Graco 3A0869H User Manual

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Operation

ProMix

2KE

3A0869H

Meter-Based Plural Component Proportioner

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

Important Safety Instructions

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

See page 3 for model information, including maximum working pressure and approvals.

ti15698a

Contents

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

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Important Two-Component Material Information . 7

Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 7

Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 7

Keep Components A and B Separate . . . . . . . . . 7

Moisture Sensitivity of Isocyanates . . . . . . . . . . . 7

Changing Materials . . . . . . . . . . . . . . . . . . . . . . . 7

Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Component Identification and Definition . . . . . . . 9

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

General Information . . . . . . . . . . . . . . . . . . . . . . 9

Intrinsically Safe Installation Requirements . . . 10

Display Module . . . . . . . . . . . . . . . . . . . . . . . . . 12

Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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

Tubing Chart and Diagrams . . . . . . . . . . . . . . . 18

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Check Resistance . . . . . . . . . . . . . . . . . . . . . . . 21

Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Icon Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Screen Summary . . . . . . . . . . . . . . . . . . . . . . . 25

Ranges for User Inputs . . . . . . . . . . . . . . . . . . . 26

Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Pre-Operation Tasks . . . . . . . . . . . . . . . . . . . . . 31

Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Initial System Setup . . . . . . . . . . . . . . . . . . . . . 31

Prime the System . . . . . . . . . . . . . . . . . . . . . . . 32

Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . 32

Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Color Change . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Purge/Color Change Detail . . . . . . . . . . . . . . . . 36

Pressure Relief Procedure . . . . . . . . . . . . . . . . 37

Lock Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Valve Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Use of Optional USB Module . . . . . . . . . . . . . . . . 39

USB Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Download Procedure . . . . . . . . . . . . . . . . . . . . . 41

Recommended USB Flash Drives . . . . . . . . . . . 41

Run Mode Details . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Run Mix Spray (Screen 2) . . . . . . . . . . . . . . . . . 42

Run Home (Screen 1) . . . . . . . . . . . . . . . . . . . . 42

Run Mix Batch (Screen 3) . . . . . . . . . . . . . . . . . 42

Run Mix Totals (Screen 4) . . . . . . . . . . . . . . . . . 43

Run Job Number (Screen 38) . . . . . . . . . . . . . . 43

Run Log Errors (Screens 5-14) . . . . . . . . . . . . . 44

Setup Mode Details . . . . . . . . . . . . . . . . . . . . . . . . 45

Password (Screen 16) . . . . . . . . . . . . . . . . . . . . 45

Setup Home (Screen 17) . . . . . . . . . . . . . . . . . . 45

Configure 1-4 (Screens 18-21) . . . . . . . . . . . . . 45

Recipe 0 (Screen 27) . . . . . . . . . . . . . . . . . . . . . 47

Recipe 1-1 (Screen 28) . . . . . . . . . . . . . . . . . . . 47

Recipe 1-2 (Screen 29) . . . . . . . . . . . . . . . . . . . 47

Maintenance 1-3 (Screens 24-26) . . . . . . . . . . . 48

Maintenance Recommendations . . . . . . . . . . . . 48

Calibration 1 and 2 (Screens 22 and 23) . . . . . . 49

Troubleshooting (Screens 35-37) . . . . . . . . . . . 49

Dosing Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Sequential Dosing . . . . . . . . . . . . . . . . . . . . . . . 51

Dynamic Dosing . . . . . . . . . . . . . . . . . . . . . . . . 53

System Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

System Alarms . . . . . . . . . . . . . . . . . . . . . . . . . 55

System Advisory/Record Codes . . . . . . . . . . . . 55

To Clear Error and Restart . . . . . . . . . . . . . . . . 55

Air Flow Switch (AFS) Function . . . . . . . . . . . . . 55

System Idle Notice (IDLE) . . . . . . . . . . . . . . . . . 56

Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Alarm Troubleshooting . . . . . . . . . . . . . . . . . . . 58

Dynamic Dosing Restrictor Selection Graphs . . 65

Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Dimensions and Mounting . . . . . . . . . . . . . . . . . . 78

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 80

2 3A0869H

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 Description

24F084 A 1 color/1 catalyst 3000 (27.58, 275.8) 24F085 A 3 colors/1 catalyst 3000 (27.58, 275.8) 24F086 A 1 color/1 catalyst 3000 (27.58, 275.8)

24F087 A 3 colors/1 catalyst 3000 (27.58, 275.8)

Approvals*

psi (MPa, bar)

Models

USB Port

✔ ✔

II 2 G

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

See Special Conditions for Safe Use in Related Manuals, page 4.

Intrinsically safe and purged

Class I, Division 1, Group D, T3

#53

equipment for

Ta = 0°C to 54°C

0359

* 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.

Approved for Non-Hazardous Location

Part No. Series Description

Maximum Working Pressure

psi (MPa, bar)

USB Port

Approvals*

24F080 A 1 color/1 catalyst 3000 (27.58, 275.8)

24F081 A 3 colors/1 catalyst 3000 (27.58, 275.8)

24F082 A 1 color/1 catalyst 3000 (27.58, 275.8)

24F083 A 3 colors/1 catalyst 3000 (27.58, 275.8)

✔

#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.

3A0869H 3

Warnings

Related Manuals

Manual Description

3A0870 ProMix 2KE, Repair/Parts 313599 Coriolis Meter, Instructions/Parts 308778 G3000 Flow Meter, Instructions/Parts 312781 Fluid Mix Manifold, Instructions/Parts 312782 Dosing Valve, Instructions/Parts 312784 Gun Flush Box Kit 15V826 406714 Rebuild Kit for High Pressure

Dispense Valve

406823 Dispense Valve Seat Kit

Manual Description

3A1244 Graco Control Architecture

Module Programming 3A1323 16G353 Alternator Conversion Kit 3A1324 16G351 Electric Power Conversion Kit 3A1325 ProMix 2KE Stand Kits 3A1332 24H255 3-Color Valve Stack Kit 3A1333 24H253 USB Module Kit 313542 Beacon Tower

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.

4 3A0869H

Warnings

WARNING

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing equipment.

• Connect only to grounded power source.

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

INTRINSIC SAFETY

Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe equipment will create a hazardous condition and can cause fire, explosion, or electric shock. Follow local regulations and the following safety requirements.

• Only models with model numbers 24F084-24F087, 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.

3A0869H 5

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.

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.

6 3A0869H

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.

3A0869H 7

• 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

Coriolis Meter - a non-intrusive flow meter often used in

low flow applications or with light viscosity, shear sensitive, or acid catalyzed materials. This meter uses vibration to measure flow.

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.

Overdose Alarm - when either the resin (A) or catalyst (B) component dispenses too much material and the system cannot compensate for the additional material.

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

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

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

Purge 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.

Sequential Color Change - the process when a color change is initiated and the system automatically flushes the old color and loads a new color.

Sequential Dosing - Components A and B dispense sequentially in the necessary volumes to attain the mix ratio.

K-factor - an assigned value that refers to the amount of material per pulse that passes through a meter.

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

Standby - refers to the status of the system.

8 3A0869H

Overview

Usage

Overview

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

Table 1: Component Description

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 A1 and B, additional dose valves A2 and A3 (optional), as well as solvent valves.

•Meters

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

including choosing recipes, reading/clearing alarms, 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.

• There must be a shutoff valve between each fluid supply line and the ProMix 2KE system.

• A 100 mesh minimum fluid filter must be installed on component A and B fluid supply lines.

3A0869H 9

• 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.

Installation

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.

ALTERNATOR MODULE

10' CAN CABLE

50' OPTION

2' CAN CABLE

20" CAN CABLE

USB MODULE

FLUID CONTROL MODULE

CABLE ASSEMBLY

USER INTERFACE

FLOW

METER A

G3000

G3000HR

S3000

MODULE

FLOW

METER B

G3000

G3000HR

S3000

FIG. 1. Hazardous Location Installation

10 3A0869H

Non-Hazardous Locations

Installation

LINE POWER

FILTER

POWER SUPPLY

CAN CABLE

20" CAN CABLE

USB MODULE

FLUID CONTROL MODULE

10' CAN CABLE

50' OPTION

CABLE ASSEMBLY

FLOW METER A

G3000 G3000HR S3000 CORIOLIS

USER INTERFACE

MODULE

FLOW METER B

G3000 G3000HR S3000 CORIOLIS

FIG. 2. Non-Hazardous Location Installation

3A0869H 11

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 Mod-

ule.

• 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.

12 3A0869H

ti16456a

Installation

Air Connections

See the System Pneumatic Schematic on page 72 (hazardous location) or page 73 (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 and all pneumatic control valves.

Main Air Inlet

TI15729a

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 line 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. Atomizing Air Connection

. 3. Main Air Connection

3A0869H 13

Installation

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 air spray or air-assisted systems with a capacity of up to 3800 cc/min.

• Multiple color system: connect supply lines to the component A2 and A3 dose valve inlets (DVA2, DVA3). See F

NOTE: Solvent supplied by a single source can cause cross contamination and damage to the system. Install check valves or use separate solvent sources.

NOTE: Paint Recirculating System Only

• If you are recirculating paint, use the standard inlet on Dose Valve A1 (A2, A3) or Dose Valve B. Remove the plug directly opposite it on the dose valve for the recirculation outlet. The second port is on the back of the valve and must be reached from inside the control box.

. 6.

• 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.

• See manual 313599 for Coriolis meter installation and operation instructions.

NOTE: The Coriolis meter can be used only on non-IS systems 24F080-24F083. When installed on these systems, the meter’s hazardous location intrinsically safe status is voided.

• If you are using dynamic dosing, see Fluid Connec-

tions, this page. See also Set Up the Fluid Manifold for Dynamic Dosing, page 16.

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. 6. 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).

• Single color system: connect component supply line to the component A1 dose valve inlet (DVA1).

Second port

ti16338a

FIG. 5. Paint Recirculation Port

• Another option is to use a tee fitting to recirculate.

NOTE: Verify that all unused fluid ports on the color change valve stack are plugged before operation. An open port will leak fluid.

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

NOTE: The component A and B fluid meter inlets have fluid check valves to prevent backflow from fluid supply pressure fluctuations. Backflow can cause ratio inaccuracies.

4. Connect the gun fluid supply line between the static mixer (SM) outlet and the gun fluid inlet.

14 3A0869H

Installation

SVA

DVA1

DVA2 and

DVA3 (behind)

CVA

Key:

MA Component A Meter DVA1 Component A Dose Valve DVA2 Second Color/Catalyst Valve DVA3 Third Color/Catalyst Valve SVA Solvent Valve A CVA Meter A Check Valve

FIG. 6. Fluid Controls, Sequential Dosing

MB Component B Meter DVB Component B Dose Valve SVB Solvent Valve B CVB Meter B Check Valve SM Static Mixer FI Fluid Integrator Assembly

SVB

DVB

CVB

ti15699a

3A0869H 15

Installation

Set Up the Fluid Manifold for Dynamic Dosing

NOTE: For more information about Dynamic Dosing,

see page 53.

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.

If you will be operating using dynamic dosing, the fluid manifold must be set up properly for your application. Order the 15U955 Injection Kit (accessory).

1. See F

2. Loosen the static mixer nut (N1). Remove and retain

3. Loosen the u-tube nuts (N2 and N3). Discard the

. 7. Remove the screws (A) and static mixer

bracket assembly (B).

the static mixer (SM).

u-tube (C) and the static mixer fitting (D).

4. Remove and retain the 1/4 npt(m) fitting (F). Remove the integrator (G) and discard

5. See F

. 8. Remove the remaining parts from the restrictor housing (H). Retain the plug (J) and base (K). Discard all the used o-rings.

6. Rotate the restrictor housing (H) 180° so the setscrew (S) is at top left, as shown in F

. 8. Remove and retain the two setscrews (S). The position of these screws will be reversed when reassembled.

7. Install one larger o-ring (L1*) in the housing (H). Screw the injection cap (M*) into the housing.

8. Determine the desired flow range for your application. Select the appropriate size restrictor for your selected flow and ratio, using the Dynamic Dosing Restrictor Selection Graphs on pages 66-70, as a guide. Install the restrictor (R*) in the base (K).

9. Assemble the smaller o-ring (L2*), restrictor (R*) and base (K), one larger o-ring (L1*), and plug (J) as shown.

ti16334a

FIG. 7. Disassemble Integrator and Static Mixer

10. Install the two setscrews. Install the long setscrew (S) at the front of the housing, for ease of access.

16 3A0869H

11. Screw the static mixer (SM) into the injection cap (M*). Install the retained fitting (F) on the static mixer tube and secure with the nut (N1).

* These parts are included in the

15U955 Injection Kit.

Installation

. 8. Install 15U955 Injection Kit

L1*

L2*

L1*

ti16335a

12. Follow instructions under Fluid Connections on page 14.

NOTE: Use a minimum 20 ft (6.1 m) x 1/4 in. (6 mm) ID gun fluid supply hose when using dynamic dosing. If the material is harder to integrate, use a longer hose.

13. Tune the fluid pressure and flow.

3A0869H 17

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 A1 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 Green Dose Valve A2 On 5G 5G 0.156 (4.0) Air Green Dose Valve A3 On 6G 6G 0.156 (4.0) Air Red Solvent Valve A Off 1R 1R 0.156 (4.0) Air Red Dose Valve A1 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 Red Dose Valve A2 Off 5R 5R 0.156 (4.0) Air Red Dose Valve A3 Off 6R 6R 0.156 (4.0) Air ----- Main Air to Pressure Gauge A1 A1 0.156 (4.0) Air Natural Solenoid Air A2 A2 0.25 (6.3) Air Natural Main Air to Filter A3 A3 0.25 (6.3) Fluid ----- Valve Stack A to Meter A A4 A4 0.375 (9.5) Fluid ----- Valve Stack B to Meter B A5 A5 0.375 (9.5) Air Black Alternator Air Exhaust* A6 A6 0.5 (12.7) Air Natural Air Regulator to Alternator* A7 A7 0.375 (9.5)

* Used only on IS models.

ti13861a

GFB1-S

ATOM-1

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GFB1-P (Pressurized air line)

GFB1-A

GFB1-C GFB1-S

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1R 2R 3R 4R

5R 6R

GFB1-C

IS Models

ti16771a

ti16770a

A7*

A6*

18 3A0869H

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

Installation

A Side

GFB1-A

ATOM-1

ATOM-2

A Side

B Side

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ti16768a

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3A0869H 19

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.

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

. 10.

Line

Neutral

FIG. 9. Control Box Electrical Connection

TERMINAL

BLOCK

L N GRND

L GRND N

LINE POWER

FILTER

L N

SWITCH

ROCKER

Ground

ti16391a

POWER SUPPLY

3. Close the Control Box. Restore power.

4. Follow instructions in Grounding, page 21.

FIG. 10. Electrical Schematic

20 3A0869H

Installation

Grounding

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

Feed Pumps or Pressure Pots

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

Air and Fluid Hoses

Use grounded hoses only.

Spray Gun

• 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

TI15712a

FIG. 11. Ground Screw and Power Switch

Gun Flush Box

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

Flow Meters

Verify that the meter cables are connected as shown in the Hazardous Location Electrical Schematic on page 74-75. Failure to properly connect the shield may cause incorrect signals.

NOTE: The Coriolis meter can be used only on non-IS systems 24F080-24F083. When installed on these systems, the meter’s hazardous location intrinsically safe status is voided.

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

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

3A0869H 21

Installation

Key:

Control Box ground screw

Control Box ground wire

Gun Flush Box ground screw

Gun Flush Box ground wire

Power cable, Display Module/Control Box

True Earth Ground - check your local code for requirements.

ti16466a

FIG. 12. Grounding

22 3A0869H

Display Module

LCD Display

Ratio

Potlife timers

Soft keys

Navigation Keys

Standby Key

. 13. Display Module

Screen number

Error code

Potlife state

Setup Key

ti16319a

Active recipe

Operation mode; see page 24 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 46. 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.

Up/Down Arrows:

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

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.

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

Use to clear alarm

Stops the current

Press to select the

3A0869H 23

Display Module

Icon Key

The following tables present a printable version of the information on the ProMix 2KE icon card. See Table 5, page 57, 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

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

24 3A0869H

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 31. For further detail on individual screens, see Run Mode Details, page 42, or Setup Mode Details, page 45.

Run Mode

The run mode has two 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 A1 (A2, A3) 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

Setup Mode

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), dosing type (sequential or dynamic dosing), gun flush box enable, number of guns (1 or 2), and system color configuration (1 or 3).

• Configure 2 (Screen 19) controls hose length and diameter for one or two guns and flow rate region for dynamic dosing.

• 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 and volume.

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

• Recipe 2-1 (Screen 30) and 2-2 (Screen 31) control Material 2/Color 2 parameters and flush.

• Recipe 3-1 (Screen 32) and 3-2 (Screen 33) control Material 3/Color 3 parameters and flush.

Maintenance (Screens 24-26)

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

• Maintenance 2 (Screen 25) controls dose valves A1 and B maintenance timer actual and target. Dose valves A2 and A3 are included if 3 colors are selected on Configure 1 (Screen 18).

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

Calibration (Screens 22 and 23)

1-Color

• Calibration 1 (Screen 22) controls k factors (cc/pulse) for Meter A and Meter B.

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

3-Color

• Calibration 1 (Screen 22) controls k factors (cc/pulse) for Meter B and for Meter A using colors A1, A2, and A3.

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

Troubleshooting Mode

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

System Inputs (Screen 35)

. 17, page 30.

Recipe (Screens 27-33)

• Recipe 0 (Screen 27) includes timers for the system first, second, and third flush and a third flush material selection.

3A0869H 25

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 accepted for each user input. See the page indicated in the table for further screen information, if needed.

Page Screen User Input Range/Options Default

42 Run Mix Batch (3) 43 Run Job Number 45 Password (16) 46 Configure 1 (18)

46 Configure 1 (18)

46 Configure 1 (18) 46 Configure 1 (18) 46 Configure 1 (18) 46 Configure 2 (19) 46 Configure 2 (19) 46 Configure 2 (19)

46 Configure 3 (20)

46 Configure 3 (20) 46 Configure 3 (20) 46 Configure 3 (20) 46 Configure 3 (20) 46 Configure 3 (20) 46 Configure 4 (21) 46 Configure 4 (21) 47 Recipe 1-1 (28)

Recipe 2-1 (30) Recipe 3-1 (32)

47 Recipe 1-1 (28)

Recipe 2-1 (30) Recipe 3-1 (32)

47 Recipe 1-1 (28)

Recipe 2-1 (30) Recipe 3-1 (32)

47 Recipe 0 (27)

Recipe 1-2 (29) Recipe 2-2 (31) Recipe 3-2 (33)

48 Maintenance 1 (24) 48 Maintenance 1 (24) 48 Maintenance 2 (25) 48 Maintenance 3 (26) 49 Calibration 1 (22) 49 Calibration 2 (23)

Target Volume User Number Password System Type

Dosing Type

Gun Flush Box Enable Number of Guns Number of Colors Gun 1 or Gun 2 hose length Gun 1 or Gun 2 hose diameter Flow Rate Region

USB Log Language

Date Format Date Time Password Backlight Timer Distance Units Volume Units Ratio

Ratio Tolerance

Potlife Timer

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

Meter A or Meter B Solvent Valve A or B Dose Valve A1, A2, A3, or B Fluid Filter A or B, or Air Filter Meter A1, A2, A3, or B K-Factor Actual Dispensed Volume

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

Pump; 125cc Pump; 150cc Pump

50cc Sequential (A-B 50cc)

100cc Sequential (A-B 100cc)

High (250 cc/min or higher) or

Chinese; Dutch; English; French; German;

Italian; Japanese; Korean; Portuguese;

Russian; Spanish; Swedish;

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

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.

0 to 2,000,000 L / 0 to 528,344 gal 0

1 to 9999 cc 0 cc

000000000 to 999999999 000000000

0000 to 9999 0000 (disabled)

Meters

Dynamic (A B)

On or Off Off

1 or 2 guns 1 gun

1 or 3 colors 1 color

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

Low (<250 cc/min)

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

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 9,999,999 0

0 to 9999 days 0 days

0 to 0.873 cc/pulse 0.119 cc/pulse

0 to 9999 cc 0 cc

50 cc Sequential

High

English

1:1

60 minutes

60 seconds

26 3A0869H

Display Module

. . .

Run Home

Totals

Errors

Mix

FIG. 14. Run Mode Screen Map

3A0869H 27

Spray Batch

Display Module

. 16.

See F

Set-Up Home

Configure

Password

FIG. 15. Setup Mode Screen Map, page 1

28 3A0869H

Recipe

Display Module

Set-Up Home

. 15.

See F

Calibration - 1 color

Calibration - 3 colors

Maintenance

FIG. 16. Setup Mode Screen Map, page 2

3A0869H 29

Display Module

System Outputs 1

Membrane Test

Push to enter forced mode, (System Outputs 2)

To Membrane Test

Password

Set-Up Home

System Outputs 2

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 Inputs

To Membrane Test

To Setup Home

Membrane Test

FIG. 17. Troubleshooting Screen Map

30 3A0869H

Basic Operation

Pre-Operation Tasks

Go through the Pre-Operation Checklist in Table 2.

Table 2: Pre-Operation Checklist

✓ Checklist

System grounded

Verify all grounding connections were made. See

Grounding, page 21.

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 all supply containers - A1 (A2 and A3, if present), B, and solvent.

Dose valves set

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

tings, page 38, 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. 18. 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. Display Module screen will display after five seconds.

FIG. 19. 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 46.

2. Set recipe and flush information as described in Recipe 0 (Screen 27), Recipe 1-1 (Screen 28), and Recipe 1-2 (Screen 29), page 47.

3. Set maintenance timers for meters, solvent valves, dose valves, fluid filters and air filters, as described in Maintenance 1-3 (Screens 24-26), page 48.

3A0869H 31

Basic Operation

Prime the System

NOTE: See Run Mode Details, pages 42-43, 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 34. 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

9. Press . The system will purge, then load mixed material to the gun. If the gun flush box is not used,

trigger the gun into a grounded metal pail until the system returns to Standby.

Meter Calibration

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

page 49, for further screen information, if needed.

Calibrate the meter:

• The first time the system is operated.

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

• As part of regular maintenance to retain meter accuracy.

• Whenever a flow meter is serviced or replaced.

Standby

4. Adjust component A and B fluid supplies as needed 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.

5. Open the fluid supply valves to the system.

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

7. If using a gun flush box, place the gun in the box and close the lid.

NOTE:

• Meter 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/pulse, regardless of the units set in Configure 4 (Screen 21).

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

32.

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

3. Press to display Calibration 1 (Screen 22).

K-factors are shown for B and A1 (A2, A3 if present).

8. Use to change to desired color recipe.

32 3A0869H

Basic Operation

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

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

brate. Press . An X displays in the box.

6. Press to start the calibration on the checked

meter (A with fluid A1, A2, or A3, 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 calibra-

tion.

8. The volume that the ProMix 2KE measured displays on the Display Module.

Volume measured by system displays here.

10. After the volume for A1 (A2, A3) or B is entered, the ProMix 2KE controller calculates the new k-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 42-43, for further

screen information, if needed.

1. Calibrate the meters as described in Meter Calibra- tion, page 32. Meter k-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 49.

Enter dispensed volume here.

FIG. 20. 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.

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 active recipe.

3A0869H 33

Basic Operation

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.

Active recipe

Flow rate

. 21. Flow Rate Display

If the fluid flow rate is too low: increase air pres-

sure 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:

Purging

NOTE: See Run Mode Details, pages 42-43, for further

screen information, if needed.

Purge the system:

• at the end of potlife

• breaks in spraying that exceed the potlife

• overnight shutdown or end of shift

• the first time material is loaded into equipment

• servicing

• shutting down equipment for an extended period of time

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.

• 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.

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.

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.

34 3A0869H

Basic Operation

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

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

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.

Color Change

Color Change Sequence

Color Change Procedures

1. Place the gun in the gun flush box if used, and close the lid.

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

from any screen to put the system in Standby.

3. Use the scroll keys, color. Press

sequence.

4. If a gun flush box is not used, trigger the gun into a grounded metal pail until the color change sequence is complete. If your system has two guns, trigger both guns at the same time.

NOTE: The color change timer does not start until the gun is triggered and fluid flow is detected. If no flow is detected within 2 minutes, the color change operation aborts. The Display Module enters

or ,

to select the new

to begin the color change

Step 1. Color Purge. The system flushes out the color with solvent. The selected color change solvent valve opens during Purge Time and closes when the time expires.

Step 2. Catalyst Purge. The system flushes out the catalyst with solvent. The catalyst change solvent valve opens during Purge Time and closes when the time expires.

Step 3. Final Purge. The system fills the line with the selected purge media (usually solvent). The selected purge valve opens during the Final Purge Time and closes when the time expires.

Step 4. Catalyst Fill. The system fills the line with new catalyst. The new catalyst valve opens during the Fill Time and closes when the fill volume is reached.

Step 5. Color Fill. The system fills the line with new color. The new color valve opens during the Fill Time and closes when the fill volume is reached.

Step 6. Mixed Material Fill. The system fills the line with mixed material. The system begins mixing components A and B until the fill volume expires.

Standby mode at the previous color.

Error SG occurs if the gun flush box is open. Error SAD1 or SAD2 occurs if the AFS is on.

5. Trigger the gun (or guns) while the system flushes the current color, purges with solvent, and loads the new color.

NOTE: If your system uses 2 guns, you must trigger both guns simultaneously during the entire color purge, solvent purge, and load color sequence.

NOTE: If you do not see clear solvent flow, the system did not flush successfully. Stop the color change. Look for a clog in the line or increase the flush time.

6. During color change, the Recipe icon blinks on and off, and you’ll see the number of the current color and the new color. When the color change is complete, Standby is highlighted.

7. When you are ready to spray, remove the gun from the gun flush box if used, and close its door.

NOTE: The gun flush box door must be closed for the atomizing air valve to open.

8. Press to start spraying.

3A0869H 35

Basic Operation

Purge/Color Change Detail

Purge/Flush

The Purge Sequence flushes the lines from the A & B color stacks though the mix manifold and out to the gun(s).

"A" has a pre-assigned (not selectable) valve. "B" has a pre-assigned (not selectable) valve.

If you choose a third flush option, it can be "A" or "B" (not "A" and "B"). You do not have an option to select something other than "A" or "B" valve. For example, if "A" was water and "B" was solvent. The third flush options would have to be "A" water or "B" solvent. You couldn't assign a third option like air.

The following should be the only selectable flush sequence options:

A, B, 0 A, B, A A, B, B A, 0, A

A, 0, B 0, B, 0 0, B, A 0, B, B

There are 4 basic purge sequences as follows:

Pre-Mix Fill

Premix fill sequence (right after purge sequence) loads 60 cc of the A1, A2, or A3 and B1, from the color stack, to the mix manifold.

In the premix fill sequence, a SFA1/SFA2/SFA3/SFB1 alarm (Premix fill, low flow) is generated if there are less than 10 ccs in 60 seconds.

SHA1/SHA2/SHA3/SHB1 alarm (Not enough premix fill volume) is generated if there are less than 50 ccs in 60 seconds.

NOTE: Premix fill always starts with the “B” side.

Mix Fill

The mix fill sequence (right after premix fill) loads A1, A2, or A3: B1 mixed material (Ratio specified by user) out to the gun(s). It loads 110% of the volume of the hoses plus the volume of the manifold: (hose 1 + hose 2 + manifold) x 1.1

SM (mix fill low flow) is generated if there are less than 50ccs in 60 seconds during a mix fill sequence.

1. Selecting the purge button on the pendant. The purge sequence from the recipe that you are currently in is used. The system is left full of solvent.

2. Color Change from A1, A2 or A3 to A1, A2 or A3. The purge sequence from the recipe you are leaving is used. After the purge sequence completes, the premix fill, from the recipe that you are going to, starts (blinking recipe number, etc).

3. Color Change from A1, A2 or A3 to Zero. The recipe zero purge sequence is used. The system is left full of solvent.

4. Color change from Zero to Zero. The recipe zero purge sequence is used. The system is left full of solvent.

NOTE: Color Change from Zero to A1, A2 or A3. The system does not do a purge sequence. It immediately starts the premix fill sequence.

A SPSA/SPSB alarm (Not enough volume during purge) is generated when the end of a purge phase is reached (Time specified by user), and the system has not totaled at least 10cc of material.

SN (Not enough mix fill volume) is generated if less than the mix fill volume is loaded in 5 minutes during a mix fill sequence.

36 3A0869H

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. Shut off the A1 (plus A2 and A3, if using multiple colors) and B fluid supply pumps/pressure pots.

3. Remove the Control Box cover.

4. With the gun triggered, push the manual override on the A1 (A2, A3) and B dose valve solenoids to relieve pressure. See F

. 22.

5. Follow Purging procedure, page 34.

6. Shut off the fluid supply to solvent valves A and B.

7. With the gun triggered, push the manual override on the A and B solvent valve solenoids to relieve solvent pressure. See F

. 22. Verify that solvent pres-

sure is reduced to 0.

8. Reinstall the Control Box cover.

Manual overrides

Solvent Valve A Solenoid

Dose Valve A1 Solenoid

Solvent Valve B Solenoid

Dose Valve B Solenoid

Dose Valve A1 and A2 Solenoid location, if used

Gun Flush Box Solenoid location, if used.

ti15730a

FIG. 22. Solenoid Valves in Control Box

3A0869H 37

Basic Operation

Lock Mode

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

hose length, hose diameter, dosing type, or number of colors 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. The lock icons display.

Lock icons

FIG. 23. System Lock Mode

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 operation with incorrect settings.

Shutdown

1. Follow Purging, page 34.

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). NOTE: The system will restart in Recipe 0.

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

. 24. Valve Adjustment

. To close dose or purge valves (for

clockwise.

See FIG. 24.

TI11581a

38 3A0869H

Use of Optional USB Module

USB Logs

Job Log 1

See example in FIG. 25. 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, mix ratio, and the recipe used. Job total volumes are in cubic centimeters. A log entry is made whenever a new job is initiated, which occurs when batch totals are cleared, when the job number is incremented from Run Job Number (Screen 38), or when a color change is performed. 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. 26. 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. 25. Sample Job Log

3A0869H 39

Use of Optional USB Module

FIG. 26. 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. 27. Select Language for USB Logs

40 3A0869H

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 41.

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

Excel® by

default. However, they can also be opened in any

text editor or Microsoft

Word.

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

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.

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

Recommended USB Flash 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

FIG. 28. USB Port

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

3A0869H 41

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.

Standby PurgeMix

1 Gun

2 Guns

Gun status

Material

Flow rate

Home

Target ratio

Actual ratio

Potlife time

Potlife for each gun

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

Run Mode screen sections: Mix or Errors .

• Press to enter the Setup screens.

Run Mix Batch (Screen 3)

Run Mix Batch (Screen 3) displays if is selected from Run Mix Spray (Screen 2). Use the Mix Batch screen to dispense set volumes. Target volume can be set from 1 to 9999 cc.

Target ratio

ctual ratio

Target volume

Actual volume

Start

FIG. 31. Run Mix Batch (Screen 3)

Stop

Material

Home

FIG. 29. Run Mix Spray (Screen 2)

• 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).

• 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).

Run Home (Screen 1)

Screen Number

FIG. 30. Run Home (Screen 1)

Mix

Errors

42 3A0869H

Run Mode Details

Run Mix Totals (Screen 4)

Run Mix Totals (Screen 4) displays if is selected from Run Mix Batch (Screen 3). Use this screen to view grand and batch totals for material A1, A2, A3, and material B, and to clear batch totals if desired.

Batch total

Grand total

Clear batch totals/ increment job

FIG. 32. Run Mix Totals (Screen 4)

• Press to clear all batch totals. A verification

screen appears. Use to highlight and press

on to clear the batch totals, or on to return

to the 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

Increment job

FIG. 34. 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.

Home

FIG. 33. 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).

3A0869H 43

Run Mode Details

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 to 5; Screen 6 displays errors 6 to 10, etc.).

Error codes

Error icons

FIG. 35. Run Log Errors (Screen 5)

• Use to view the next page. See F page 55, for an explanation of the different error icons. See Table 5, page 57, for an explanation of the different error codes.

. 57,

44 3A0869H

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)

From any Run screen, press to access the password screen. Password (Screen 16) displays if a pass-

word has been set. Set the password to 0000 to prevent the Password Screen from displaying. See Configure 3 (Screen 20), page 46, to set or change the password.

Setup Mode Details

Software Version:

Display Module

Fluid Control Module

USB Module

Recipe SettingsConfigure Calibration

FIG. 37. Setup Home (Screen 17)

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

Configure , Recipe , Maintenance , or

Calibration .

FIG. 36. 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.

• 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 Password (Screen 16). 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).

• Press to toggle between Run Mode and Setup Mode.

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), the type of dosing (sequential or dynamic), number of guns (1 or 2), and the system color configuration (1 or 3).

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.

NOTE: If your application requires only 2 colors, the system is still configured for 3 colors. Select 3 from the dropdown menu.

Dynamic vs. Sequential Dosing: See page 51 and following for a description of each type of dosing, to help you select the best option for your system. The options are:

• A-B 50cc (Select for sequential dosing, 50cc dose size.)

• A-B 100cc (Select for sequential dosing, 100cc dose size.)

• A B (Select for dynamic dosing.)

3A0869H 45

Setup Mode Details

System type

Dosing type

Gun flush box

Number of guns

Number of colors

Home

FIG. 38. Configure 1 (Screen 18)

• Press to highlight the desired field. Press

to display the dropdown menu for that field.

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 (meter to pump), number of guns, dosing type, or number of colors, a ver-

ification 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.

Gun 1 hose

length

Gun 1 hose

diameter

Gun 2 hose length

Gun 2 hose diameter

Home

FIG. 40. 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 and volume.

USB log language

Date format

Date

Time

Configure 3

Password

Backlight timer

Distance units

Volume units

Configure 4

Home

FIG. 41. Configure 3 (Screen 20) and Configure 4 (Screen 21)

FIG. 39. 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. A change in any of these fields will trigger the lock. See NOTE in previous paragraph.

46 3A0869H

Setup Mode Details

Recipe 0 (Screen 27)

The Recipe Screens allow the user to set up the basic

recipes. Recipe 0 (Screen 27) displays if is selected on Setup Home (Screen 17). Recipe 0 allows users to set up a full flush, independent of recipe purge timers, with no material load. It includes timers for first, second and third flush. See Recipe 1-2 (Screen 29), page 47, for flush timer details.

Third flush time (uses material set in next field)

Recipe number

First flush time (A purge)

Second flush time (B purge)

Third flush source

FIG. 42. Recipe 0 (Screen 27)

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.

Press to move through the Recipe screens. The Recipe Screens allow the user to set up the basic recipe: Recipe 1-1 (Screen 28) is for A1 (color 1) and B. In 3-Color systems, Recipe 2-1 (Screen 30) is for A2 (color

2) and B, and Recipe 3-1 (Screen 32) is for A3 (color 3) and B. These screens include the ratio of Material A1 (A2, A3) to Material B (0 to 30), ratio tolerance (1 to 99 percent), and potlife time (0 to 240 minutes).

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 for A1 (color 1). In 3-Color systems, Recipe 2-2 (Screen 31) and Recipe 3-2 (Screen 33) allow users to set flush timers for the additional materials A2 and A3 (colors 2 and 3).

• 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.

Third flush time (uses material set in next field)

Recipe number

First flush time (A purge)

Second flush time (B purge)

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

Third flush source

Recipe number

Potlife timer

• Press to highlight the desired field and press

to select. Press to move between dig-

its. Press to change a digit. Press when

Ratio

Ratio tolerance

Home

field is correct.

• Press to move through the Recipe screens.

FIG. 43. Recipe 1-1 (Screen 28)

3A0869H 47

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 meters and solvent valves (Maintenance 1, Screen 24), dose valves (Maintenance 2, Screen 25), and fluid filters and air filters (Maintenance 3, Screen 26). Timers for meters are settable from 0 to 2,000,000 L or 0 to 528,344 gallons. Timers for valves are settable from 0 to 9,999,999 counts. Timers for filters are settable from 0 to 9999 days.

Meters

Maintenance

actual and

target

Maintenance 1

Solvent valves

Home

Clear totals

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 5 days,

Air Filter 30 days

Pumps 250,000 cycles

Dose Valves 1,000,000 cycles

Meters 5,000 gallons

Frequency

daily check is recommended

Dose valves

Maintenance 2

Fluid Filters

Maintenance 3

Air filter

Days

FIG. 45. 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 confirmation 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.

48 3A0869H

Setup Mode Details

Calibration 1 and 2 (Screens 22 and 23)

NOTE: See Meter Calibration, page 32, for detailed

instructions.

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

factor (cc/pulse) for Meter A with fluid A1 (A2 and A3, if present) and Meter B. The system starts at the default factor(s) for the meters. 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 0 to 0.873 cc/pulse.

Meter k factors

Home

• Press to highlight the meter you wish to cali-

brate. Press . An X displays in the box.

• Press to start the calibration on the checked

meter (A with fluid A1, A2, or A3, or B). Press to cancel the calibration.

• 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)

FIG. 46. Calibration 1 (Screen 22)

Press to display Calibration 2 (Screen 23). This screen allows the user to perform a calibration. It displays Meter A (with fluid A1, A2, and A3) and Meter B k-factors, the target dispense volume, the actual dispense volume (settable from 0 to 9999 cc), and the material to dispense.

Meter A k factors

Start Meter A or Meter B Calibration

Meter B k factor

Cancel Meter Calibration

Selected material

Home

Active Recipe

Target dispense volume

Actual dispense volume

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

20), page 46, 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. 48. Setup Home with Troubleshooting

FIG. 47. Calibration 2 (Screen 23)

3A0869H 49

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 Air Flow Switch 1 or 2 is on and if the gun is in the Gun Flush Box. This screen also displays Meter A and Meter B pulses. The fields relating to pump function can be ignored.

Pump B up or down (not used)

Pump A up or down (not used)

Air Flow Switch on

Gun in Gun Flush Box

FIG. 49. 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).

Pump Pressures (not used)

Meter Pulses

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), solvent valves (B and A), the gun trigger,

and the alarm. Press to start Forced Mode. A second set of check boxes displays. Manually actuate the valves, alarm, or gun trigger. For properly working components, an X will display in the corresponding 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. 50. 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. 51. Troubleshooting System Outputs (Screen

37)

50 3A0869H

Dosing Options

Sequential Dosing

Components A and B dispense sequentially in the necessary volumes to attain the mix ratio.

1. The operator presses

2. The ProMix 2KE controller sends signals to activate the solenoid valves. The solenoid valves activate Dose Valves A1 (A2 or A3, depending on recipe selection) and B. Fluid flow begins when the gun is triggered.

3. Components A1 and B are introduced into the fluid integrator (FI) one at a time as follows.

a. The A side dose valve (DVA1, DAV2, or DVA3)

opens, and fluid flows into the integrator.

b. Flow Meter A (MA) monitors the fluid volume

dispensed and sends electrical pulses to the ProMix 2KE controller. The controller monitors these pulses and signals.

c. When the target volume dispenses, Dose Valve

A closes.

to begin operation.

d. Dose Valve B (DVB) opens, and fluid flows into

the integrator and is aligned proportionately with component A.

e. Flow Meter B (MB) monitors the fluid volume

dispensed and sends electrical pulses to the ProMix 2KE controller.

f. When the target volume is dispensed, Dose

Valve B closes.

4. The components are pre-mixed in the integrator, then uniformly blended in the static mixer (SM).

NOTE: To control output from the static mixer to the gun, install an optional fluid pressure regulator.

5. Components A and B are alternately fed into the integrator as long as the gun is triggered.

6. If the gun is not triggered for two minutes, the system switches to Idle mode, which closes off the mix manifold dose valves.

7. When the gun is triggered again, the ProMix 2KE continues the process where it left off.

NOTE: Operation can be stopped at any time by

NOTE: The dispense volume of component A and B

is based on the mix ratio and dose size set by the user and calculated by the ProMix 2KE controller.

Table 3: Sequential Dosing Operation

Ratio = 2.0:1 Dose 1 Dose 2 Dose 3

A = 2

B = 1

pressing or shutting off the main power

switch.

3A0869H 51

Dosing Options

SVA

DVA1

DVA2 and

DVA3 (behind)

Key:

MA Component A Meter DVA1 Component A Dose Valve DVA2 Second Color/Catalyst Valve DVA3 Third Color/Catalyst Valve SVA Solvent Valve A

MB Component B Meter DVB Component B Dose Valve SVB Solvent Valve B SM Static Mixer FI Fluid Integrator

SVB

DVB

ti15699a

FIG. 52. Fluid Module, Sequential Dosing

52 3A0869H

Dynamic Dosing

Dosing Options

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.

. 55 for a

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.

Select a Component B Restrictor Size

See Set Up the Fluid Manifold for Dynamic Dosing, page 16. Use the charts on pages 66 to 70 to select an appropriate restrictor size based on the desired flow and mix ratio.

Select Dynamic Dosing

1. On the Display Module press

Home (Screen 17). Select to display Configure 1 (Screen 18).

2. Select A B from the dosing type drop down menu.

to access Setup

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.

. 53 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 Display Module for warning messages which provide information on system performance, and adjust pressures accordingly. See Table 5 on page 57.

3A0869H 53

Dosing Options

B Pressure Too Low

B Pressure

Too High

A Pressure B Pressure

FIG. 53. A/B Control Range with Properly Sized Restrictor

(

)

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.

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

F Restrictor

Component A (continuous flow) Proportioned Material

Component B (pulsed injection)

. 55. Schematic Diagram of Dynamic Dosing Operation

Table 4: Dynamic Dosing Troubleshooting Guide

(for complete system troubleshooting, see Alarm Troubleshooting beginning on page 58)

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

54 3A0869H

System Errors

NOTE: Do not use the fluid in the line that was dispensed off ratio as it may not cure properly.

System Alarms

System alarms alert you of a problem to 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 icon and code.

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

Error Code Indicator

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 44, to view the last 50 errors, with date and time stamps.

To reset errors, see Table 7 and Alarm Troubleshoot- ing, page 58. Many errors can be cleared by simply

pressing .

Air Flow Switch (AFS) Function

Air or Air-assisted Guns

The air flow switch (AFS) detects air flow to the gun and signals the ProMix 2KE controller when the gun is triggered. The AFS functions with the flow meters to ensure that system components are functioning correctly.

For example, if a flow meter fails or clogs, 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.

. 56. Display Module Alarm Codes

System Advisory/Record Codes

Table 6 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.

Record - no icon

Alarm icon

Advisory icon

FIG. 57. Error Log Icons

If the ProMix 2KE detects through the AFS signal that the gun is triggered, yet there is no fluid flow through the meter, a Dose Time Alarm (QTA1 or QTB1) occurs after 40 seconds and the system shuts down.

Operating Without Air Flow Switch

It is not recommended to run without an air flow switch. If a switch fails, replace it as soon as possible.

Airless Gun

It is not recommended to use an airless gun with the ProMix 2KE. Two issues can arise from operating without an air flow switch:

• Without a gun trigger/air flow switch input the ProMix 2KE does not know it is spraying and will not generate a Dose Time Alarm. This means there is no way to detect a failed meter. You could spray pure resin or catalyst for 2 minutes without knowing.

3A0869H 55

System Errors

• Since the ProMix 2KE does not know it is spraying because there is no gun trigger/air flow switch input, it will go into System Idle every 2 minutes when in Mix mode.

System Idle Notice (IDLE)

This warning occurs if the ProMix 2KE 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.

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

56 3A0869H

Error Codes

System Errors

Table 5: 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 43

CAU1 USB Communication Error 43

EQU2 USB Installed when not in Standby 43

SG Gun Flush Box Error 43

SAD1 SAD2

SPSA SPSB

SFA1 SFA2 SFA3

SFB1

SHA1 SHA2 SHA3

SHB1

SM MixFill Start Error 44

SN MixFill Complete Error 44

QPD1 QPD2

R1 Ratio Low Error 44

R4 Ratio High Error 45

QDA1 QDA2 QDA3

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

Purge Volume Error A Purge Volume Error B

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

Table 5: System Alarm/Advisory/Record Codes

Code Description Details

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

ES System defaults loaded N/A

ET System performed an autodump after

a potlife

EQU1 USB Drive connected while in Standby N/A

N/A

QDB1

QTA1 QTA2 QTA3

QTB1

QLAX QLBX

P6A1 P6B1

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

MFA1 Meter A maintenance due N/A

MFB1 Meter B maintenance due N/A

MEA1 Mix valve A1 maintenance due N/A

MEA2 Mix valve A2 maintenance due N/A

MEA3 Mix valve A3 maintenance due N/A

Overdose B, A Dose too Short

Dose Time A Error

Dose Time B Error

Leak Error A Leak Error B

Pressure Transducer Error A Pressure Transducer Error B

3A0869H 57

System Errors

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 or

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 or

Verify that the cable is correctly connected.

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.

replace the USB cable.

58 3A0869H

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 environ-

ment. 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

Close the cover and clear the alarm.

Purge the system with solvent or fresh

mixed material:

• Solvent Purge - See Purging on

To prevent mixed material from curing in the equipment, do not

• New Mixed Material Purge - Go to

shut off power. Follow one of the solutions at right.

SPSA or SPSB Purge Volume Error

Insufficient volume during first 10 seconds of A or B purge sequence.

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.

Solvent line, valve, or meter is plugged or stuck.

Solvent pump is not working.

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.

Check components and clean, repair, or

replace as necessary.

Check and repair pump. See pump

manual for repair procedures and

replacement parts.

Replace air flow switch.

Insert the gun into the Gun Flush Box.

Test using Troubleshooting Screens.

See page 49. Repair/replace air shutoff

valve as needed.

Inspect air line for kinks, damage, or

loose connections. Repair or replace as

needed.

SFA1, SFA2, SFA3 or SFB1 PreMix Error

In systems with a gun flush box, insufficient quantity of resin/color (SFA1, SFA2, or SFA3) or catalyst (SFB1) is detected during the 10-second PreMix sequence.

SHA1, SHA2, SHA3 or SHB1

Gun, line, valve, or meter is plugged or stuck.

Feeder pump or solvent pump is not turned on or is not working.

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.

Check and repair pump. See pump

manual for repair procedures and

replacement parts.

Check air line path. See System Pneu-

matic Schematic, page 72 or 73. Verify

that solenoid is working.

Increase fluid pressure.

PreFill Error

Total PreFill sequence volume is not reached for color (SHA1, SHA2, or SHA3) or catalyst (SHB1) during the 5-minute PreFill sequence.

System Errors

page 34. The system purges until the preset purge time is complete.

Mix mode and spray the required volume to restart the potlife timer.

3A0869H 59

System Errors

Alarm and Description Cause Solution

Gun Flush Box is not triggering gun.

MixFill Start Error

In systems with a gun flush box, insufficient volume of mixed material is detected

Line or gun is plugged or restricted.

Flow rate is too low.

during the 10-second mixed fill sequence.

Valve is stuck.

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

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

the mixed material for Gun 1 (QPD1) or Gun 2 (QPD2).

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.

Purge the mixed material line. See page

34.

Check that hose length and diameter have been entered correctly. See Configure 2 (Screen 19), page 46.

Spray the required volume to restart the potlife timer.

60 3A0869H

Alarm and Description Cause Solution

R1 Ratio Low Error

The mix ratio is lower than the set tolerance for an A to B

There is too much restriction in the system.

• Check that the system is fully

• Check that the supply pump’s cycle

component volume comparison.

• Check that the spray tip/nozzle is

• Check that the fluid regulator is set

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.

regulator pressures until they are about

equal.

about equal,

and B dose valves are operating prop-

erly.

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

Manually operate the Dose Valve A1

(A2, A3) and B solenoid valves by

pressing and releasing solenoid valve

override buttons. Valves should snap

open and shut quickly.

• Air pressure to the valve actuators is

• Increase air pressure. Air pressure

too low.

• Something is restricting the solenoid

• There may be dirt or moisture in the or tubing and interrupting valve actuation air.

• Dose Valve A1 (A2, A3) is turned in

• Refer to Valve Settings, page 38, too far. Dose Valve B is open too far.

• Fluid pressure is high and air pres-

• Adjust air and fluid pressure. See sure is low.

• Fluid Seal in valve has failed. • See corresponding valve manual

System Errors

loaded with material.

rate is set properly.

properly sized for the flow and application, and that it is not clogged.

properly.

djust component A and B fluid supply

If the pressures are already

verify that component A

must be 75-120 psi (0.52-0.84 MPa,

5.2-8.4 bar); 120 psi is recommended.

air supply. Filter appropriately.

for adjustment guidelines.

recommended air pressure above.

for repair instructions.

3A0869H 61

System Errors

Alarm and Description Cause Solution

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

Ratio High Error

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

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.

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

• Air pressure to the valve actuators is too low.

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

• Dose Valve B is turned in too far. Dose Valve A1 (A2, A3) is open too far.

• Fluid pressure is high and air pressure is low.

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.

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,

verify that component A and B dose valves are operating properly.

Manually operate the Dose Valve A1 (A2, A3) and B solenoid valves to check operation.

• Increase air pressure. Air pressure

must be 75-120 psi (0.52-0.84 MPa,

5.2-8.4 bar); 120 psi is recommended.

• There may be dirt or moisture in the

air supply. Filter appropriately.

• Refer to Valve Settings, page 38,

for adjustment guidelines.

• Adjust air and fluid pressure. See

recommended air pressure above.

62 3A0869H

Alarm and Description Cause Solution

QDA1, QDA2, QDA3 Overdose A

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

Valve seal or needle/seat are leaking. Repair the valve. Flow meter fluctuations caused by pres-

sure pulsations.

Check for pressure pulsations:

1. Close all the manifold valves.

2. Turn on the circulating pumps and

capacity.

QDB1 Overdose B

The B dose has overshot,

3. Check if the ProMix 2KE is reading

forcing an A dose that, when combined with B, is too large

4. If the ProMix 2KE shows there is

for the mix manifold capacity.

5. Close the fluid shutoff valve

System Errors

all the booth equipment (such as fans and conveyors).

any fluid flow.

fluid flow and there are no leaks from the gun or any other seals or fittings, the flow meters are probably being affected by pressure pulsations.

between the fluid supply system and the flow meter. The flow indication should stop.

Slow actuation of component A or B valves.

Running a high mix ratio and a high flow rate.

6. If necessary, install pressure regulators or a surge tank on the fluid inlets to the ProMix 2KE to reduce the fluid supply pressure. Contact your Graco distributor for information.

See Ratio Low Error and Ratio High Error, pages 61-62.

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

3A0869H 63

System Errors

Alarm and Description Cause Solution

QTA1, QTA2, QTA3, or QTB1 Dose Time Error

The gun trigger is active, but no A pulses (QTA1, QTA2, QTA3) or no B pulses (QTB1) are detected during the dose

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. Flow meter or cable failed or flow meter

clogged.

time selected.

Fully trigger the gun.

To check meter sensor operation, remove meter cap to expose sensor. Pass a ferrous metal tool in front of the sensor.

QLAX or QLBX Leak Error

Meter A (QLAX) or Meter B (QLBX) measures fluid with all valves closed.

TI12792a

If there is a meter or cable failure, you will see a large difference between the amount of fluid dispensed and the flow meter volume displayed by the Display Module. Clean or repair meter as necessary.

Slow actuation of component A or B valves.

See Ratio Low Error and Ratio High

Error, pages 61-62. The supply pump is not turned on. Turn on the supply pump. There is an air leak downstream from the

Check the air lines for leaks and repair. air flow switch.

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

Pressure on circulation system is fluctu-

Replace check valve in front of meter.

ating and generating meter pulses.

Valve is leaking. Replace valve seat, valve, or valve

seal.

Gun, manifold, or line is leaking. Repair leak downstream of meters.

64 3A0869H

Dynamic Dosing Restrictor Selection Graphs

Use the graphs on pages 66- 70 as a guide to determine the correct restrictor size for your desired flow and material viscosity. Table 6 lists the available restrictor sizes.

Table 6: 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.

3A0869H 65

Dynamic Dosing Restrictor Selection Graphs

psi

(bar, MPa)

4000

(276, 27.6)

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

66 3A0869H

psi

(bar, MPa)

1400

(97, 9.7)

Dynamic Dosing Restrictor Selection Graphs

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

3A0869H 67

Dynamic Dosing Restrictor Selection Graphs

psi

(bar, MPa)

800

(55, 5.5)

Key

700

(48, 4.8)

600

(41, 4.1)

500

(34, 3.4)

400

(28, 2.8)

300

(21, 2.1)

200

(14, 1.4)

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

Differential Pressure between A and B

100

(7, 0.7)

(14, 1.4)

(10, 1.0)

(3.4, 0.34)

200

150

100

(7, 0.7)

500 1000 1500 2000 30002500 35000

4000

Flow Rate (cc/min)

Detail View

500 1000

FIG. 60. Dynamic Dosing Performance (10:1 Ratio, 90 centipoise fluid, 100 psi A side pressure)

68 3A0869H

psi

(bar, MPa)

300

(21, 2.1)

Dynamic Dosing Restrictor Selection Graphs

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

3A0869H 69

Dynamic Dosing Restrictor Selection Graphs

psi

(bar, MPa)

200

(14, 1.4

(12.4, 1.2

(11, 1.1)

9.7, 0.9)

8.3, 0.8)

(5.5, 0.55)

(4.1, 0.41)

(2.8, 0.28)

Differential Pressure between A and B

(1.4, 0.14)

180

160

140

120

100

(7, 0.7)

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

4000

70 3A0869H

Dynamic Dosing Restrictor Selection Graphs

3A0869H 71

Schematics

Hazardous Location System Pneumatic Schematic

PURGE B

VALVE

MANIFOLD

PURGE A

VALVE

5/32 TUBE

DOSE A1

VALVE

OPEN

5/32 TUBE

DOSE B

VALVE

DOSE A2

VALVE

(OPTIONAL)

DOSE A3

VALVE

OPEN

5/32 TUBE

OPEN

5/32 TUBE

OPEN

(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.

20 MICRON

18 PSI (.12 MPa,

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

72 3A0869H

Non-Hazardous Location Pneumatic Schematic

PURGE B

VALVE

DOSE B

MANIFOLD

PURGE A

VALVE

5/32 TUBE

OPEN

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)

5/32 TUBE

Schematics

OPEN

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-WAY SOLENOID

3/8" AIR REG.

AUTO DRAIN

5 MICRON

100 PSI (.7 MPa, 7 BAR)

GAUGE

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

3A0869H 73

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

74 3A0869H

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

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

LINEAR SENSOR/

UNUSED

UNUSED UNUSED UNUSED UNUSED

FERRITE FERRITE

1 2 3 4 5

1 2 3 4 5 6 7 8

J11 1 2 3 4

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

3A0869H 75

Schematics

Non-Hazardous Location Electrical Schematic

CAN_L

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)

ARW

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_RIGHT BUTTON_LEFTARW

BUTTON_ENTER BUTTON_FUNC3 BUTTON_FUNC2 COM(BUTTONS) SHIELD

MANIFOLD

3X CABLE

USB BASE MODULE

ALARM

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

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

SIG COM

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

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

T 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

76 3A0869H

Non-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" PRESSURE TRANSDUCER

FLOW METER A SIG

COMMON

DOSE A2 (+) DOSE A3 (+)

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

REED SWITCH CABLE

LINEAR SENSOR/

CAN_L

+V_CAN

V_CAN_RTN

CAN_H SHIELD

UNUSED ALARM (+)

COMMON

PURGE A (+) DOSE A1 (+)

+12 VDC

+5 VDC

AI (-)

COMMON

AI (+)

SHIELD

UNUSED UNUSED UNUSED UNUSED

J12

"A" REED SWITCH

"A" LINEAR SENSOR

1 2 3

FLUID

CONTROL

MODULE

1 2 3 4 5

J14

1 2 3 4 5 6 7 8

J25

1 2 3 4

J25

1 2 3 4

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

"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

3A0869H 77

Dimensions and Mounting

Depth:

14.8 in. (38 cm)

36.1 in. (92 cm)

0.55 in

(1.4 cm)

33.5 in.

(85 cm)

14.74 in. (37 cm)

12.74 in. (32 cm)

1.0 in

(2.5 cm)

35.5 in.

(90 cm)

20.1 in. (51 cm)

78 3A0869H

Technical Data

ProMix 2KE, Meter-Based Systems

US Metric

Maximum fluid working pressure See Models, page 3. 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 On-ratio accuracy up to ± 1%, user selectable Fluid inlet sizes 1/4 npt(f) 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 200 lb 91 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

Fluid flow rate range

G3000, G250 Meter 0.02 to 1.00 gal/min 75 to 3800 cc/min G3000HR, G250HR Meter 0.01 to 0.50 gal/min 38 to 1900 cc/min Coriolis Meter 0.005 to 1.00 gal/min 20 to 3800 cc/min S3000 Solvent Meter (accessory) 0.01 to 0.50 gal/min 38 to 1900 cc/min

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

3A0869H 79

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 3A0869

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revision H, December 2014

Graco 3A0869H 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

Check Resistance

Display Module

Display

Icon Key

Screen Summary

Ranges for User Inputs

Basic Operation

Pre-Operation Tasks

Power On

Initial System Setup

Prime the System

Meter Calibration

Spraying

Purging

Color Change

Purge/Color Change Detail

Pressure Relief Procedure

Lock Mode

Shutdown

Valve Settings

Use of Optional USB Module

USB Logs

Setup

Download Procedure

Recommended USB Flash Drives

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)

Setup Mode Details

Password (Screen 16)

Setup Home (Screen 17)

Configure 1-4 (Screens 18-21)

Recipe 0 (Screen 27)

Recipe 1-1 (Screen 28)

Recipe 1-2 (Screen 29)

Maintenance 1-3 (Screens 24-26)

Maintenance Recommendations

Calibration 1 and 2 (Screens 22 and 23)

Troubleshooting (Screens 35-37)

Dosing Options

Sequential Dosing

Dynamic Dosing

System Errors

System Alarms

To Clear Error and Restart

Air Flow Switch (AFS) Function

System Advisory/Record Codes

System Idle Notice (IDLE)

Error Codes

Alarm Troubleshooting

Dynamic Dosing Restrictor Selection Graphs