 45:1 Merkur, A and B 4500 (31.0, 310)

24F099 A 3:1

24F100 A 23:1

24F101 A 35:1

Series Ratio Pumps

Merkur A, Merkur Bellows B

Pressure

psi (MPa, bar)

300 (2.1, 21)

2300 (15.8, 158)

3500 (24.1, 241)

300 (2.1, 21)

2300 (15.8, 158)

3500 (24.1, 241)

USB Port

✔ ✔ ✔ ✔

✔

Approvals*

#53

* ProMix 2KE non-hazardous location equipment manufactured in the United States, with serial number beginning

with A or 01, has FM and CE approvals. Equipment manufactured in Belgium, with serial number beginning with M or 38, has CE approval.

Related Manuals

Manual Description

3A0870 ProMix 2KE, Repair/Parts 312781 Fluid Mix Manifold, Instructions/Parts 312782 Dosing Valve, Instructions/Parts 312784 Gun Flush Box Kit 15V826 312792 Merkur Displacement Pump 312793 Merkur Bellows Displacement Pump 312796 NXT Air Motor 406714 Rebuild Kit for High Pressure

Dispense Valve

Manual Description

406823 Dispense Valve Seat Kit 3A1244 Graco Control Architecture

Module Programming 3A1323 16G353 Alternator Conversion Kit 3A1324 16G351 Electric Power Conversion Kit 3A1325 ProMix 2KE Stand Kits 3A1333 24H253 USB Module Kit 313542 Beacon Tower

4 3A0868G

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.

SPECIAL CONDITIONS FOR SAFE USE

• To prevent the risk of electrostatic sparking, the equipment’s non-metallic parts should be cleaned only with a damp cloth.

• The aluminum adapter plate may spark upon impact or contact with moving parts, which may cause fire or explosion. Take precautions to avoid such impact or contact.

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.

3A0868G 5

Warnings

WARNING

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 model numbers 24F102-24F115, utilizing the air-driven alternator, are approved for installation in a Hazardous (explosive atmosphere) Location. See Models, page 3.

• Be sure your installation complies with national, state, and local codes for the installation of electrical apparatus in a Class I, Group D, Division 1 (North America) or Class I, Zones 1 and 2 (Europe) Hazardous Location, including all of the local safety fire codes, NFPA 33, NEC 500 and 516, and OSHA 1910.107.

• To help prevent fire and explosion:

• Do not install equipment approved only for a non-hazardous location in a hazardous location. See model ID label for the intrinsic safety rating of your model.

• Do not substitute system components as this may impair intrinsic safety.

• Equipment that comes in contact with the intrinsically safe terminals must be rated for Intrinsic Safety. This includes DC voltage meters, ohmmeters, cables, and connections. Remove the unit from the hazardous area when troubleshooting.

• The equipment is intrinsically safe when no external electrical components are connected to it.

• Do not connect, download, or remove USB device unless unit is removed from the hazardous (explosive atmosphere) location.

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.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• 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 the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

6 3A0868G

Warnings

WARNING

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 from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• 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.

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.

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 MSDSs 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, dispensing, 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, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

3A0868G 7

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

Some materials may become self-igniting if applied too thickly. Read material manufacturer’s warnings and material MSDS.

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.

Changing Materials

Keep Components A and B Separate

Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination of the equipment’s wetted parts, never interchange component A (resin) and component B (isocyanate) parts.

8 3A0868G

• 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.

Glossary of Terms

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

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

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

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

Intrinsically Safe (IS) - refers to the ability to locate 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.

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

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

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

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

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

Purge - when all mixed material is flushed from the system.

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

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

Standby - refers to the status of the system.

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

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

3A0868G 9

Overview

Usage

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

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

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

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

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

Component Identification and Definition

Component Description

Control Box • Advanced Fluid Control Module

• Power supply or alternator

• Solenoid valves

• Air flow switch(es)

• Optional USB Module

• Audible alarm

• Optional pressure switch for gun flush box

Fluid Module • Mix manifold, which includes the fluid integrator and static mixer.

• Color/catalyst valve stacks, includes pneumatically operated dose valves for material A and B, as well as solvent valves.

• Pumps

Display Module Used to set up, display, operate, and monitor the system. Used for daily painting functions

including choosing recipes, reading/clearing errors, and placing the system in Spray, Standby, or Purge mode.

Installation

General Information

• Reference numbers and letters in parentheses in the text refer to numbers and letters in the illustrations.

• Be sure all accessories are adequately sized and pressure-rated to meet system requirements.

• To protect the Display Module screens from paints and solvents, clear-plastic protective shields are available in packs of 10 (Part No. 24G821). Clean the screens with a dry cloth if necessary.

10 3A0868G

Intrinsically Safe Installation Requirements

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

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

Hazardous (Classified) Locations

Class 1, Div 1, Group D, T3 (US and Canada)

Class 1, Zone 1, Group IIA, T3 (ATEX only)

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

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

Installation

18 PSI

1.5 FCM (MIN)

ALTERNATOR MODULE

10' CAN CABLE

50' OPTION

2' CAN CABLE

20" CAN CABLE

LINEAR SENSOR/

REED SWITCH CABLE

"A" REED SWITCH

"A" LINEAR

SENSOR

USB MODULE

FLUID CONTROL MODULE

"B" REED SWITCH

"B" LINEAR SENSOR

LINEAR SENSOR/ REED SWITCH CABLE

USER INTERFACE

MODULE

"A" PRESSURE TRANSDUCER

"B" PRESSURE TRANSDUCER

FIG. 1. Hazardous Location Installation

3A0868G 11

Installation

Non-Hazardous Locations

LINE POWER

FILTER

POWER SUPPLY

LINEAR SENSOR/

REED SWITCH CABLE

CAN CABLE

20" CAN CABLE

"A" REED SWITCH

"A" LINEAR SENSOR

USB MODULE

FLUID CONTROL MODULE

"B" REED SWITCH

"B" LINEAR SENSOR

10' CAN CABLE

50' OPTION

LINEAR SENSOR/ REED SWITCH CABLE

USER INTERFACE

MODULE

"A" PRESSURE TRANSDUCER

"B" PRESSURE TRANSDUCER

FIG. 2. Non-Hazardous Location Installation

12 3A0868G

Installation

Display Module

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

2. Snap the Display Module into the bracket.

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

4. The other end of the cable comes from the factory connected as shown, depending on the configuration of your system:

• Wall Power Systems

with USB Module:

Connect the CAN cable to P3 on the USB Module.

• Wall Power Systems

without USB Module:

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

ti16672a

ti16604a

ti16580a

Air Supply

Requirements

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

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

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

• Air regulator and bleed-type shutoff valve: include in each air line to fluid supply equipment. Install an additional shutoff valve upstream of all air line accessories to isolate them for servicing.

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

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

ti16579a

• Alternator Power Sys-

tems (with or without USB Module): Connect

CAN cable to J3 on the alternator.

ti16456a

3A0868G 13

Installation

Air Connections

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

1. Tighten all ProMix 2KE system air and fluid line connections as they may have loosened during shipment.

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

pumps. See F

Main Air Inlet

. 3. Air Supply Inlet

. 3.

ti15708a

Fluid Supply

Requirements

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

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

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

• Fluid supply pressure tanks, feed pumps, or circulating systems can be used.

• Materials can be transferred from their original containers or from a central paint recirculating line.

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

Atomizing air outlets

Atomizing air inlets

Solenoid air inlet

ti15709a

FIG. 4. Connect atomizing air

NOTE: The fluid supply must be free of pressure spikes,

which are commonly caused by pump stroke changeover. If necessary, install pressure regulators or a surge tank on the ProMix 2KE fluid inlets to reduce pulsation. Contact your Graco distributor for additional information.

Fluid Connections

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

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

NOTE: Paint Recirculating System Only

• If you are recirculating paint, use the standard inlet on Dose Valve A or Dose Valve B. Remove the plug directly opposite it on the dose valve for the recirculation outlet. See F

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

4. Connect the gun fluid supply line between the mix manifold (MM) outlet and the gun fluid inlet.

. 5.

14 3A0868G

Installation

Component Inlet

SVA

Remove plug;

Solvent inlet

recirculation outlet.

ti16755a

ti16754a

SVB

DVA

DVB

ti15697a

Key:

PA Component A Pump DVA Component A Dose Valve SVA Solvent Valve A

PB Component B Pump DVB Component B Dose Valve SVB Solvent Valve B MM Mix Manifold

FIG. 5. Fluid Connections

3A0868G 15

Installation

Tubing Chart and Diagrams

Type Color Description Starting Point Ending Point Tube OD in. (mm)

Air Green Solvent Valve A On 1G 1G 0.156 (4.0) Air Green Dose Valve A On 2G 2G 0.156 (4.0) Air Green Solvent Valve B On 3G 3G 0.156 (4.0) Air Green Dose Valve B On 4G 4G 0.156 (4.0) Air Red Solvent Valve A Off 1R 1R 0.156 (4.0) Air Red Dose Valve A Off 2R 2R 0.156 (4.0) Air Red Solvent Valve B Off 3R 3R 0.156 (4.0) Air Red Dose Valve B Off 4R 4R 0.156 (4.0) Air Natural Solenoid Air A1 A1 0.25 (6.3) Air Natural Air Regulator to Pump B A2 A2 0.375 (9.5) Air Natural Air Regulator to Pump A A3 A3 0.375 (9.5) Fluid ---- Pump B to Valve Stack B A4 A4 ----Fluid ---- Pump A to Valve Stack A A5 A5 ----Fluid ---- Valve Stack A to Mix Manifold A6 A6 ----Fluid ---- Valve Stack B to Mix Manifold A7 A7 ----Air Natural Air Regulator to Alternator* A8 A8 0.375 (9.5) Air Black Alternator Air Exhaust* A9 A9 0.5 (12.7)

* Used only on IS models.

1R 2R 3R 4R

ti13861a

GFB1-S

ATOM-1

ti16770a

GFB1-C

GFB1-P (Pressurized air line)

GFB1-A

IS Models

A8*

A9*

ti16771a

GFB1-C

GFB1-S

16 3A0868G

ti13863a

GFB1-A

ATOM-1

ATOM-2

Installation

B Side

A Side

ti16772a

4G 4R

A Side B Side

ti16765a

ti16766a

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

A Side

B Side

ti16764a

3A0868G 17

Installation

Electrical

Power Connection (non-IS units only)

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

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

Line

Ground

Neutral

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

Not included with system:

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

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

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

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

. 6.

3. Close the Control Box. Restore power.

4. Follow instructions in Grounding, page 19.

FIG. 6. Control Box Electrical Connection

TERMINAL

BLOCK

L N GRND

L GRND N

LINE POWER

FILTER

L N

SWITCH

ROCKER

POWER SUPPLY

ti16391a

FIG. 7. Electrical Schematic

18 3A0868G

Grounding

Installation

Air and Fluid Hoses

Use grounded hoses only.

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

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

AC Power

Ground Screw

TI15712a

FIG. 8. Ground Screw and Power Switch

Gun Flush Box

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

Feed Pumps or Pressure Pots

Spray Gun

Follow the grounding instructions in your gun manual.

• Non-Electrostatic: Ground the spray gun through connection to a Graco-approved grounded fluid supply hose.

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

Fluid Supply Container

Follow local code.

Object Being Sprayed

Follow local code.

All Solvent Pails Used When Purging

Follow local code. Use only conductive metal pails/containers placed on a grounded surface. Do not place the pail/container on a nonconductive surface, such as paper or cardboard, which interrupts the grounding continuity.

Check Resistance

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

3A0868G 19

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

Installation

Key:

Control Box ground screw

Control Box ground wire

Pump B ground screw

Pump B ground wire

Pump A ground screw

Pump A ground wire

Gun Flush Box ground screw

Gun Flush Box ground wire

True Earth Ground - check your local code for requirements.

Power cable, Display

Module/Control Box

FIG. 9. Grounding

ti16467a

20 3A0868G

Display Module

Ratio

LCD display

Potlife timers

Soft keys

Navigation keys

Standby key

Setup key

. 10. Display Module

Screen number

Error code

Potlife state

ti16319a

Active recipe

Operation mode; see page 22 for key

Navigation keys

Flow rate

Enter key

Error Reset key

Display

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

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

Key Function

Setup:

Press to enter or exit

Setup mode.

Enter:

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

Left/Right Arrows:

from screen to screen.

Use to move

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

NOTICE

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

Up/Down Arrows:

among fields on a screen, items on a dropdown menu, or digits in a settable field.

Error Reset:

so cause can be fixed. Also use to cancel a data entry field.

Standby:

operation and puts the system into standby.

Soft keys:

specific screen or operation shown on the display directly above each key

Stops the current

Press to select the

Use to move

Use to clear alarm

3A0868G 21

Display Module

Icon Key

The following tables present a printable version of the information on the ProMix 2KE icon card. See Table 3, page 52, for a printable version of the error code information on the reverse side of the card.

General Icons

Icon Description

Pump

Meter

Dose Valve

Solvent Valve

Air Filter

Fluid Filter

Gun Flush Box

Park Pumps

Flush Time

Hose Length

Hose Diameter

Spray Gun States

Icon Description

Mix

Mix Spray

In Flush Box

Purge

Purge in Flush Box

Standby

Idle

Locked

Operation Modes

Icon Description

Standby

Screen Shortcuts

Icon Description

Home

Spray

Alarm Log

Run Pumps

System Configuration

Recipes

Maintenance

Calibrate

Softkeys

Icon Description

Mix/Spray

Ratio

Potlife

Length

Volume

Pressure

Air Flow Switch

Flow Rate High/Low

Job Number

User Number

Mix

Purge

Color Change

Dispense A

Dispense B

Batch

Calibrate

Forced

Park

Locked

Standby

Purge

Reset Counter

Start

Stop/Standby

22 3A0868G

Display Module

Screen Summary

NOTE: This summary is a one-page guide to the ProMix 2KE screens, followed by screen maps. For operating

instructions, see Basic Operation, page 29. For further detail on individual screens, see Run Mode Details, page 39, or Setup Mode Details, page 42.

Run Mode

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

Mix (Screens 2-4, 38)

• Spray (Screen 2) controls most mixing operations.

• Batch (Screen 3) controls dispense of a set volume.

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

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

Error Log (Screens 5-14)

• 10 screens, 5 errors per page.

• Displays date, time, and error.

Pump Control (Screen 15)

• Manually start or stop a pump.

• Park pumps for brief shutdowns.

Setup Mode

Recipe (Screens 28 and 29)

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

Maintenance (Screens 24-26)

• Maintenance 1 (Screen 24) controls maintenance timer actual and target for Pump A, Pump B, Solvent Valve A, and Solvent Valve B.

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

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

Calibration (Screens 22 and 23)

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

• Calibration 2 (Screen 23) allows the user to perform a calibration.

Troubleshooting

The troubleshooting mode has three screen sections that allow an authorized user to troubleshoot system operation. See F

. 14, page 28.

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

Configure (Screens 18-21)

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

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

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

• Configure 4 (Screen 21) controls units for distance, volume and pressure.

3A0868G 23

System Inputs (Screen 35)

Membrane Test (Screen 36)

System Outputs and Manual Activation (Screen 37)

Display Module

Ranges for User Inputs

This table is a one-sheet reference of the data range/options accepted for each user input and the default setting. See the page indicated in the table for further screen information, if needed.

Page Screen User Input Range/Options Default

39 Run Mix Batch (3)

40 Run Job Number (38)

42 Password (16)

43 Configure 1 (18)

43 Configure 2 (19)

44 Configure 3 (20)

44 Configure 4 (21)

44 Recipe 1-1 (28)

44 Recipe 1-2 (29)

45 Maintenance 1 (24)

45 Maintenance 2 (25)

45 Maintenance 3 (26)

46 Calibration 1 (22)

46 Calibration 2 (23)

Target Volume

User Number

Password

System Type

Gun Flush Box Enable

Number of Guns

Gun 1 or Gun 2 hose length

Gun 1 or Gun 2 hose diameter

Flow Rate Region

Air Flow Switch

USB Log Language

Date Format

Date

Time

Password

Backlight Timer

Distance Units

Volume Units

Pressure Units

Ratio

Ratio Tolerance

Potlife Timer

Flush Times- First (A purge), Second (B purge), or Third (using A or B, chosen by user)

Pump A or Pump B

Solvent Valve A or Solvent Valve B

Dose Valve A or Dose Valve B

Fluid Filter A or B, or Air Filter

Pump A or Pump B Factor

Actual Dispensed Volume

Meters; 50cc Pump; 75cc Pump; 100cc Pump;

High (250 cc/min or higher) or

Chinese; Dutch; English; French; German; Ital-

ian; Japanese; Korean; Portuguese;

Russian; Spanish; Swedish;

Liters; Gallons US; Gallons Imperial Gallons US

Note: Enter 0 to dispense A only.

Note: If set to 0, potlife alarm is disabled.

Note: If set to 0, the valve(s) will not flush.

1 to 9999 cc 0 cc

000000000 to 999999999 000000000

0000 to 9999 0000 (disabled)

Meters

125cc Pump; 150cc Pump

On or Off Off

1 or 2 guns 1 gun

0.1 to 45.7 m / 0.3 to 150 ft 1.53 m / 5.01 ft

0.1 to 1 inch 0.25 inches

High

Low (<250 cc/min)

On or Off On

English

mm/dd/yy; dd/mm/yy;

yy/mm/dd

01/01/00 to 12/31/99 Set at factory

00:00 to 23:59 Set at factory

0000 to 9999 0000 (disabled)

0 to 99 minutes 0 minutes

Feet/inches or Meters/cm Feet/inches

psi; Bar; MPA psi

0:1 to 30:1

1 to 99 percent* 5 percent

0 to 240 minutes

0 to 240 seconds

0 to 9,999,999 0

0 to 9999 days 0 days

5 to 50 cc/in 50cc: 10 cc/in.

1 to 9999 cc 0 cc

mm/dd/yy

1:1

60 minutes

60 seconds

75cc: 15 cc/in.

100 cc: 20 cc/in.

125cc: 25 cc/in. 150cc: 30 cc/in.

* The system will attempt to hold whatever accuracy is entered. For some ratios and applications, testing shows that actual sys-

tem accuracy may be ±2% or ±5%. See Technical Data, page 73.

24 3A0868G

Display Module

Pump Control

Job Number

Run Home

Totals

. . .

Errors

Mix

Spray Batch

FIG. 11. Run Mode Screen Map

3A0868G 25

Display Module

Set-Up Home

See F

Password

FIG. 12. Setup Mode Screen Map, page 1

26 3A0868G

Configure

Recipe

Display Module

Set-Up Home

Calibration

. 12.

See F

Maintenance

FIG. 13. Setup Mode Screen Map, page 2

3A0868G 27

Display Module

Password

Set Password to 9909 (See Configure 3, Screen 20), then enter it here.

Press to exit Setup. Press to reenter Setup. Setup Home (Screen 17) displays, with Troubleshooting options.

System Outputs 1

Screen 36

Push to enter forced mode, (System Outputs 2)

To Membrane Test

Membrane Test

Set-Up Home

System Outputs 2

System Inputs

To Screen 36

To Setup Home

FIG. 14. Troubleshooting Screen Map

28 3A0868G

Basic Operation

Pre-Operation Tasks

Go through the Pre-Operation Checklist in Table 1.

Table 1: Pre-Operation Checklist

✓ Checklist

System grounded

Verify all grounding connections were made. See

Grounding, page 19.

All connections tight and correct

Verify all electrical, fluid, air, and system connections are tight and installed according to the manual instructions.

Fluid supply containers filled

Check component A and B and solvent supply containers.

Dose valves set

Check that dose valves are set correctly. Start with the settings recommended in Valve Set-

tings, page 35, then adjust as needed.

Fluid supply valves open and pressure set

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

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

I = ON

TI16336a

FIG. 15. Power Switch

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

Component A and B fluid supply pressures should be equal unless one component is more viscous and requires a higher pressure setting.

Solenoid pressure set

75-100 psi inlet air supply (0.5-0.7 MPa, 5.2-7 bar)

Power On

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

. 16. Run Mix Spray (Screen 2)

Initial System Setup

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

2. Set recipe and flush information as described in

Recipe 1-1 (Screen 28) and Recipe 1-2 (Screen

29), page 44.

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

3A0868G 29

Basic Operation

Prime the System

NOTE: See Run Mode Details, pages 39-41, for further

screen information, if needed.

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

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

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

Standby

8. Open the fluid supply valve to the pump.

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

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

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

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

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

cycles, press again.

11. Repeat for Pump B.

4. Press to show the dropdown menu.

5. Press to highlight Pump A, then press .

6. Put Pump A into supply pail.

7. Adjust air pressure to component A pump for your application. Use lowest pressure possible.

NOTE: Do not exceed the maximum rated working pressure shown on the system identification label or the lowest rated component in the system.

30 3A0868G

Basic Operation

Pump Calibration

NOTE: See Calibration 1 and 2 (Screens 22 and 23),

page 46, for further screen information, if needed.

Calibrate the pump:

• The first time the system is operated.

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

• At least once per month as part of regular maintenance.

• Whenever a pump is serviced or replaced.

NOTE:

• Pump factors on Calibration 1 (Screen 22) are

updated automatically after the calibration procedure is completed. You also may manually edit them if desired.

• All values on this screen are in cc or cc/in.,

regardless of the units set in Configure 4 (Screen 21).

• During each calibration the dispense valve will

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

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

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

6. Press to start the calibration on the checked

pump (A or B). Press to cancel the calibration.

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

NOTE: Stop triggering the gun when desired amount is

reached. Do not press , as it will cancel the calibration.

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

Volume measured by system displays here.

Enter dispensed volume here.

FIG. 17. Dispensed Volume Comparison

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

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

• If the screen and actual volumes are different, press

to highlight the dispense volume field. Press

. Press to move between digits. Press

to change a digit. Press when field is

correct.

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

3. Press to display Calibration1 (Screen 22).

Pump calibration factors are shown for Pump A and Pump B.

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

5. Press to highlight the pump you wish to cali-

brate. Press . An X displays in the box.

3A0868G 31

Basic Operation

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

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

a. Go to Mix mode.

b. Trigger the gun into a grounded metal pail until

mixed material flows from the gun nozzle.

Spraying

NOTE: See Run Mode Details, pages 39-41, for further

screen information, if needed.

1. Calibrate the pumps as described in Pump Calibra- tion, page 31. Pump factors will update automatically based on calibration results. Make additional manual changes, if desired, as described in Cali- bration 1 and 2 (Screens 22 and 23), page 46. Adjust the flow rate.

2. Press . The system will load the correct potlife

volume based on hose length and diameter entered on Configure 2 (Screen 19). Once material is

loaded, the system returns to Standby. Press

again to spray the loaded recipe.

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

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

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

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

NOTE:

• Pressure adjustments of each component will

vary with fluid viscosity. Start with the same fluid pressure for component A and B, then adjust as needed.

• Do not use the first 4-5 oz. (120-150 cc) of

material as it may not be thoroughly mixed due to errors while priming the system.

NOTICE

Do not allow a fluid supply tank to run empty. It is possible for air flow in the supply line to turn gear meters in the same manner as fluid. This can damage the meters and lead to the proportioning of fluid and air that meets the ratio and tolerance settings of the equipment. This can further result in spraying uncatalyzed or poorly catalyzed material.

Purging

NOTE: See Run Mode Details, pages 39-41, for further

screen information, if needed.

There are 2 purging procedures in this manual:

• Purging Mixed Material

Flow rate

FIG. 18. Flow Rate Display

32 3A0868G

• Purging Fluid Supply System

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

Basic Operation

Purging Mixed Material

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

• end of potlife

• breaks in spraying that exceed the potlife

• overnight shutdown or end of shift

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

1. Press on Run Mix Spray (Screen 2) or

from any screen to put the system in Standby.

2. Trigger the gun to relieve pressure.

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

4. If using an electrostatic gun shut off the electrostatics before flushing the gun.

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

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

10. If spray tip was removed, reinstall it.

11. Adjust the solvent supply regulator back to its normal operating pressure.

NOTE: The system remains full of solvent.

NOTE: If your system uses 2 guns, you must trigger

both guns simultaneously during a purge to purge both guns and lines. Verify that clean solvent flows from each gun. If not, repeat purge or clear clog/blockage in system.

Purging Fluid Supply System

Follow this procedure before:

• the first time material is loaded into equipment

• servicing

• shutting down equipment for an extended period of time

• putting equipment into storage

1. Press on Run Mix Spray (Screen 2) or

from any screen to put the system in Standby.

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

7. Press on Run Mix Spray (Screen 2). The

purge sequence automatically starts.

If the gun flush box is not used, trigger the gun into a grounded metal pail until the purge sequence is complete.

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

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

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

2. Trigger the gun to relieve pressure.

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

4. If using an electrostatic gun, shut off the electrostatics before flushing the gun.

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

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

7. Remove the Control Box cover to access the solenoid valves. See F

. 19.

3A0868G 33

Basic Operation

8. Purge as follows:

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

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

• Repeat to thoroughly clean the mix manifold.

9. Reinstall the Control Box cover.

10. Shut off the solvent fluid supply.

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

NOTE: The system remains full of solvent.

Manual overrides

Solvent Valve A Solenoid

Dose Valve A Solenoid

Solvent Valve B Solenoid

. 19. Solenoid Valves in Control Box

Dose Valve B Solenoid

Gun Flush Box Solenoid location, if used.

ti15730a

34 3A0868G

Basic Operation

Pressure Relief Procedure

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

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

1. Press on Run Mix Spray (Screen 2) or

from any screen to put the system in Standby.

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

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

4. With the gun triggered, push the manual override on the A and B dose and solvent valve solenoids to relieve pressure. See F sure is reduced to 0.

5. Reinstall the Control Box cover.

. 19. Verify that fluid pres-

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

Valve Settings

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

counterclockwise

low viscosity materials), turn

FIG. 21. Valve Adjustment

. To close dose or purge valves (for

clockwise.

See FIG. 21.

TI11581a

Lock Mode

NOTE: Do not change system type, number of guns,

hose length or hose diameter when material is loaded in the system. Change these inputs only if system hardware is changed.

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

Lock icons

FIG. 20. System Lock Mode

Shutdown

1. Follow Purging, on page 32.

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

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

3A0868G 35

Use of Optional USB Module

USB Logs

Job Log 1

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

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

Error Log 2

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

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

FIG. 22. Sample Job Log

36 3A0868G

Use of Optional USB Module

FIG. 23. Sample Error Log

Setup

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

FIG. 24. Select Language for USB Logs

3A0868G 37

Language dropdown menu

Use of Optional USB Module

Download Procedure

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

1. Press on Run Mix Spray (Screen 2) or

from any screen to place the system in Standby.

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

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

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

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

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

dows

Explorer.

7. Open Graco folder.

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

9. Open DOWNLOAD folder.

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

11. Open log file. Log files open in Microsoft default. However, they can also be opened in any

text editor or Microsoft

NOTE:

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

Word.

Excel® by

Recommended USB Flash

4. Remove flash drive from USB port.

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

USB Port

TI15712a

FIG. 25. USB Port

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

Drives

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

• Crucial Gizmo! JDO4GB-730)

• Transcend JetFlash (model TS4GJFV30)

• OCZ Diesel OCZUSBDSL4G)

™

4GB USB flash drive (model

V30 4GB USB flash drive

™

4GB USB flash drive (model

38 3A0868G

Run Mode Details

Run Mix Spray (Screen 2)

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

Target ratio

Actual ratio

Potlife time

Mix

Potlife for each gun

FIG. 26. Run Mix Spray (Screen 2)

Standby

1 Gun

Purge

2 Guns

Gun status

Flow rate

Home

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

Run Mode screen sections: Mix , Errors ,

or Pump Control .

• Press to enter the Setup screens.

Run Mix Batch (Screen 3)

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

Target ratio Actual ratio

Target volume Actual volume

Start

FIG. 28. Run Mix Batch (Screen 3)

Stop

Home

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

38).

• Press to access Run Home (Screen 1).

Run Home (Screen 1)

Screen number

FIG. 27. Run Home (Screen 1)

• Press to set the target dispense volume. Use

to change each digit, then to move

to the next digit. Press when finished.

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

38).

3A0868G 39

Run Mode Details

Run Mix Totals (Screen 4)

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

Batch total

Grand tota

Clear batch totals/ increment job

FIG. 29. Run Mix Totals (Screen 4)

• Press to clear all batch totals. A verification

screen appears. Use to highlight and press

on the to clear the batch totals, or on the

to return to Run Totals (Screen 4) without clearing.

Home

Run Job Number (Screen 38)

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

Job number

User number

Home

FIG. 31. Run Job Number (Screen 38)

• Press to set the user number. Use to

change each digit, then to move to the next

digit. Press when finished.

• Press increment the job number.

FIG. 30. Confirm Clear Batch Totals

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

38).

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

38).

Run Log Errors (Screens 5-14)

Run Log Errors (Screens 5-14) display if is selected from Run Home (Screen 1). It displays the last

50 errors in the log. (Screen 5 displays errors 1-5; Screen 6 displays errors 6-10, etc.).

Error codes

Error Icons

FIG. 32. Run Log Errors (Screen 5)

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

. 54,

40 3A0868G

Run Pump Control (Screen 15)

Run Pump Control (Screen 15) displays if is selected from the Run Home Screen. Use this screen to

manually start and stop a pump.

Pump/Park selection dropdown

Run Mode Details

Start

Stop

Home

FIG. 33. Run Pump Control (Screen 15)

• Press to show the dropdown menu.

• Press to highlight, then press to select a pump or the Park option.

• If Pump A or Pump B is selected, use or to start. The selected pump will run for 12 cycles. To

stop before the 12 cycles are completed, press .

• If Park is selected, use to move the pump to the bottom of the stroke to park it so pump rod is fully

enclosed in the lower and material can’t dry on shaft during break or overnight.

3A0868G 41

Setup Mode Details

Press on any screen to enter the Setup screens. If the system has a password lock, Password (Screen 16)

displays. If the system is not locked (password is set to

0000), Setup Home (Screen 17) displays.

Password (Screen 16)

Software Version:

Display Module

Fluid Control Module

USB Module

From any Run screen, press to access the password screen. The Password Screen displays if a pass-

word has been set. Set the password to 0000 to prevent Password (Screen 16) from displaying. See Configure 3 (Screen 20), page 44, to set or change the password.

FIG. 34. Password (Screen 16)

• Press to enter the password (0000 to 9999).

Press to move between digits. Press

to change a digit. Press when field is

correct. Setup Home (Screen 17) displays.

Recipe MaintenanceConfigure Calibration

FIG. 35. Setup Home (Screen 17)

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

Configure , Recipe , Maintenance , or

Calibration .

• Press to toggle between Run Mode and Setup Mode.

• Select to display Run Home (Screen 1). Entering an incorrect password also displays Run Home (Screen 1).

Setup Home (Screen 17)

Setup Home (Screen 17) displays if is selected on any screen and the system is not locked, or when a cor-

rect password is entered on the Password Screen. The Setup Home screen displays the software versions of the boards in the Display Module, Advanced Fluid Control Module, and the USB Module (if applicable).

42 3A0868G

Configure 1-4 (Screens 18-21)

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

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

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

Gun flush box

System type

FIG. 36. Configure 1 (Screen 18)

• Press to highlight the desired field. Press

to display the dropdown menu for that field.

Number of guns

Home

Setup Mode Details

FIG. 37. Confirm Change of System Type

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

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

• Select the High setting if your flow rate is 250 cc/min or higher. The High setting has a 100cc overdose volume.

• Select the Low setting if your flow rate is less than 250 cc/min. The Low setting has a 50 cc overdose volume.

Press to choose from the menu options and

to set. Press to move to the next field.

• Press to move through Configure 2 (Screen

19), Configure 3 (Screen 20), and Configure 4 (Screen 21).

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

to highlight and press on the to make the

change, or on the to return to Configure 1 (Screen

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

The air flow switch can be disabled here for airless

applications. Select to enable or to disable.

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

Gun 1

hose

length

Gun 1

hose

diameter

Flow rate

region

Gun 2 hose length

Gun 2 hose diameter Air flow switch

Home

FIG. 38. Configure 2 (Screen 19)

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

3A0868G 43

Setup Mode Details

USB log language

Date format

Date

Time

Configure 3

Pressure

units

Configure 4

Password

Backlight timer

Distance units

Volume units

Home

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

Recipe 1-2 (Screen 29)

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

that valve will not flush.

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

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

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

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

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

Recipe 1-1 (Screen 28)

Note about Settings of 0: If Ratio is set to 0, the sys-

tem will dispense the A material only. If Potlife Time is set to 0, the potlife alarm is disabled.

Recipe 1-1 (Screen 28) displays if is selected on Setup Home (Screen 17). The Recipe Screens allow the user to set up the basic recipe. Recipe 1-1 (Screen 28) includes the ratio of Material A to Material B (0 to 30), ratio tolerance (1 to 99 percent), and potlife time (0 to 240 minutes).

Recipe number

Ratio

Ratio tolerance

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

Potlife timer

Home

e of 0 seconds to skip a flush. For example, enter 0 seconds for A , 30 seconds for B, 30 seconds for the third flush time, and sele ct A for the third flush source. The system will skip the first A flush, go directly to the seco nd flush with the B purge valve for 30 seconds followed by the third flush with the A purge valve for 30 second s.

Third flush time

First flush time (A purge)

Recipe number

Second flush time (B purge)

(uses material set in next field)

Third flush source

Home

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

• Press to highlight the desired field and press

to select. Press to move between dig-

its. Press to change a digit. Press when field is correct.

• Press to toggle between the Recipe screens.

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

44 3A0868G

Setup Mode Details

Maintenance 1-3 (Screens 24-26)

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

9999999. Timers for filters are settable from 0 to 9999 days.

Pumps

Maintenance actual and target

Maintenance 1

Clear Totals

Solvent valves

Home

Maintenance Recommendations

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

Recommended Maintenance

Component

Solvent Valves 1,000,000 cycles Fluid Filter daily Air Filter monthly Pumps 250,000 cycles Dose Valves 1,000,000 cycles

Frequency

Dose valves

Maintenance 2

Air filter

Fluid filters

Maintenance 3

Days

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

• Press to move through the three maintenance screens.

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

to highlight and press on the to clear

the batch totals. No other button press will clear the

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

3A0868G 45

Setup Mode Details

Calibration 1 and 2 (Screens 22 and 23)

NOTE: See Pump Calibration, page 31, for detailed

instructions.

Calibration 1 (Screen 22) displays if is selected on Setup Home (Screen 17). This screen displays the

pump factor for Pump A and Pump B. The factor is the pump displacement per inch. The system starts at the default factor for the pump size chosen on Configure 1 (Screen 18, page 43). Factor values update automatically as needed based on calibration results from Calibration 2 (Screen 23). Factor values also can be set on this screen, from 5 to 50 cc/in.

Pump B Factor

Pump A Factor

Home

FIG. 43. Calibration 1 (Screen 22)

• Press to highlight the pump you wish to cali-

brate. Press . An X displays in the box.

• Press to start the calibration on the highlighted

pump (A or B). Press to cancel the calibration.

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

• Press to highlight the actual dispense vol-

ume field. Press to set the volume (from 0 to

9999 cc). Press to move between digits.

Press to change a digit. Press when field is correct.

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

Troubleshooting (Screens 35-37)

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

Pump B Factor

Pump A Factor

Start Pump Calibration

FIG. 44. Calibration 2 (Screen 23)

Cancel Pump Calibration

Material to dispense

Target dispense volume

Actual dispense volume

Home

Screens for testing system controls can be accessed by setting the password to 9909. See Configure 3 (Screen

20), page 44, to set or change the password.

After setting the password to 9909, press to exit

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

options.

Troubleshooting screen options appear here.

FIG. 45. Setup Home with Troubleshooting

46 3A0868G

Setup Mode Details

Troubleshooting System Inputs (Screen 35)

From Setup Home (Screen 17) with Troubleshooting

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

Air Flow

Pump B up or down

Pump A up or down

FIG. 46. Troubleshooting System Inputs (Screen 35)

• Press , then again to move to Trouble-

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

Switch on

Pump Pressures

Meter Pulses (not used)

Gun in Gun Flush Box

Troubleshooting System Outputs (Screen 37)

From Setup Home (Screen 17) with Troubleshooting

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

Press to start Forced Mode. A second set of check

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

upon actuation. Press to exit Forced Mode. Moving

to any other screen also will exit Forced Mode.

Dose Valves

Start Forced Mode

Solvent Valves

Gun Trigger

Alarm

Membrane Test (Screen 36)

From Setup Home (Screen 17) with Troubleshooting

active, press , then again. Membrane Test

(Screen 36) displays. You could also press , then

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

FIG. 47. Membrane Test (Screen 36)

• Press three times to return to Setup Home

(Screen 17). Direct access to any other screen is not possible.

Stop Forced Mode

FIG. 48. Troubleshooting Screen Outputs (Screen 37)

3A0868G 47

Setup Mode Details

Dynamic Dosing

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

General Operating Cycle, Dynamic Dosing

Overview

Dynamic Dosing provides on-demand proportioning, eliminating the need for an integrator and therefore minimizing undesired material contact. This feature is especially useful with shear-sensitive and waterborne materials.

A restrictor injects component B into a continuous stream of component A. The software controls the duration and frequency of each injection. See F schematic diagram of the process.

Dynamic Dosing System Parameters

The following parameters affect dynamic dosing performance:

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

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

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

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

. 52 for a

Balancing A/B Pressure

If component B pressure is too high, it will push the component A stream aside during B injection. The valve will not open long enough, causing a Ratio High error.

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

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

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

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

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

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

15).

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

FIG. 49. Monitor Pump Pressures

Select a Component B Restrictor Size

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

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

restrictor size based on the desired flow and mix ratio.

48 3A0868G

B Pressure Too Low

B Pressure

Too High

A Pressure B Pressure

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

Setup Mode Details

(

)

B Pressure Too Low

B Pressure

Too High

A Pressure B Pressure

NOTE: If the restrictor is too small, it may be

necessary to supply more differential pressure than is available in your system.

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

Restrictor

Component A (continuous flow) Proportioned Material

Component B (pulsed injection)

. 52. Schematic Diagram of Dynamic Dosing Operation

Table 2: Dynamic Dosing Troubleshooting Guide

(for complete system troubleshooting, see Table 3 beginning on page 52)

Error Message Solution

Ratio Low Error (R1) • Increase A pressure or decrease B pressure.

• Use a smaller restrictor.

Ratio High Error (R4) • Increase B pressure.

• Clean restrictor or use a larger size.

• Verify B valve is opening properly.

To Static

Mixer

3A0868G 49

System Errors

NOTE: Do not use the fluid in the line that was dis-

pensed off ratio as it may not cure properly.

Record - no icon

System Alarms

System alarms alert you of a problem and help prevent off-ratio spraying. If an alarm occurs, operation stops and the following occurs:

• Alarm buzzer sounds.

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

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

Error Code Indicator

Alarm icon

Advisory icon

FIG. 54. Error Log Icons

To Clear Error and Restart

NOTE: When an error occurs be sure to determine the

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

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

pressing .

Air Flow Switch (AFS) Function

Air or Air-assisted Guns

. 53. Display Module Alarm Codes

System Advisory/Record Codes

ABLE

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

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

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

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

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

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

50 3A0868G

System Idle Warning (IDLE)

This warning occurs if the ProMix is set to Mix ,

and 2 minutes have elapsed since the system last received the air flow switch signal (gun trigger). The Gun

Idle icon is displayed. This warning is not active in

systems with a 45:1 pump ratio, using an airless gun.

System Errors

In applications using the AFS,

the warning and you can start spraying again.

Without the AFS,

alarm. To start spraying again, you must press ,

then , then trigger the gun.

triggering the gun does not clear the

triggering the gun clears

3A0868G 51

System Errors

Error Codes

Table 3: System Alarm/Advisory/Record Codes

Code Description Details

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

CA Communication Error 53

CAU1 USB Communication Error 53

EQU2 USB Installed when not in Standby 54

SG Gun Flush Box Error 54

SAD1 SAD2

SFA1 SFB1

SHA1 SHB1

SM MixFill Start Error 55

SN MixFill Complete Error 55

QPD1 QPD2

R1 Ratio Low Error 56

R4 Ratio High Error 57

QDA1 QDB1

QTA1 QTB1

QLAX QLBX

DJA1 DJB1

DKA1 DKB1

P4A1 P4B1

P6A1 P6B1

DDA1 DDB1

EFA1 EFB1

DFA1 DFB1

DGA1 DGB1

DHA1 DHB1

Atomizing Air During Purge - Gun 1 Atomizing Air During Purge - Gun 2

PreMix Error - Color PreMix Error - Catalyst

PreFill Error - Color PreFill Error - Catalyst

Potlife Error - Gun 1 Potlife Error - Gun 2

Overdose A, B Dose too Short Overdose B, A Dose too Short

Dose Time A Error Dose Time B Error

Leak Error A Leak Error B

Linear Sensor Error - Pump A Linear Sensor Error - Pump B

Reed Switch Error - Pump A Reed Switch Error - Pump B

Pressure High Error - Pump A Pressure High Error - Pump B

Pressure Transducer Error - Pump A Pressure Transducer Error - Pump B

Diving/Cavitation Error - Pump A Diving/Cavitation Error - Pump B

Park Error - Pump A Park Error - Pump B

Stall Up Error - Pump A Stall Up Error - Pump B

Stall Down Error - Pump A Stall Down Error - Pump B

No Stall Error - Pump A No Stall Error - Pump B

Table 3: System Alarm/Advisory/Record Codes

Code Description Details

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

MAA1 Pump A maintenance due N/A

MAB1 Pump B maintenance due N/A

MEA1 Mix valve A maintenance due N/A

MEB1 Mix valve B maintenance due N/A

MESA Solvent valve A maintenance due N/A

MESB Solvent valve B maintenance due N/A

MGA1 Fluid Filter A maintenance due N/A

MGB1 Fluid Filter B maintenance due N/A

MGP1 Air Filter maintenance due N/A

ES System defaults loaded N/A

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

EL System powered on N/A

EC System setup changed N/A

EP Pump park operation completed N/A

ET System performed an autodump after

a potlife

EQU1 USB Drive connected while in Standby N/A

N/A

52 3A0868G

Alarm Troubleshooting

Alarm and Description Cause Solution

CA Communication Error

The Display Module is not communicating with the Advanced Fluid Control Module.

CAU1 USB Communication Error

The system detected a USB Module at last power up, but does not detect it currently.

The CAN cable between the Display Module and the Advanced Fluid Control Module is not connected.

The CAN cable is cut or bent. Verify that the cable has not been cut

The cable or connector failed. Replace cable. Alternator Powered Systems:

Check that the Advance Fluid Control Module (AFCM), Display Module (DM), and USB Module have power (green LED) and are communicating (amber LED blinking)

There may be a short in one of the solenoid/meter cables connected to the AFCM.

The AFCM power supply may be bad, as indicated by the status LEDs (red, yellow, green) being off. Verify the power supply works by disconnecting from the AFCM and connecting to another module, either the Display Module or USB Module.

The DM and the AFCM have different versions of software installed.

The red LED on the AFCM is on. If on solid, replace module.

NOTE:

1. If the AFCM loses communication (no flickering amber LED) but then comes back on the alarm will auto clear and will not log the alarm.

2. If the DM loses communication (no flickering amber LED) but then comes back on you will have to manually clear the alarm and there will be an alarm log.

3. If the USB module loses communication (no flickering amber LED) but then comes back on you will not get an alarm.

The module has been removed. Put system in standby and install the

The cable is disconnected or broken. Put system in standby and reconnect

Verify that the cable is correctly connected.

or bent at a radius smaller than 1.6 in. (40 mm).

1. For any module that does not have power, disconnect and check the voltage on the cable produced by the alternator module (See Alternator Module Power Output). If the proper voltage is not detected, troubleshoot the Alternator Module.

2. If the proper voltage is detected, verify the cable connecting the two modules is good.

3. If the cable is good, replace the module.

Replace the cable (16E890)

Replace the module.

Install the latest software from token kit 16D922 on all modules.

If blinking, contact your distributor.

USB Module.

or replace the USB cable.

System Errors

3A0868G 53

System Errors

Alarm and Description Cause Solution

EQU2 USB Drive Error

The USB drive has been

Most USB drives do not conform to IS standards, so it is hazardous to use one while the system is running.

Put system in Standby. Insert the USB drive only in a non-hazardous

environment. inserted when the system is not in Standby.

SG Gun Flush Box Error

A gun flush box is enabled, but the system does not detect a gun in the gun flush box during purge, color change, or auto-dump.

The cover of the gun flush box is not closed.

For systems with a gun flush box, the gun is not in the box when purge is active.

NOTICE

To prevent mixed material from

Close the cover and clear the alarm.

Purge the system with solvent or

fresh mixed material:

• Solvent Purge - See Purging Mixed Material on page 33. The system purges until the preset purge time is complete.

curing in the equipment, do not shut off power. Follow one of the solutions at right.

• New Mixed Material Purge - Go to Mix mode and spray the required volume to restart the potlife timer.

SAD1 or SAD2 Atomizing Air During Purge

Atomizing air to Gun 1 (SAD1) or Gun 2 (SAD2) is detected when purge is selected or during purge sequence.

Atomizing air is stuck on.

Gun is not in Gun Flush Box.

Gun Flush Box air shutoff is not working.

Air leak in atomizing air line.

Replace air flow switch.

Insert the gun into the Gun Flush Box.

Test using Troubleshooting Screens. See page 46. Repair/replace air shutoff valve as needed.

Inspect air line for kinks, damage, or loose connections. Repair or replace as needed.

54 3A0868G

Alarm and Description Cause Solution

SFA1 or SFB1 PreMix Error

In systems with a gun flush box, insufficient quantity of resin/color (SFA1) or catalyst (SFB1) is detected during the 10-second PreMix sequence.

SHA1 or SHB1 PreFill Error

Gun, line, or valve is plugged or stuck.

Pump(s) not working or out of fluid.

Air lines or solenoids are plumbed incorrectly or solenoids are not working.

Flow rate is too low.

Check components and clean, repair, or replace as necessary.

Refill fluid supply. Check and repair pump. See pump manual for repair procedures and replacement parts.

Check air line path. See System Pneumatic Schematic, page 66 or

67. Verify that solenoid is working. Increase fluid pressure.

Total PreFill sequence volume is not reached for color (SHA1) or catalyst (SHB1) during the 5-minute PreFill sequence.

SM MixFill Start Error

In systems with a gun flush box, insufficient volume of mixed material is detected during the 10-second mixed fill sequence.

Gun Flush Box is not triggering gun.

Line or gun is plugged or restricted.

Flow rate is too low.

Valve is stuck.

Verify trigger is being pulled. Adjust as needed.

Clean line, tip, or filter.

Increase fluid pressure or decrease restriction.

Clean valve or verify that solenoid is triggering valve properly.

SN MixFill Complete Error

Insufficient volume of mixed material is detected during the 5-minute mixed fill sequence.

QPD1 or QPD2 Potlife Error

Potlife has been exceeded for the mixed material for Gun 1 (QPD1) or Gun 2 (QPD2).

Have not sprayed enough volume to keep fresh mixed fluid in the mix manifold, hose, and gun.

Purge the mixed material line. See page 33.

Check that hose length and diameter have been entered correctly. See Configure 2 (Screen 19), page 43.

System Errors

Spray the required volume to restart the potlife timer.

3A0868G 55

System Errors

Alarm and Description Cause Solution

R1 Ratio Low Error

The mix ratio is lower than the set tolerance for an A to B component volume comparison.

There is too much restriction in the system.

• Check that the system is fully loaded with material.

• Check that the supply pump’s cycle rate is set properly.

• Check that the spray tip/nozzle is properly sized for the flow and application, and that it is not clogged.

• Check that the fluid regulator is set properly.

If the alarm occurs during start up, after purging, the flow rate was probably too high.

If the alarm occurred after you were spraying for some time, the pressures from the fluid supplies could be unbalanced.

Restrict gun needle travel to slow down the initial fluid delivery rate until fluid hoses are loaded with material.

djust component A and B fluid supply regulator pressures until they are about equal.

If the pressures are

already about equal,

ponent A and B dose valves are operating properly.

Slow actuation of the component A or B valves. This can be caused by:

Manually operate the Dose Valve A and B solenoid valves as instructed in the ProMix 2KE Repair-Parts manual to check operation.

• Air pressure to the valve actuators is too low.

• Increase air pressure. Air pressure must be 75-120 psi (0.52-0.84 MPa, 5.2-8.4 bar); 120 psi is recommended.

• Something is restricting the solenoid or tubing and interrupting valve actuation air.

• There may be dirt or moisture in the air supply. Filter appropriately. Verify that solenoids are operational.

• Dose Valve B is turned in too far. Dose Valve A is open too far.

• Fluid pressure is high and air pressure is low.

• Refer to Valve Settings, page 35, for adjustment guidelines.

• Adjust air and fluid pressure. See recommended air pressure above.

verify that com-

56 3A0868G

Alarm and Description Cause Solution

R4 Ratio High Error

The mix ratio is higher than the set tolerance for an A to B component volume comparison.

There is too little restriction in the system. • Check that the system is fully

loaded with material.

• Check that the supply pump’s cycle rate is set properly.

• Check that the spray tip/nozzle is properly sized for the flow and application, and that it is not worn.

• Check that the fluid regulator is set properly.

If the alarm occurs during start up, after purging, the flow rate was probably too high.

If the alarm occurred after you were spraying for some time, the pressures from the fluid supplies could be unbalanced.

Restrict gun needle travel to slow down the initial fluid delivery rate until fluid hoses are loaded with material.

djust component A and B fluid supply regulator pressures until they are about equal.

If the pressures are

already about equal,

ponent A and B dose valves are operating properly.

Slow actuation of the component A or B valves. This can be caused by:

Manually operate the Dose Valve A and B solenoid valves to check operation.

• Air pressure to the valve actuators is too low.

• Increase air pressure. Air pressure must be 75-120 psi (0.52-0.84 MPa, 5.2-8.4 bar); 120 psi is recommended.

• Something is restricting the solenoid or tubing and interrupting valve actuation air.

• Dose Valve B is turned in too far. Dose Valve A is open too far.

• Fluid pressure is high and air pressure is low.

• There may be dirt or moisture in the air supply. Filter appropriately.

• Refer to Valve Settings, page 35, for adjustment guidelines.

• Adjust air and fluid pressure. See recommended air pressure above.

QDA1 Overdose A

The A dose has overshot and, when combined with B, is too large for the mix manifold capacity.

Valve seal or needle/seat are leaking. Repair the valve. Slow actuation of component A or B valves. See Ratio Low Error and Ratio High

Error, pages 56-57.

Running a high mix ratio and a high flow rate.

It may be necessary to restrict the flow rate through the component B dose valve by adjusting its hex nut.

QDB1 Overdose B

The B dose has overshot, forcing an A dose that, when combined with B, is too large for the mix manifold capacity.

System Errors

verify that com-

3A0868G 57

System Errors

Alarm and Description Cause Solution

QTA1 or QTB1 Dose Time Error

The gun trigger is active, but no A pump (QTA1) or B pump (QTB1) movement is detected during the dose time selected.

System is in Mix mode and gun is only partially triggered, allowing air but no fluid to pass through gun.

Fluid flow rate is too low. Increase flow rate. Slow actuation of component A or B valves. See Ratio Low Error and Ratio High

Fully trigger the gun.

Error, pages 56-57.

A or B pump has no air pressure. Verify that main air supply is turned

on and valves are open.

There is an air leak downstream from the air flow switch.

Check the air lines for leaks and repair.

The air flow switch is stuck open. Clean or replace air flow switch.

QLAX or QLBX Leak Error

Pump A (QLAX) or Pump B (QLBX) is running with all

A or B dose valve leak Replace valve needle and seat.

A or B pump is not seating and continues to move/creep.

Replace pump packings, balls, and seats.

valves closed.

DJA1 or DJB1 Linear Sensor Error

System does not detect the pump A (DJA1) or pump B (DJB1) linear position sensor, or has an invalid position reading.

Sensor not recognized by system.

Magnet fell off.

Sensor readings are out of range.

Verify that sensor is plugged in. Verify that sensor and AFCM are operational. Verify cable connections. Replace any malfunctioning component.

Replace magnet and holder on top side of air motor piston.

Verify that the sensor is threaded down completely.

DKA1 or DKB1 Reed Switch Error

System does not detect the pump A (DKA1) or Pump B (DKB1) reed switch sensor, or detects an invalid state.

P4A1 or P4B1 Pressure High Error

System detects a high pressure reading on pump A (P4A1) or pump B (P4B1).

Reed switch installed backward.

Reed switches are stuck, or both reed switches are on at once

Magnet in air valve not functioning properly.

Pump air pressure is set too high.

Thermal expansion occurring in lines.

Pressure transducer malfunction.

Flip reed switch 180 degrees to align with magnet in air valve.

Verify cable is connected on both ends. Verify that reed switch, cable, and AFCM are operational. Replace any malfunctioning component.

Verify that magnet is installed properly and is operational.

Reduce pressure on air supply to system or pumps.

Relieve pressure if system has been idle. Decrease environmental temperature.

Replace transducer. Verify that cable and AFCM are operational.

P6A1 or P6B1 Pressure Transducer Error

Pressure transducer malfunction.

Replace transducer. Verify that cable

and AFCM are operational. System does not detect pressure transducer A (P6A1) or pressure transducer B (P6B1).

58 3A0868G

Alarm and Description Cause Solution

DDA1 or DDB1 Diving/Cavitation Error

Pump A (DDA1) or Pump B (DDB1) is diving or cavitating.

EFA1 or EFB1 Park Error

Pump A (EFA1) or Pump B (EFB1) does not park (does not reach bottom changeover).

Fluid supply is empty.

Displacement pump is not seating properly.

Air in fluid supply system.

Gun not open.

Fluid lines plugged.

Dispense valve malfunction.

Refill fluid supply system.

Rebuild displacement pump and replace packings, balls, and seats.

Tighten all fittings.

Trigger gun and allow fluid to flow while pump is attempting to park.

Check and clear all fluid lines, gun tip, and the mix manifold.

Clean or rebuild dispense valve. Verify that solenoid is operational. Clear air lines to valve.

DFA1 or DFB1 Stall Up Error

Pump A (DFA1) or Pump B (DFB1) does not stall up dur-

Displacement pump is not seating properly.

Dispense valve not seating/sealing.

Rebuild displacement pump and replace packings, balls, and seats.

Replace needle/seat on dispense valve.

ing the pump calibration and stall test (keeps moving up when dosing valve is closed).

DGA1 or DGB1 Stall Down Error

Pump A (DGA1) or Pump B (DGB1) does not stall down

Displacement pump is not seating properly.

Dispense valve not seating/sealing.

Rebuild displacement pump and replace packings, balls, and seats.

Replace needle/seat on dispense valve.

during the pump calibration and stall test (keeps moving down when dosing valve is closed).

DHA1 or DHB1 No Stall Error

Pump A (DHA1) or Pump B (DHB1) does not stall in either

Displacement pump is not seating properly.

Dispense valve not seating/sealing.

Rebuild displacement pump and replace packings, balls, and seats.

Replace needle/seat on dispense valve.

direction during the pump calibration and stall test (keeps moving when dosing valve is closed).

System Errors

3A0868G 59

Dynamic Dosing Restrictor Selection Graphs

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

Table 4: Restrictor Sizes

Example:

Application:

Fluid Supply:

Flow Rate:

Select the Restrictor Size:

or 0.070 orifice, to ensure that the pressure differential is not more than 10-20 psi (0.7-1.4 bar,

0.07-0.14 MPa), provided the fluid viscosities are similar to those tested.

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

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

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

air spray system with a 5:1 mix ratio

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

300 cc/min at the gun

choose either the 0.040

Size Code Orifice Size Part No.

2* 0.020 15U936 3* 0.030 15U937

4* 0.040 15U938 5✓ 0.050 15U939 6✓ 0.060 15U940

7* 0.070 15U941 8✓ 0.080 16D554

* These restrictors are included in Injection Kit

15U955.

✓

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

60 3A0868G

psi

(bar, MPa)

4000

(276, 27.6)

Dynamic Dosing Restrictor Selection Graphs

(241, 24.1)

(207, 20.7)

(172, 17.2)

(138, 13.8)

(103, 10.3)

(69, 6.9)

Differential Pressure between A and B

(34, 3.4)

3500

3000

2500

2000

1500

1000

500

Key

#2 Restrictor #3 Restrictor

#4 Restrictor #7 Restrictor

500 1000 1500 2000 30002500 35000

4000

Flow Rate (cc/min)

Detail View

1000

(69, 6.9)

750

(52, 5.2)

500

(34, 3.4)

375

(26 2.6)

250

(17, 1.7)

125

(8.6, 0.86)

500

1000

FIG. 55. Dynamic Dosing Performance (1:1 Ratio, 90 centipoise fluid, 100 psi A side pressure)

3A0868G 61

Dynamic Dosing Restrictor Selection Graphs

psi

(bar, MPa)

1400

(97, 9.7)

Differential Pressure between A and B

1200

(83, 8.3)

1000

(69, 6.9)

800

(55, 5.5)

600

(41, 4.1)

400

(28, 2.8)

200

14, 1.4)

Key

#2 Restrictor #3 Restrictor #4 Restrictor #7 Restrictor

500 1000 1500 2000 30002500 35000

4000

Flow Rate (cc/min)

Detail View

400

(28, 2.8)

300

(21, 2.1)

200

(14, 1.4)

100

(7, 0.7)

(3.4, 0.34)

500 1000

FIG. 56. Dynamic Dosing Performance (5:1 Ratio, 90 centipoise fluid, 100 psi A side pressure)

62 3A0868G

psi

(bar, MPa)

800

(55, 5.5)

700

(48, 4.8)

600

(41, 4.1)

500

(34, 3.4)

400

(28, 2.8)

300

(21, 2.1)

200

(14, 1.4)

Dynamic Dosing Restrictor Selection Graphs

Key

#2 Restrictor #3 Restrictor

#4 Restrictor #7 Restrictor

Differential Pressure between A and B

100

(7, 0.7)

500 1000 1500 2000 30002500 35000

4000

Flow Rate (cc/min)

Detail View

200

(14, 1.4)

150

(10, 1.0)

100

(7, 0.7)

(3.4, 0.34)

500 1000

FIG. 57. Dynamic Dosing Performance (10:1 Ratio, 90 centipoise fluid, 100 psi A side pressure)

3A0868G 63

Dynamic Dosing Restrictor Selection Graphs

psi

(bar, MPa)

300

(21, 2.1)

(17.2, 1.72)

(14, 1.4)

10.3, 1.03)

(7.0, 0.7)

(3.4, 0.34)

Differential Pressure between A and B

250

200

150

100

(7, 0.7)

100

Key

500 1000 1500 2000 30002500 35000

#2 Restrictor #3 Restrictor

#4 Restrictor #7 Restrictor

4000

Flow Rate (cc/min)

Detail View

(5.2, 0.52)

(3.4, 0.34)

(1.7, 0.17)

500 1000

FIG. 58. Dynamic Dosing Performance (20:1 Ratio, 90 centipoise fluid, 100 psi A side pressure)

64 3A0868G

(bar, MPa)

(14, 1.4

(12.4, 1.2

(11, 1.1)

9.7, 0.9)

8.3, 0.8)

(7, 0.7)

(5.5, 0.55)

(4.1, 0.41)

(2.8, 0.28)

Differential Pressure between A and B

(1.4, 0.14)

psi

200

180

160

140

120

100

Dynamic Dosing Restrictor Selection Graphs

Key

#2 Restrictor #3 Restrictor

#4 Restrictor #7 Restrictor

500 1000 1500 2000 30002500 35000

Flow Rate (cc/min)

Detail View

(2.8, 0.28)

(2.1, 0.21)

(1.4, 0.14)

(0.7, 0.07)

500 1000

FIG. 59. Dynamic Dosing Performance (30:1 Ratio, 90 centipoise fluid, 100 psi A side pressure)

4000

3A0868G 65

Schematics

Hazardous Location System Pneumatic Schematic

PURGE B

VALVE

MANIFOLD

PURGE A

VALVE

DOSE A1

VALVE

OPEN

5/32 TUBE

DOSE B

VALVE

DOSE A2

VALVE

(OPTIONAL)

DOSE A3

OPEN

5/32 TUBE

OPEN

5/32 TUBE

OPEN

VALVE

(OPTIONAL)

5/32 TUBE

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

TURBINE/POWER SUPPLY

GFB #1

VALVE

(OPTIONAL)

OPEN

5/32 TUBE

OPEN

AIR EXHAUST MUFFLER

AIR SUPPLY

12 VDC

MERKUR

B A

4-WAY SOLENOID

MOTOR B

12 VDC

B A

4-WAY SOLENOID

PUMP B PILOT

12 VDC

B A

4-WAY SOLENOID

12 VDC

B A

4-WAY SOLENOID

GAUGE

12 VDC

B A

4-WAY SOLENOID

AIR REGULATOR

12 VDC

B A

4-WAY SOLENOID

3/8" TUBE

TO MANIFOLD

RELIEF VALVE

12 VDC

3-WAY SOLENOID

3/8" AIR FILTER

AUTO DRAIN

5 MICRON

100 PSI (.7 MPa, 7 BAR)

GAUGE

MPa, 5.8/7.6 BAR)

85/110 PSI (.58/.76

3/4" BALL VALVE

BLEED TYPE

3/4" AIR FILTER

AUTO DRAIN

ALTERNATOR

AIR REG.

18 PSI (.12 MPa,

20 MICRON

1.2 BAR)

AIR

INPUT

RELIEF VALVE

20 PSI (.12 MPa,

1.2 BAR)

PUMPS SYSTEMS ONLY

MERKUR

MOTOR A

PUMP A PILOT

GAUGE

AIR REGULATOR

66 3A0868G

Non-Hazardous Location Pneumatic Schematic

PURGE B

VALVE

DOSE B

MANIFOLD

PURGE A

VALVE

OPEN

5/32 TUBE

DOSE A1

VALVE

OPEN

5/32 TUBE

OPEN

VALVE

OPEN

5/32 TUBE

DOSE A2

VALVE

(OPTIONAL)

OPEN

5/32 TUBE

DOSE A3

VALVE

(OPTIONAL)

OPEN

5/32 TUBE

GFB #1

VALVE

(OPTIONAL)

OPEN

5/32 TUBE

Schematics

12 VDC

AIR EXHAUST MUFFLER

MERKUR

B A

4-WAY SOLENOID

MOTOR B

12 VDC

B A

4-WAY SOLENOID

PUMP B PILOT

12 VDC

B A

4-WAY SOLENOID

12 VDC

B A

4-WAY SOLENOID

GAUGE

12 VDC

B A

4-WAY SOLENOID

12 VDC

B A

4-WAY SOLENOID

3/8" TUBE

TO MANIFOLD

12 VDC

3/8" AIR REG.

GAUGE

3-WAY SOLENOID

AUTO DRAIN

5 MICRON

100 PSI (.7 MPa, 7 BAR)

3/4" BALL VALVE

BLEED TYPE

AIR

INPUT

AIR REGULATOR

PUMPS SYSTEMS ONLY

RELIEF VALVE

MPa, 5.8/7.6 BAR)

85/110 PSI (.58/.76

3/4" AIR FILTER

AUTO DRAIN

20 MICRON

PUMPS SYSTEMS ONLY

PUMP A PILOT

MERKUR

MOTOR A

GAUGE

AIR REGULATOR

3A0868G 67

Schematics

Hazardous Location Electrical Schematic

CAN_L

+V_CAN

2 3

V_CAN_RTN

CAN_H

SHIELD

CAN_L +V_CAN V_CAN_RTN CAN_H SHIELD

LED_YELLOW LED_BLUEA LED_GREEN UNUSED LED_BLUEB UNUSED LED_RED UNUSED COM(LEDS)

UNUSED UNUSED UNUSED UNUSED

CAN_L

+V_CAN

2 3

V_CAN_RTN

CAN_H

SHIELD

CAN_L

+V_CAN

V_CAN_RTN

CAN_H

4 5

SHIELD

1 2 3 4 5

USER INTERFACE

MODULE

1 2 3 4 5 6 7 8 9 10 11 12 13 14

1 2 3 4 5 6 7 8 9

1 2 3 4

CAN_L +V_CAN V_CAN_RTN CAN_H SHIELD

UNUSED

2 3

UNUSED

SOLENOID

4-WAY

12 VDC

SOLENOID

3-WAY

12 VDC

FLOW METER A

AIR FLOW SWITCH 1

GFB 1 PRESSURE SWITCH/ AIR FLOW SWITCH 2

FLOW METER B

18 PSI

1.5 FCM (MIN)

GRND

MEMBRANE

ALTERNATOR MODULE

BUTTON_DOWNARW BUTTON_UPARW BUTTON_CLEAR BUTTON_STOP BUTTON_FUNC4 BUTTON_FUNC1 BUTTON_START BUTTON_RIGHTARW BUTTON_LEFTARW BUTTON_ENTER BUTTON_FUNC3 BUTTON_FUNC2 COM(BUTTONS) SHIELD

1 2 3 4 5

PURGE A

DOSE A1

PURGE B

DOSE B

DOSE A2

DOSE A3

GFB #1

MANIFOLD

3X CABLE

USB BASE MODULE

ALARM

PWR (RED) COM (BLACK) SIG (WHITE) SHIELD/GRN

BLACK RED BLACK RED BLACK RED BLACK RED BLACK RED BLACK RED BLACK RED

PWR (RED) COM (BLACK) SIG (WHITE) SHIELD/GRN

SIG COM

UNUSED

3 4

UNUSED

V CAN

V CAN RTN

CHASSIS GND

V CAN RTN

BIT 3

BIT 2

GND

SCK

V CAN

V CAN RTN

CAN L

CAN H

V CAN RTN

BIT 0

BIT 1

VTOKEN

LOFO

/HOLD

/CS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

USB COMPONENT MODULE

1 2 3 4 5 6 7 8 9 10 11 12 13 14

GROUND TERMINAL

68 3A0868G

Hazardous Location Electrical Schematic (continued)

Schematics

SOLENOID/METER CABLE HARNESS

1 2 3 4 5 6 7 8 9 10 11 12 13 14

"A" REED SWITCH

"A" LINEAR SENSOR

1 2 3 4 5

J12

J14

J25

FLUID CONTROL

1 2

MODULE

3 4 5

1 2 3 4 5

1 2 3 4 5 6 7 8

1 2 3 4

CAN_L

+V_CAN

V_CAN_RTN

CAN_H SHIELD

UNUSED

ALARM (+)

COMMON PURGE A (+) DOSE A1 (+)

+12 VDC

FLOW METER A SIG

COMMON

DOSE A2 (+) DOSE A3 (+)

+5 VDC

"A" PRESSURE TRANSDUCER

REED SWITCH CABLE

LINEAR SENSOR/

AI (-)

COMMON

AI (+)

SHIELD

LINEAR SENS "A" SIG.

UNUSED

REED SWITCH_BTM (DOWN)

REED SWITCH_TOP (UP)

REED SWITCH_COM

LINEAR SENS "A" +5 VDC

LINEAR SENS "A" COM

UNUSED

UNUSED UNUSED UNUSED UNUSED

FERRITE FERRITE

1 2 3 4 5

1 2 3 4 5 6 7 8

1 2 3 4

J13

J15

J11

"B" REED SWITCH

"B" LINEAR SENSOR

UNUSED UNUSED UNUSED UNUSED UNUSED

UNUSED AFS #1 (+) COMMON PURGE B (+) DOSE B (+)

+12 VDC FLOW METER B SIG COMMON

GFB INPUT/AFS #2 (+) GFB OUTPUT

+5 VDC AI (-) COMMON AI (+) SHIELD

LINEAR SENS "B" SIG. UNUSED REED SWITCH_BTM (DOWN) REED SWITCH_TOP (UP) REED SWITCH_COM LINEAR SENS "B" +5 VDC LINEAR SENS "B" COM UNUSED

UNUSED UNUSED UNUSED UNUSED

"B" PRESSURE TRANSDUCER

LINEAR SENSOR/

REED SWITCH CABLE

SOLENOID/METER CABLE HARNESS

1 2 3 4 5 6 7 8 9 10 11 12 13 14

3A0868G 69

Schematics

Non-Hazardous Location Electrical Schematic

CAN_L

CAN_L +V_CAN V_CAN_RTN CAN_H SHIELD

HTARW

LED_YELLOW LED_BLUEA LED_GREEN UNUSED LED_BLUEB UNUSED LED_RED UNUSED COM(LEDS)

UNUSED UNUSED UNUSED UNUSED

+V_CAN

2 3

V_CAN_RTN

CAN_H

SHIELD

2 3 4 5

PURGE A

4-WAY

12 VDC

DOSE A1

PURGE B

DOSE B

DOSE A2

DOSE A3

3-WAY

12 VDC

GFB #1

2 3 4 5

2 3 4 5 6 7 8 9

10 11 12 13 14

2 3 4 5 6 7 8 9

2 3 4

USER INTERFACE MODULE

CAN_L +V_CAN V_CAN_RTN CAN_H SHIELD

UNUSED

SOLENOID

FLOW METER A

AIR FLOW SWITCH 1

GFB 1 PRESSURE SWITCH/ AIR FLOW SWITCH 2

FLOW METER B

TERMINAL

BLOCK

L N GRND

L GRND N

LINE POWER FILTER

L N

SWITCH ROCKER

MEMBRANE

POWER SUPPLY

BUTTON_DOWNARW BUTTON_UPARW BUTTON_CLEAR BUTTON_STOP BUTTON_FUNC4 BUTTON_FUNC1 BUTTON_START

BUTTON_RIG BUTTON_LEFTARW

BUTTON_ENTER BUTTON_FUNC3 BUTTON_FUNC2 COM(BUTTONS) SHIELD

MANIFOLD

3X CABLE

USB BASE MODULE

ALARM

PWR (RED) COM (BLACK) SIG (WHITE) SHIELD/GRN

BLACK RED BLACK RED BLACK RED BLACK RED BLACK RED BLACK RED BLACK RED

PWR (RED) COM (BLACK) SIG (WHITE) SHIELD/GRN

SIG COM

CAN_L

+V_CAN

V_CAN_RTN

CAN_H

SHIELD

V CAN

V CAN RTN

CHASSIS GND

V CAN RTN

BIT 3

BIT 2

GND

SCK

V CAN

V CAN RTN

CAN L

CAN H

V CAN RTN

BIT 0

BIT 1

VTOKEN

LOFO

/HOLD

/CS

USB COMPONENT

2 3

MODULE

4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 19

20 21 22 23 24 25 26 27 28 29 30

1 2 3 4 5 6 7 8 9 10 11 12 13 14

GROUND TERMINAL

70 3A0868G

Non-Hazardous Electrical Schematic (continued)

Schematics

SOLENOID/METER CABLE HARNESS

1 2 3 4 5 6 7 8 9 10 11 12 13 14

"A" PRESSURE TRANSDUCER

REED SWITCH CABLE

CAN_L

+V_CAN

V_CAN_RTN

CAN_H SHIELD

UNUSED ALARM (+)

COMMON

PURGE A (+) DOSE A1 (+)

+12 VDC

FLOW METER A SIG

COMMON

DOSE A2 (+) DOSE A3 (+)

+5 VDC

AI (-)

COMMON

AI (+)

SHIELD

LINEAR SENS "A" SIG.

UNUSED

REED SWITCH_BTM (DOWN)

REED SWITCH_TOP (UP)

REED SWITCH_COM

LINEAR SENS "A" +5 VDC

LINEAR SENS "A" COM

UNUSED

LINEAR SENSOR/

UNUSED UNUSED UNUSED UNUSED

J12

"A" REED SWITCH

"A" LINEAR SENSOR

1 2 3

FLUID

CONTROL

J14

J25

MODULE

1 2 3 4 5

1 2 3 4 5 6 7 8

1 2 3 4

J7 1 2 3 4 5

1 2 3 4 5

J13 1 2 3 4 5

1 2 3 4 5

J15 1 2 3 4 5 6 7 8

J11

1 2 3 4

J11 1 2 3 4

"B" REED SWITCH

"B" LINEAR SENSOR

CAN_L +V_CAN V_CAN_RTN CAN_H SHIELD

UNUSED AFS #1 (+) COMMON PURGE B (+) DOSE B (+)

+12 VDC FLOW METER B SIG COMMON

GFB INPUT/AFS #2 (+) GFB OUTPUT

+5 VDC AI (-) COMMON AI (+) SHIELD

LINEAR SENS "B" SIG. UNUSED REED SWITCH_BTM (DOWN) REED SWITCH_TOP (UP) REED SWITCH_COM LINEAR SENS "B" +5 VDC LINEAR SENS "B" COM UNUSED

UNUSED UNUSED UNUSED UNUSED

"B" PRESSURE TRANSDUCER

LINEAR SENSOR/

REED SWITCH CABLE

SOLENOID/METER CABLE HARNESS

1 2 3 4 5 6 7 8 9 10 11 12 13 14

3A0868G 71

Dimensions and Mounting

Depth:

18.0 in. (46 cm)

0.55 in

(1.4 cm)

33.5 in. (85 cm)

14.76 in. (37 cm)

12.76 in.

(32 cm)

1.0 in

(2.5 cm)

Merkur:

57 in. (145 cm)

Merkur Bellows:

65 in. (165 cm)

44.5 in.

(113 cm)

7 in.

(18 cm)

22.00 in. (56 cm)

26.8 in. (68 cm)

72 3A0868G

Technical Data

ProMix 2KE

US Metric

Maximum fluid working pressure See Models, pages 3 and 4. Maximum working air pressure 100 psi 0.7 MPa, 7 bar Air supply 75 to 100 psi 0.5 to 0.7 MPa, 5.2 to 7 bar Air filter inlet size

Air filtration for air logic (Graco-supplied) 5 micron (minimum) filtration required; clean and dry air Air filtration for atomizing air (user-supplied) 30 micron (minimum) filtration required; clean and dry air Mixing ratio range 0.1:1 to 30:1 Viscosity range of fluid 20 to 5000 cps Fluid filtration (user-supplied) 100 mesh minimum Fluid outlet size (static mixer) 1/4 npt(f) External power supply requirements 85 - 250 Vac, 50/60 Hz, 2 amps maximum draw

15 amp maximum circuit breaker required

8 to 14 AWG power supply wire gauge Operating temperature range 41° to 122°F 5° to 50°C Approximate weight 300 lb 136 kg Environmental conditions rating indoor use, pollution degree (2), installation category II Fluids handled one or two component:

• solvent and waterborne paints

• polyurethanes

• epoxies

• acid catalyzed varnishes

• moisture sensitive isocyanates

On-ratio accuracy

1:1 to 10:1 Mixing Ratio ± 2%

10.1:1 to 30:1 Mixing Ratio ± 5%

Noise level

Sound pressure level

Sound power level

Materials of construction

Wetted materials on all models

303, 304 SST; Tungsten carbide (with nickel binder);

perfluoroelastomer; PTFE

3/8 npt(f)

below 70 dBA

Below 85 dBA

3A0868G 73

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. 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 warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to

the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissen rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

t avoir convenu que la

Graco Information

For the latest information about Graco products, visit www.graco.com.

For patent information, see www.graco.com/patents.

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor. Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Graco reserves the right to make changes at any time without notice.

Original instructions.

This manual contains English. MM 3A0868

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revision G, June 2014

Graco 3A0868G User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Models

Warnings

Important Two-Component Material Information

Isocyanate Conditions

Material Self-ignition

Moisture Sensitivity of Isocyanates

Changing Materials

Keep Components A and B Separate

Glossary of Terms

Overview

Usage

Component Identification and Definition

Installation

General Information

Intrinsically Safe Installation Requirements

Display Module

Air Supply

Fluid Supply

Tubing Chart and Diagrams

Electrical

Grounding

Display Module

Display

Icon Key

Screen Summary

Ranges for User Inputs

Basic Operation

Pre-Operation Tasks

Power On

Initial System Setup

Prime the System

Pump Calibration

Spraying

Purging

Pressure Relief Procedure

Valve Settings

Lock Mode

Shutdown

Use of Optional USB Module

USB Logs

Setup

Download Procedure

Run Mode Details

Run Mix Spray (Screen 2)

Run Mix Batch (Screen 3)

Run Home (Screen 1)

Run Mix Totals (Screen 4)

Run Job Number (Screen 38)

Run Log Errors (Screens 5-14)

Run Pump Control (Screen 15)

Setup Mode Details

Password (Screen 16)

Setup Home (Screen 17)

Configure 1-4 (Screens 18-21)

Recipe 1-2 (Screen 29)

Recipe 1-1 (Screen 28)

Maintenance 1-3 (Screens 24-26)

Maintenance Recommendations

Calibration 1 and 2 (Screens 22 and 23)

Troubleshooting (Screens 35-37)

Dynamic Dosing

System Errors

System Alarms

To Clear Error and Restart

Air Flow Switch (AFS) Function

System Advisory/Record Codes

System Idle Warning (IDLE)

Error Codes

Alarm Troubleshooting

Dynamic Dosing Restrictor Selection Graphs

Schematics

Dimensions and Mounting

Technical Data

Graco Standard Warranty