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Graco ProMix 2KE Operation

Pump-based plural component proportioner
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Operation
ProMix
Pump-Based Plural Component Proportioner
Self-contained, electronic two-component paint proportioner. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
See page 3 for model information, including maximum
working pressure and approvals.
®
2KE
3A0868A
ENG
ti15696a

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Summary of Contents for Graco ProMix 2KE

  • Page 1 Operation ® ProMix 3A0868A Pump-Based Plural Component Proportioner Self-contained, electronic two-component paint proportioner. For professional use only. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. See page 3 for model information, including maximum working pressure and approvals. ti15696a...

  • Page 2: Table Of Contents

    Spraying ......27 Graco Standard Warranty ....60 Pressure Relief Procedure .

  • Page 3: Models

    Warnings, page 5. 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.
  • Page 4 Merkur Bellows 35:1 3500 (24.1, 241) 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.

  • Page 5: Warnings

    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.
  • Page 6 Warnings WARNING INTRINSIC SAFETY Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe equipment will create a hazardous condition and can cause fire, explosion, or electric shock. Follow local regulations and the following safety requirements. • Only models with model numbers 24F102-24F115, utilizing the air-driven alternator, are approved for installation in a Hazardous (explosive atmosphere) Location.
  • Page 7 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.

  • Page 8: Important Two-Component Material Information

    Important Two-Component Material Information Important Two-Component Material Information Isocyanate Conditions Moisture Sensitivity of Isocyanates Isocyanates (ISO) are catalysts used in two component coatings. ISO will react with moisture (such as humidity) Spraying or dispensing materials containing to form small, hard, abrasive crystals, which become isocyanates creates potentially harmful mists, vapors, suspended in the fluid.

  • Page 9: Glossary Of Terms

    Glossary of Terms Glossary of Terms Coriolis Meter - a non-intrusive flow meter often used in Mix - when cross-linking of the resin (A) and catalyst (B) low flow applications or with light viscosity, shear sensi- occurs. tive, or acid catalyzed materials. This meter uses vibra- tion to measure flow.

  • Page 10: Overview

    Overview Overview Usage The ProMix 2KE is an electronic two-component paint • Can proportion at ratios from 0.1:1 to 30.0:1. proportioner. It can blend most two-component paints. It is not for use with quick-setting paints (those with a pot •...

  • Page 11: Intrinsically Safe Installation Requirements

    Installation Intrinsically Safe Installation Requirements 2. Multiple earthing of components is allowed only if high integrity equipotential system realized between the points of bonding. Do not substitute or modify system components as 3. For ATEX, install per EN 60079-14 and applicable this may impair intrinsic safety.
  • Page 12 Installation Non-Hazardous Locations DISPLAY 10' CAN CABLE MODULE 50' OPTION USB MODULE LINE POWER POWER FILTER BASE SUPPLY FLUID CAN CABLE CONTROL MODULE LINEAR SENSOR/ LINEAR SENSOR/ REED SWITCH CABLE REED SWITCH CABLE "B" REED "A" REED SWITCH SWITCH "B" LINEAR "A"...

  • Page 13: Air Supply

    (hazardous location) or page 53 (non-hazardous loca- tion). NOTE: See Dimensions and Mounting on page 58 for additional air supply/consumption information. 1. Tighten all ProMix 2KE system air and fluid line con- nections as they may have loosened during ship- ment. 3A0868A...

  • Page 14: Fluid Supply

    (MM) outlet and the gun fluid inlet. which are commonly caused by pump stroke change- over. 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.
  • Page 15 Installation ti15697a Key: . 6. Component Identification 3A0868A...

  • Page 16: Electrical

    Connect the ProMix 2KE ground wire to the ground Enclose all cables routed in the spray booth and high screw. Connect the clamp to a true earth ground. If wall...

  • Page 17: Check Resistance

    Installation Object Being Sprayed Check Resistance Follow local code. All Solvent Pails Used When Purging To ensure proper grounding, resistance between Follow local code. Use only conductive metal pails/con- components and true earth ground must be less than tainers placed on a grounded surface. Do not place the 1 ohm.

  • Page 18: Display Module

    Display Module Display Module Potlife state Active recipe Operation mode; see . 11 for key Navigation keys LCD display Enter key Soft keys Navigation keys Error Reset Standby key Setup key ti16319a . 10. Display Module Display Keys are used to input numerical data, enter setup screens, navigate within a screen, scroll through screens, and select setup values.
  • Page 19 Display Module ti16321a ti16320a . 11. Display Module Icon Key and Error Codes 3A0868A...

  • Page 20: Screen Summary

    Display Module Screen Summary The Display Module has two operating modes: Run Mode Recipe (Screens 28 and 29) • Recipe 1-1 (Screen 28) and 1-2 (Screen 29) The run mode has three screen sections that control the control Material 1/Color 1 parameters and flush. mixing operations.
  • Page 21 Display Module . 12. Run Mode Screen Map 3A0868A...
  • Page 22 Display Module . 13. Setup Mode Screen Map, page 1 3A0868A...
  • Page 23 Display Module . 14. Setup Mode Screen Map, page 2 3A0868A...
  • Page 24 Display Module Password Must be set to 9909 Press to exit Setup. Press reenter Setup. Setup Home (Screen 17) displays, with Troubleshooting options. System Outputs 1 Set-Up Home System Inputs Screen Screen System Outputs 2 Screen Setup Home Membrane Test .

  • Page 25: Basic Operation

    . 16. Power Switch tions are tight and installed according to the man- ual. Fluid supply containers filled 2. Graco logo will display after five seconds, followed by Run Mix Spray (Screen 2). Check component A and B and solvent supply containers.

  • Page 26: Prime The System

    Basic Operation Prime the System 7. Open the fluid supply valve to the pump. 8. If using an electrostatic gun, shut 1. Adjust the main air pressure. Most applications off the electrostatics before flushing require about 80 psi (552 kPa, 5.5 bar) air pressure the gun.

  • Page 27: Spraying

    Basic Operation Spraying 4. Turn on atomizing air to the gun. Check the spray pattern as instructed in your spray gun manual. NOTE: 1. Calibrate the pumps as described in Pump Calibra- tion, page 41. Pump factors will update automati- •...

  • Page 28: Pressure Relief Procedure

    2. Close main air shutoff valve on air supply line and on ProMix 2KE. Lock Mode 3. Non-IS Systems: Shut off ProMix 2KE power If you change system type or number of guns, the sys- (0 position). tem locks so that you cannot spray or mix. If you have changed to a meter system, the system also locks if you change the dosing type or the number of colors.

  • Page 29: Run Mode Details

    Run Mode Details Run Mode Details Run Mix Spray (Screen 2) • Press a soft key button to select one of the main Run Mode screen sections: Mix , Errors Run Mix Spray (Screen 2) displays at startup or if or Pump Control is selected from Run Home (Screen 1).

  • Page 30: Run Totals (Screen 4)

    Run Mode Details Run Totals (Screen 4) Run Pump Control (Screen 15) Run Totals (Screen 4) displays if is selected Run Pump Control (Screen 15) displays if from the Run Mix Batch Screen. Use this screen to view selected from the Run Home Screen. Use this screen to grand and batch totals for material A and material B, and manually start and stop a pump.

  • Page 31: Setup Mode Details

    Setup Mode Details Setup Mode Details 3. The system will note the incorrect password and Press on any screen to enter the Setup screens. If return to Run Home (Screen 1). the system has a password lock, the Password Screen displays.

  • Page 32: Configure 1-4 (Screens 18-21)

    Setup Mode Details Configure 1-4 (Screens 18-21) Configure 1 (Screen 18) displays if is selected on Gun 1 hose length Gun 2 hose Setup Home (Screen 17). This screen allows users to length set up the system type (pump or meter) and number of Gun 1 hose guns (1 or 2).

  • Page 33: Recipe 1-1 And 1-2 (Screens 28 And 29)

    Setup Mode Details Recipe 1-1 and 1-2 (Screens 28 Maintenance 1-3 (Screens 24-26) and 29) Maintenance 1 (Screen 24) displays if is selected on Setup Home (Screen 17). The Maintenance Screens Recipe 1-1 (Screen 28) displays if is selected on display actual and target maintenance timers for pumps Setup Home (Screen 9).

  • Page 34: Calibration 1 And 2 (Screens 22 And 23)

    Setup Mode Details Calibration 1 and 2 (Screens 22 • Press to highlight the pump you wish to cali- and 23) brate. Press . An X displays in the box. NOTE: See Pump Calibration, page 41, for detailed • Press to start the calibration on the highlighted instructions.
  • Page 35 Setup Mode Details Troubleshooting System Inputs (Screen 35) • Press three times to return to Setup Home From Setup Home (Screen 17) with Troubleshooting (Screen 17). Direct access to any other screen is not possible. active, press to display Troubleshooting System Inputs (Screen 35).

  • Page 36: Dynamic Dosing

    Setup Mode Details Dynamic Dosing In typical operation (ratios 1:1 and above), component A • Component A Flow: Ensure that the supply pump is dispenses constantly. Component B dispenses intermit- sized to provide sufficient and uninterrupted flow. tently in the necessary volume to attain the mix ratio. Note that component A provides majority of system flow at higher mix ratios.
  • Page 37 Setup Mode Details Balancing A/B Pressure If component B pressure is too high, it will push the com- B Pressure ponent A stream aside during B injection. The valve will Too Low not open long enough, causing a High Ratio alarm. If component B pressure is too low, it will not be injected B Pressure in sufficient volume.
  • Page 38 Setup Mode Details Table 3: Dynamic Dosing Troubleshooting Guide (for complete system troubleshooting, see Table 4 beginning on page 45) Error Message Solution B Pressure Too Low • Increase B pressure. • Clean restrictor or use a larger size. • Verify B valve is opening properly.

  • Page 39: Purging

    Purging Purging When done purging, the system automatically switches to Standby mode. 7. If the system is not completely clean, repeat step 6. There are 2 purging procedures in this manual: NOTE: If necessary, adjust purge sequence so only • Purging Mixed Material one cycle is required.
  • Page 40 Purging 6. Adjust the solvent fluid supply pressure. Use the • Purge component B side. Press the manual lowest possible pressure to avoid splashing. override on the Dose Valve B solenoid valve and trigger the gun into a grounded metal pail 7.

  • Page 41: Pump Calibration

    Pump Calibration Pump Calibration NOTE: Stop triggering the gun when desired amount is reached. Do not press , as it will cancel the calibra- tion. Calibrate the pump: 8. The volume that the ProMix measured displays on • The first time the system is operated. the Display Module.

  • Page 42: Use Of Optional Usb Module

    USB, the user can access the 50 most recent errors via the Display Module. 2. Insert USB flash drive into USB port (DR). Use only Graco-recommended USB flash drives; see Rec- NOTE: For both the Job Log and the Error Log, when ommended USB Flash Drives, page 43.

  • Page 43: Recommended Usb Flash Drives

    (16A004) included with the kit for data download. The following USB flash drive also can be used, how- 7. Open Graco folder. ever, but are not available through Graco. 8. Open sprayer folder. If downloading data from more ™...

  • Page 44: System Errors

    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 trig- gered. The gun icon on the Display Module shows spray when the AFS is activated.
  • Page 45 System Errors Table 4: System Alarm/Advisory/Record Codes Table 4: System Alarm/Advisory/Record Codes Code Description Details Code Description Details Advisory Codes - No alarm, system continues operat- Alarm Codes - Alarm sounds, system stops, icon dis- ing, icon displays on active screen until cleared plays until problem is solved and alarm is cleared.

  • Page 46: Alarm Troubleshooting

    System Errors Alarm Troubleshooting Alarm and Description Cause Solution The CAN cable between the Display Mod- Verify that the cable is correctly con- Communication Error ule and the Advanced Fluid Control Mod- nected. The Display Module is not ule is not connected. communicating with the The CAN cable is cut or bent.
  • Page 47 System Errors Alarm and Description Cause Solution SFA1 or SFB1 Check components and clean, repair, or Gun, line, or valve is plugged or stuck. PreMix Error replace as necessary In systems with a gun flush Refill fluid supply. Check and repair Pump(s) not working or out of fluid.
  • Page 48 System Errors Alarm and Description Cause Solution There is too much restriction in the sys- • Check that the system is fully Ratio Low Error tem. loaded with material. The mix ratio is lower than the • Check that the supply pump’s cycle set tolerance for an A to B rate is set properly.
  • Page 49 System Errors Alarm and Description Cause Solution There is too little restriction in the system. • Check that the system is fully Ratio High loaded with material. The mix ratio is higher than • Check that the supply pump’s cycle the set tolerance for an A to B rate is set properly.
  • Page 50 System Errors Alarm and Description Cause Solution QTA1 or QTB1 System is in Mix mode and gun is only Fully trigger the gun. Dose Time Error partially triggered, allowing air but no fluid The gun trigger is active, but to pass through gun. no A pulses (QTA1) or no B Fluid flow rate is too low.
  • Page 51 System Errors Alarm and Description Cause Solution DDA1 or DDB1 Refill fluid supply system. Fluid supply is empty. Diving/Cavitation Error Rebuild displacement pump and Displacement pump is not seating prop- Pump A (DDA1) or Pump B replace packings, balls, and seats. erly.

  • Page 52: Schematics

    Schematics Schematics Hazardous Location System Pneumatic Schematic 3A0868A...
  • Page 53 Schematics Non-Hazardous Location Pneumatic Schematic 3A0868A...
  • Page 54 Schematics Hazardous Location Electrical Schematic CAN_L +V_CAN V_CAN_RTN CAN_H SHIELD UNUSED CAN_L CAN_L UNUSED +V_CAN +V_CAN UNUSED V_CAN_RTN V_CAN_RTN UNUSED CAN_H CAN_H UNUSED SHIELD SHIELD V CAN CAN_L USB COMPONENT USB BASE V CAN +V_CAN MODULE V CAN MODULE V_CAN_RTN V CAN RTN CAN_H V CAN RTN...
  • Page 55 Schematics Hazardous Location Electrical Schematic (continued) UNUSED CAN_L UNUSED +V_CAN UNUSED V_CAN_RTN UNUSED CAN_H UNUSED SHIELD FLUID CONTROL UNUSED UNUSED MODULE AFS #1 (+) ALARM (+) COMMON COMMON PURGE A (+) PURGE B (+) DOSE B (+) DOSE A1 (+) +12 VDC +12 VDC FLOW METER B SIG...
  • Page 56 Schematics Non-Hazardous Location Electrical Schematic CAN_L +V_CAN V_CAN_RTN CAN_H SHIELD POWER SUPPLY LINE POWER CAN_L CAN_L FILTER +V_CAN +V_CAN V_CAN_RTN V_CAN_RTN CAN_H CAN_H SHIELD SHIELD V CAN USB COMPONENT USB BASE V CAN MODULE V CAN MODULE V CAN RTN V CAN RTN CHASSIS GND CHASSIS GND...
  • Page 57 Schematics Non-Hazardous Electrical Schematic (continued) CAN_L CAN_L +V_CAN +V_CAN FLUID V_CAN_RTN V_CAN_RTN CAN_H CAN_H CONTROL SHIELD SHIELD MODULE UNUSED UNUSED ALARM (+) AFS #1 (+) COMMON COMMON PURGE A (+) PURGE B (+) DOSE A1 (+) DOSE B (+) +12 VDC +12 VDC FLOW METER B SIG FLOW METER A SIG...

  • Page 58: Dimensions And Mounting

    Dimensions and Mounting Dimensions and Mounting 14.76 in. (37 cm) 1.0 in 0.55 in (2.5 cm) 12.76 in. (1.4 cm) (32 cm) Depth: 18.0 in. (46 cm) 33.5 in. (85 cm) 44.5 in. (113 cm) Merkur: 57 in. (145 cm) Merkur Bellows: 65 in.

  • Page 59: Technical Data

    Air filter inlet size ....... 3/8 npt(f) Air filtration for air logic (Graco-supplied)... . .‘ 5 micron (minimum) filtration required; clean and dry air Air filtration for atomizing air (user-supplied) .

  • Page 60: Graco Standard Warranty

    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.

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