Graco 3A0868G User Manual

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)

+ 51 hidden pages