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Repair-Parts ® ProMix 312780K Plural Component Proportioner Automatic systems for proportional mixing of plural component coatings, with Wall Mount Fluid Station or RoboMix Fluid Station. For professional use only. For use in explosive atmospheres (except the EasyKey). See pages 4-7 for model information, including maxi- Important Safety Instructions mum working pressure.
. 1 on page 4 and F . 2 on page 6 for label loca- Manual Description tions. 312778 ProMix 2KS Automatic System EasyKey and Fluid Station Label Installation 312779 ProMix 2KS Automatic System ATEX Certificate is listed here Operation...
System Configuration and Part Numbers System Configuration and Part Numbers Wall Mount Fluid Station Configurator Key The configured part number for your equipment is printed on the equipment identification labels. See F for location of the identification labels. The part number includes one digit from each of the following six categories, depending on the configuration of your system.
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System Configuration and Part Numbers Hazardous Location Approval Models using a G3000, G3000HR, G3000A, or intrinsically safe Coriolis meter for both A and B meters are approved for installation in a Hazardous Location - Class I, Div I, Group D, T3 or Zone I Group IIA T3. Maximum Working Pressure Maximum working pressure rating is dependent on the fluid component options selected.
System Configuration and Part Numbers RoboMix Fluid Station Configurator Key The configured part number for your equipment is printed on the equipment identification labels. See F for location of the identification labels. The part number includes one digit from each of the following six categories, depending on the configuration of your system.
System Configuration and Part Numbers Hazardous Location Approval Models using a G250 or G250HR for both A and B meters are approved for installation in a Hazardous Location - Class I, Div I, Group D, T3 or Zone I Group IIA T3. Maximum Working Pressure Maximum working pressure rating for RoboMix Fluid Station Systems is 190 psi (1.31 MPa, 13.1 bar).
26A099 7 Color/1 Catalyst Change Kit 26A100 12 Color/1 Catalyst Change Kit NOTE: This is not a complete list of available accesso- ries and kits. Refer to the Graco website for more infor- mation about accessories available for use with this product.
Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama- tion 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.
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Warnings WARNING SKIN INJECTION HAZARD High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. • Tighten all fluid connections before operating the equipment.
Important Two-Component Material Information Important Two-Component Material Information Material Self-ignition Isocyanates (ISO) are catalysts used in two component materials. Isocyanate Conditions Some materials may become self-igniting if applied too thick. Read material manufacturer’s warnings and Safety Data Sheet (SDS). Spraying or dispensing materials that contain Keep Components A and B isocyanates creates potentially harmful mists, vapors, and atomized particulates.
Important Two-Component Material Information Moisture Sensitivity of NOTE: The amount of film formation and rate of crystal- lization varies depending on the blend of ISO, the Isocyanates humidity, and the temperature. Exposure to moisture (such as humidity) will cause ISO Changing Materials to partially cure;...
Important Acid Catalyst Information Important Acid Catalyst Information The 2KE Plural Component Proportioner is designed for acid catalysts (“acid”) currently used in two-component, wood-finishing materials. Current acids in use (with pH levels as low as 1) are more corrosive than earlier acids. More corrosion-resistant wetted materials of construction are required, and must be used without substitution, to withstand the increased corrosive properties of these acids.
Pressure Relief Procedure NOTE: The following procedures relieve all fluid and air pressure in the ProMix 2KS system. Use the procedure Your system must be grounded. See the Grounding instructions in your ProMix 2KS Installation manual. appropriate for your system configuration.
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Pressure Relief Procedure Systems with Color Change and without Systems with Color/Catalyst Change and Dump Valves Dump Valves NOTE: This procedure relieves pressure through the NOTE: This procedure relieves pressure through the sampling valve. dump valves. 1. Complete all steps under Single Color Systems, 1.
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Pressure Relief Procedure Solenoid Solenoid Identification Identification Label Label TI12826a Solvent Solenoid Overrides . 3: Color Change Solenoids Key: Component A Meter DVA Component A Dose Valve RVA Component A Sampling Valve SVA Component A Shutoff Valve Component B Meter DVB Component B Dose Valve RVB Component B...
Troubleshooting Troubleshooting Table 1: System Alarm Codes Code Description Communication Error Alarm Follow Pressure Relief Procedure, page 14, before Potlife Alarm cleaning, checking, or servicing equipment. Ratio High Alarm Ratio Low Alarm NOTE: Do not use the fluid in the line that was dis- Overdose A/B Dose Too Short Alarm pensed off ratio as it may not cure properly.
Troubleshooting Solenoid Troubleshooting RoboMix Fluid Station Dose Valve B Override Button Dose Valve A Override Button TI12655a Wall Mount Fluid Station Power Fiber Optic Dose A Valve Dose B Dump Valve A Dump Valve B Optional Solenoid GFB 1 Locations GFB 2 3rd Purge Valve Dose Valve A...
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Something is restricting the solenoid or tubing. Check for air output from air line for corresponding solenoid when valve is actuated. Clear restric- tion. • A dose valve is turned in too far. See ProMix 2KS Operation manual for settings. • Fluid pressure is high and air pressure is low.
Troubleshooting Wall Mount Fluid Manifold Troubleshooting See F . 6. To remove the fluid manifold, see page 51. See manual 312781 for complete information on the fluid manifold. DVA OFF DVB OFF DVB ON DVA ON APV ON APV OFF SPV ON SPV OFF TI12556b...
D4 turns on if barrier board is functioning. If D4 does not turn on, fuses F3 Fluid Station Board or F4 (Graco Part No. 15D979) are blown or there is no input power at J4. If there is no input power (D5 does not light), fuses F1 and F2 (Graco Part No.
Troubleshooting EasyKey Display Board Diagnostics See F . 8 and Table 3 to troubleshoot the EasyKey display board. Also see the EasyKey Electrical Schematic on page 33 and the System Electrical Schematic on pages 34 and 35. Multiple Station TI12923a Integration Control TI12924a BK885 or CR1220 Battery...
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Troubleshooting Table 3: EasyKey Display Board Diagnostics Connector/ Connector/ Indicator Description Indicator Description 24 Vdc Power Input/Alarm Output Graphic Display Backlight RS485 Communication Terminals Ribbon Cable to Membrane D7 (green) LED turns on when power is supplied to Inputs and Outputs board Remote I/O D11 (yellow) LED blinks (heartbeat) when board is...
Troubleshooting Discrete I/O Board Diagnostics See F . 9 and F . 10 to troubleshoot the Discrete I/O board. Also see the System Electrical Schematic on pages 34 and 35. I/O Terminal Strip Detail Pin 1 RS485 Integration A RS485 Integration B RS485 Integration Ground RS485 Network A RS485 Network B...
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Troubleshooting Digital Output Common/Power Flow Rate Alarm Output Flow Calibrate Active Fill Active Mix Ready Output LED D1 Mix Active Output (green) Purge/Recipe Change Active Output Digital Output Common/Power Recipe Change Input Recipe Bit 5 Input Recipe Bit 4 Input Recipe Bit 3 Input Recipe Bit 2 Input Recipe Bit 1 Input...
Troubleshooting Fluid Station Control Board Diagnostics See F . 11 and Table 4 to troubleshoot the fluid station control board. Also see the System Electrical Schematic on pages 34 and 35. (Fiber Optic Output - blue) F1 (Fuse) F2 (Fuse) J6 (Fiber Optic Input - black) J10 (Power Input) J11 (Color Change Module)
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Troubleshooting Pin 1 AFS #1 AFS #2 Solvent Switch GFB 1 PS GFB 2 PS (Not Used) Pin 1 Solvent Meter Spare Pin 1 Flow Meter A Flow Meter B Pin 1 Dose Valve A Dose Valve B Spare Pin 7 (plugged) .
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Troubleshooting Table 4: Fluid Station Control Board Diagnostics Connector and Pin Nos. Signal Description Diagnosis J1, 1 & 2 Air Flow Switch 1 Turns on when gun 1 is triggered. J1, 5 & 6 Solvent Flow Switch Turns on when solvent is flowing. J1, 9 &...
Troubleshooting Color Change Board Diagnostics See F . 13 and Table 5 to troubleshoot the color change board. Also see the System Electrical Schematic on pages 34 and 35. To replace the color change board, see manual 312787. J8, Pin 1 J9, Pin 1 J15, Pin 1 J16, Pin 1...
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Color 9 Color 22 J15, 3 & 4 Color 4 Color 17 D27 through D46 turn on when ProMix 2KS sends a signal to actuate the related solenoid valve. J14, 5 & 6 Solvent (Color) Color 13 J10, 5 & 6...
Schematic Diagrams Schematic Diagrams System Pneumatic Schematic COLOR COLOR VALVE CHANGE STACKS CONTROL AIR EXHAUST MUFFLER MANIFOLD COLOR 1 COLOR 2 12 VDC COLOR 3 COLOR 4 DOSE A VALVE 4-WAY SOLENOID COLOR 5 COLOR 6 COLOR 7 COLOR 8 12 VDC COLOR SOLVENT DOSE B...
Schematic Diagrams System Electrical Schematic NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS system. Some compo- nents shown are not included with all systems. Non-Hazardous Area NON-HAZARDOUS AREA LINE OPERATOR INTERFACE FILTER DC OK 85-250 VAC...
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Schematic Diagrams System Electrical Schematic NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS system. Some compo- nents shown are not included with all systems. Hazardous Area HAZARDOUS AREA FLUID PANEL CONTROL BOX 3X CABLE FLUID...
Schematic Diagrams RoboMix Panel Board Schematic +12VDC I/S EASYKEY SHIELD TO FLOW REGULATOR GRD (BLK) +12VDC (RED) TO COLOR SHIELD (BARE) CHANGE CAN H (WHT) CAN L (BLU) NOT USED NOT USED NOT USED MANIFOLD NOT USED BLACK SOLVENT FLOW SWITCH NOT USED BLACK NOT USED...
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Schematic Diagrams Table 6: Tubing Chart Ending Tube OD Color Description Starting Point Point in. (mm) Tube Ref. No. Green Dose A On 5/32 (4) Green Dose B On 5/32 (4) Green Purge A On 5/32 (4) Green Purge B On 5/32 (4) Green Dump A...
Service Service Before Servicing 3. Shut off ProMix 2KS power (0 position). F . 14. 4. If servicing EasyKey, also shut off power at main cir- cuit breaker. • To avoid electric shock, turn off EasyKey power before servicing. •...
7. To assemble the new parts, align connector J2 on the display board (210c) with the socket on the NOTE: If using the Graco Gateway in your system, dis- graphic display (210b). Press them together. See connect its cable from the EasyKey before updating the .
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Service Replacing Line Filter Replacing Power Switch 1. Follow Before Servicing, page 40. 1. Follow Before Servicing, page 40. 2. Unlock and open EasyKey door with its key. 2. Unlock and open EasyKey door with its key. 3. Note position of line filter input and output wires. 3.
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Service Replacing Barrier Board 8. Install the cover (214b) with 2 screws (214k), using the security tool. 9. Connect cables to J1, J4, and J5. 10. Close and lock EasyKey door with key. 11. Turn on power at main circuit breaker. NOTICE To avoid damaging circuit board when servicing, wear 12.
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Service J1 (Power In) J4 (Power to Display Board) 214g 214g 214h (Power to Fluid Station) 214g Do not remove this screw 214h Front of Barrier Board, showing Fuses and Connectors Apply thermal compound to surface of heatsink (Z). Back of Barrier Board, showing Heatsink (Z) .
Service Replacing Air Filter Element Wall Mount Fluid Station Preparation Removing a pressurized air filter bowl could cause serious injury. Depressurize air line before servicing. 1. Follow Before Servicing, page 40. Check the 5 micron air manifold filter daily and replace element (317a, Part No.
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Service See Detail Below 318, 332 TI12425a Solenoid Manifold Detail TI12426a . 20: Wall Mount Fluid Station 312780K...
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Service Replacing Control Board 3. Remove 4 screws (303). Remove connector jam nuts on the outside of the enclosure (301). Remove control board (302). F . 20. 4. Install new control board (302) with 4 screws (303). 5. Connect cables to control board (302). F .
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(red +, black –). Refer to Sys- tem Electrical Schematic, page 35. 6. Replace the cover (322). Replacing Control Board Fuse Replacing a fuse (F1 or F2) with a non-Graco fuse voids the IS system safety approval. Fuse Part No. Description...
Service Servicing Flow Meters Mounted 2. Secure meter (M) and plate (MP) to fluid station with screws (MS). on Wall Panel NOTE: You must assemble the meter sensor to the meter body before connecting the cable to the sensor for the meter to function properly. 3.
Service Servicing Fluid Manifold Removal 1. Follow Servicing Flow Meters Mounted on Wall Panel, Removal steps 1-5, page 50. 2. Disconnect air and fluid lines from the manifold (4). 3. Holding onto the fluid manifold (4), loosen the three screws (341) holding the bracket (325) to the fluid station.
Service RoboMix Fluid Station Preparation 2. Remove the RoboMix cover (410). F . 26. 3. Note the position of all RoboMix hoses, then discon- nect them. 1. Follow Before Servicing, page 40. Air Logic Inlet B Inlet A Inlet Air Purge Inlet Solvent Inlet B Dump Outlet A Dump Outlet...
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Service Replacing Control Board 4. Remove 4 screws (428). Remove control board (426). F . 28. 1. Follow Preparation, page 52. 2. Remove the control board cover (427). F . 27. TI12579a . 27: Remove Control Board Cover 3. Disconnect fiber optic wires (J4, J6) and all cables (J1, J3, J5, J7, J8, J9, J12, J13, J14, J15) from con- TI12648a trol board (426).
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. 29. Remove the screw and metal strap. 3. Pull the fuse away from the board. Replacing the fuse with a non-Graco fuse voids the IS system safety approval. 4. Install the new fuse (497). 5. Reinstall covers (427, 410).
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Service Replacing Solenoids 4. Unscrew 2 screws (P) and remove solenoid (486). See F . 31 and Table 8. The RoboMix Fluid Station has a minimum of 4 sole- noids. If you have optional 3rd flush valve or dump valve kits installed, you have additional (optional) solenoids for each additional valve.
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Service G250 and G250HR Flow Meters 5. Calibrate meter as instructed in ProMix Operation manual. Removal 6. Place board into its correct position and reassemble 1. Follow Preparation, page 52. RoboMix Panel. 2. Unscrew cable from meter connector (CC). F .
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Service Servicing RoboMix Manifold 2. Disconnect all fluid and air lines from the RoboMix manifold (477). Manifold Service Kit 15V480 is available. Kit parts are marked with an asterisk, for example (502*). For best 3. Unscrew the flexible mixer (474) from the integrator results, use all parts in the kit.
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Service 5. Unscrew the integrator cap (511) and housing 8. Remove the screws (520) and adapters (517). (510). Inspect the mixer (508) and mix cap (509). Inspect the seat (516). Replace the o-rings (515*). Replace the o-rings (504*). F . 35. 9.
Service Servicing Flow Control 6. Install a new o-ring (602) on the pressure sensor (620) and screw the sensor into the fluid plate (606). Preparation 7. Reinstall the fluid plate on the air plate. Be careful not to pinch the pressure sensor cable. Torque the screws (605) to 30-40 in-lb (3.4-4.5 N•m).
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Service Servicing the V/P Valve 1. Follow Before Servicing, page 40. *613 604* 2. Remove the four screws (605) holding the bracket Flow (614) to the housing (611). F . 37. *610 direction 3. Carefully separate the bracket from the housing and disconnect the V/P valve cable from J2 on the circuit *609 602*‡...
Parts Parts ProMix 2KS Automatic Wall Panel System Configurator Key The configured part number for your equipment is printed on the equipment identification labels. See the illustrations below for location of the identification labels. The part number includes one digit from each of the following six categories, depending on the configuration of your system.
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Parts Part No. AD000N to AD742Y and AE100N, includes EasyKey with LCD display 12 - acid model Items 310 and 329 are part of the Wall Mount Fluid Station. See the parts list beginning on page 71 for descriptions. TI29654a Detail of Automatic Upgrade Kit (26) TI12496a 312780K...
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Parts Part No. AD000N to AD742Y and AE100N, includes EasyKey with LCD display Configured Digit Ref. (see page 61) or part usage Part No. Description 277869 CONTROL/DISPLAY, EasyKey; used on AD000N to AD742Y; see page 68 standard part see page 70 PANEL, fluid standard part 289695 MANIFOLD, mix;...
Parts ProMix 2KS Automatic RoboMix Panel System Configurator Key The configured part number for your equipment is printed on the equipment identification labels. See the illustrations below for location of the identification labels. The part number includes one digit from each of the following six categories, depending on the configuration of your system.
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Parts Part No. RD000N to RD242Y, includes EasyKey with LCD display Meters (8 and 9) are underneath the RoboMix cover. See page 74 for location. Items 474, 483, and 484 are part of the RoboMix Fluid Station. See the parts list beginning on page 72 for descriptions.
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Parts Part No. RD000N to RD242Y, includes EasyKey with LCD display Configured Digit Ref. (see page 61) or part usage Part No. Description 277869 CONTROL/DISPLAY, EasyKey; used on RD000N to RD242Y; see page 68 standard part see page PANEL, fluid, RoboMix KIT, flow meter A none none...
Parts 277869 EasyKey, with Display Ref. Ref. Part No. Description Part No. Description 214l 123823 • FILTER, line, single-phase; CONTROL BOX, with display 110/250 V; 3 A 116320 SWITCH, power 214m 123824 • BRACKET, line filter LATCH; includes item 3a 15V280 HARNESS, connection 203a 117818 •...
Parts Wall Mount Fluid Station See Detail Below 318, 332 TI12425a Control Board Fuses Solenoid Manifold Detail TI12652b TI12426a 312780K...
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100139 PLUG, pipe; 1/8 npt Replacement Danger and Warning labels, tags, and 552183 PLATE, blanking cards are available at no cost. Replacing the fuse with a non-Graco fuse voids the IS system safety approval. Parts labeled n/a are not available separately. 312780K...
Parts RoboMix Fluid Station NOTE: Parts are shown on pages 74 and 75, unless noted. RoboMix Panel, no dump valve RoboMix Panel, one dump valve RoboMix Panel, two dump valves* Ref. Ref. Part No. Description Part No. Description 15U720 HOSE, component A dump; 15U712 PANEL, RoboMix 1/4 npt(mbe);...
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G250HR meters; see page 36 for connection points Replacing the fuse with a non-Graco fuse voids the 949122 KIT, flexible mixer; see page IS system safety approval. Available as kit, Part. No. 24V862.
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Parts RoboMix Fluid Station RoboMix Panel, two dump valves shown Detail of Circuit Board Assembly TI12508a Detail of Flow Meter Assembly See page 67 for description. TI12507a See page 75 for detail. TI12509a 312780K...
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Parts RoboMix Fluid Station Detail of Ratio Check Kit (493) Detail of Connection Ports A Inlet B Inlet Logic Inlet 490; Air Purge TI12514a Inlet 458; Solvent 423; Inlet A Dump See page 76 423; Outlet for detail. B Dump Outlet TI12511a 480, 489 TI12510a...
Parts Color Change Accessory Kits Low Pressure Color Change Kits Color Change Catalyst Change Kit Part Control Module Valve Stack (11; Valve Stack (12; Kit Description (10; see 312787) see 312783) see 312783) 256581 2 color 277752 15V812 none 256582 4 color 277753 15V813...
Air filtration for air logic and purge air (Graco-supplied)......5 micron (minimum) filtration required; clean and dry air Air filtration for atomizing air (user-supplied) .
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.