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Operation ® ProMix 312776B Plural Component Proportioner Manual system for proportional mixing of plural component coatings. For professional use only. Approved for use in explosive atmospheres (except the EasyKey). See page 4 for model information, including maximum working Important Safety Instructions pressure.
Fluid Station and EasyKey Manual Description See F . 1 on page 4 for label locations. 312775 ProMix 2KS Manual System Installation EasyKey and Fluid Station Label 312777 ProMix 2KS Manual System Repair-Parts 312781 Fluid Mix Manifold...
Working Pressure PART NO. SERIES SERIAL Configured Part Number is listed here MAX FLUID WPR MFG. YR. GRACO INC. P.O. Box 1441 Minneapolis, MN MAX TEMP 50°C (122°F) TI12421a 55440 U.S.A. . 1: Identification Label 312776B...
System Configuration and Part Numbers Hazardous Location Approval Models using a G3000, G3000HR, 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.
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System Configuration and Part Numbers 312776B...
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 symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable.
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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.
Glossary of Terms Glossary of Terms Air Chop - the process of mixing air and solvent Fill Time - the amount of time that is required to load together during the flush cycle to help clean the lines mix material to the applicator. and reduce solvent usage.
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Glossary of Terms Manual Mode - when the proportioning or flow control Purge - when all mixed material is flushed from the sys- system is controlling the inputs without any input from tem. an outside control. Purge Time - the amount of time required to flush all Mix - when cross-linking of the resin (A) and catalyst (B) mixed material from the system.
Overview Usage The Graco ProMix 2KS is an electronic two-component paint proportioner. It can blend most two-component solvent and waterborne epoxy, polyurethane, and acid-catalyzed paints. It is not for use with “quick-setting” paints (those with a potlife of less than 15 minutes).
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Overview Table 1: Component Descriptions Component Description Three optional flow meters are available from Graco: Flow Meters (MA, MB, MS) • G3000 is a general purpose gear meter typically used in flow ranges of 75-3800 cc/min. (0.02–1.0 gal/min.), pressures up to 4000 psi (28 MPa, 276 bar), and viscosi- ties of 20–3000 centipoise.
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Overview TI12504a . 2. Manual System, shown with G3000 Meters, Color/Catalyst Change, One Gun Flush Box, and Accessory Solvent Flow Meter 312776B...
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Overview TI12556a . 3. Wall Mount Fluid Station 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 Sampling Valve SVB Component B Shutoff Valve Solvent Meter (accessory) SPV Solvent Purge Valve...
Booth Control Booth Control Used by the operator for daily painting functions includ- Table 2: Booth Control Key and Indicator Functions ing: changing recipes, signalling job complete, read- (see F . 4) ing/clearing alarms, and placing the system in Standby, Key/Indicator Definition and Function Mix, or Purge mode.
EasyKey Display and Keyboard EasyKey Display and Keyboard Keypad LCD Display TI11630A Navigation Keys Alarm Reset Key . 5. EasyKey Display and Keypad Display Table 3: EasyKey Keypad Functions (see F . 5) Shows graphical and text information related to setup Function and spray operations.
Connector Ports TI12638a TI12657a . 6. EasyKey Connections and AC Power Switch AC Power Switch Graco Web Interface Port Turns system AC power on or off. Used to communicate from a PC to: ➜ Upgrade software I/S Power ➜ View software version ➜...
. 9 for a map of the Run screens. Detailed screen descriptions follow. Splash Screen At power up, the Graco logo and software revision will display for approximately 5 seconds, followed by the Status Screen (see page 21). . 7. Splash Screen The Splash screen will also momentarily display “Estab-...
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Run Mode Screens Press the Setup key to enter Setup mode. TI12783a . 9. Run Screens Map 312776B...
Run Mode Screens Status Screen Potlife Timer: shows remaining potlife time in min- utes. Two times are shown if there are two guns. • Use the Up or Down keys to scroll through the Run screens. Status Bar: shows current alarm or operation mode (standby, mix, purge, recipe change, or the current alarm).
Run Mode Screens Totals Screen Reset Solvent Screen . 11. Totals Screen . 13. Reset Solvent Total Screen This screen shows the job totals, grand totals, and job The screen will ask if you want to reset solvent total. number. Use the tabs to reset job totals (Job Complete), Select Yes or No.
Run Mode Screens Level Control Screen . 15. Level Control Screen This screen shows the current volume for each fluid. Adjust the actual volumes on this screen, or use the tab to go to Usage (Totals Screen, page 22). See F .
Setup Mode Setup Mode NOTE: See F . 17 for a map of the Setup screens. Press the Setup key to enter Setup mode. Detailed screen descriptions follow. Press the Setup key to enter Setup mode. This screen appears only if a password is activated.
Home Screen. Entering the wrong password returns the display to the Status Screen. NOTE: If you forget the password, you can reset the password (to 0), using the ProMix 2KS Web Interface (see manual 313386). . 20. Set Up Home Screen This screen displays when you enter Setup mode.
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Setup Mode Table 4: Component Software Versions Display (may vary from examples Component shown) Description EK (EasyKey) 2.00.012 EasyKey software version. FP (Fluid Plate) 2.00.012 Fluid Plate software version. BC (Booth Control) Booth Control not installed, not detected, or not oper- ational.
Setup Mode System Configuration Screens NOTE: See F . 21 for a map of the System Configura- NOTE: Each screen displays the current screen number tion Screens. Detailed screen descriptions follow. and the total number of screens in the group. TI12785a .
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Setup Mode Configure Screen 1 Month Enter current month. Enter current day. Year Enter current year (four digits). Time Enter current time in hours (24 hour clock) and minutes. Seconds are not adjustable. . 22. Configure Screen 1 Date Format Language Select mm/dd/yy or dd/mm/yy.
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Setup Mode Configure Screen 4 . 25. Configure Screen 4 . 27. Configure Screen 4, dynamic dosing setup mode enabled Dose Size Dose Time Alarm Select the total dose size (cc) from the pulldown menu: 100, 50, 25, 10, or select DD to turn on dynamic dosing. Enter the dose time (1 to 99 seconds).
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The default web browser IP address prefix is 192.168.178.__ Assign a unique number for each EasyKey in your system (1-99) and enter it here. Control Network ID Used for the Graco Gateway network system. See Graco Gateway manual 312785 for further information 312776B...
Setup Mode Option Screens NOTE: See F . 21 on page 27 for a map of the Option Verification Screen Screens. Detailed screen descriptions follow. NOTE: Each screen displays the current screen number and the total number of screens in the group. Option Screen 1 .
Setup Mode Advanced Setup Screens NOTE: See F . 32 for a map of the Advanced Setup Screens. Detailed screen descriptions follow. Advanced Setup screens 2, 3, 4, and 5 appear depending on selections made in Option screens 1 and 2. TI12786a .
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Setup Mode NOTE: Each screen displays the current screen number Color/Catalyst Fill and the total number of screens in the group. The total This field only appears if the system includes a color number of screens in a group and the fields displayed change module and Flush and Fill Input is set to on each screen may vary depending on selections “Global”...
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Setup Mode Advanced Setup Screen 3 Advanced Setup Screen 4 . 35. Advanced Setup Screen 3 . 36. Advanced Setup Screen 4 This screen appears only if Flush and Fill Input is set to This screen appears only if K-Factor Input is set to “Global”...
Setup Mode Recipe Setup Screens NOTE: See F . 38 for a map of the Recipe screens. Detailed screen descriptions follow. Recipe 0 Screens Recipe screens 3, 4, 5, 6, and 7 appear depending on selections made in Option screens 1 and 2 TI12787a .
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Setup Mode NOTE: Each screen displays the current screen number Recipe Setup Screen 2 and the total number of screens in the group. The total number of screens in a group and the fields displayed on each screen may vary depending on selections made in the System Configuration Screens and Option Screens.
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Setup Mode Recipe Setup Screen 3 Recipe Setup Screen 4 . 42. Recipe Setup Screen 4 . 41. Recipe Setup Screen 3 This screen appears only if Flush and Fill Input is set to This screen appears only if Flush and Fill Input is set to “Recipe”...
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Setup Mode Recipe Setup Screen 5 Recipe Setup Screen 6 . 43. Recipe Setup Screen 5 . 44. Recipe Setup Screen 6 This screen appears only if K-Factor Input is set to “Rec- This screen appears only if Flow Rate Monitor is set to ipe”...
Setup Mode Recipe 0 Screens NOTE: See F . 38 on page 35 for a map of the Recipe Air Chop Time 0 screens. Detailed screen descriptions follow. Enter the air chop time (0.0 to 99.9 seconds). Recipe 0 is typically used: Solvent Chop Time/3rd Flush Valve Chop Time •...
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Setup Mode Recipe 0 Screen 3 Recipe 0 Screen 4 . 48. Recipe 0 Screen 3 . 49. Recipe 0 Screen 4 This screen only appears if Solvent Monitor is set to This screen appears only if Flush and Fill Input is set to “Meter”...
Setup Mode Calibration Screen . 50. Calibration Screen Use this screen to calibrate a meter. Set to “Meter A,” “Meter B,” or “Solvent Meter” (available if Solvent Moni- tor in Configure Screen 5, page 30, is set to “Meter”). • Start - start calibration •...
2. The operator presses the Mix key to begin Standby operation. Stops the system. 3. The ProMix 2KS controller sends signals to activate the solenoid valves. The solenoid valves activate Dose Valves A and B. Fluid flow begins when the Purge gun is triggered.
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NOTE: To control output from the static mixer to the gun, install an optional fluid pressure regulator. 8. When the gun is triggered again, the ProMix 2KS continues the process where it left off. 6. Components A and B are alternately fed into the NOTE: Operation can be stopped at any time by integrator as long as the gun is triggered.
System Operation General Operating Cycle, Dynamic Dosing Overview Dynamic Dosing System Parameters Dynamic Dosing provides on-demand proportioning, The following parameters affect dynamic dosing perfor- eliminating the need for an integrator and therefore min- mance: imizing undesired material contact. This feature is espe- cially useful with shear-sensitive and waterborne •...
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Install the 15U955 Injection Kit in the fluid manifold as To enable DD setup mode, select On in the DD explained in the ProMix 2KS Installation manual. Use Setup mode drop down menu. This disables Off the charts provided in that manual to select an appropri-...
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System Operation 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. B Pressure If component B pressure is too low, it will not be injected Too High...
System Operation Table 6: Dynamic Dosing Troubleshooting Guide (for complete system troubleshooting, see Table 11 beginning on page 74) Warning/Alarm Message Solution B Pressure Too Low (see F . 56) • Increase B pressure. • Clean restrictor or use a larger size. •...
Dose Time Alarm (E-7 or E-8) occurs after 40 seconds and the system shuts down. • Since the ProMix 2KS does not know it is spraying because there is no gun trigger/air flow switch input, it will go into System Idle (E-15) every 2 minutes when in Mix mode.
System Operation Start Up 1. Go through the Pre-Operation Checklist in Table 8. ➜ Graco logo, software revision, and “Establishing Communication” will display, followed by Status Table 8: Pre-Operation Checklist screen. See page 19. ➜ At power up the system defaults to Recipe 61, Checklist ✓...
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System Operation 6. Adjust component A and B fluid supplies Watch the fluid flow rate displayed on the Status as needed for your application. Use low- screen while the gun is fully open. Verify that the est pressure possible. flow rate of components A and B are within 10% of each other.
Pressure Relief Procedure NOTE: The following procedures relieve all fluid and air Overnight Shutdown pressure in the ProMix 2KS system. Use the procedure 1. Leave the power on. appropriate for your system configuration. 2. Run Recipe 0 to purge solvent through meters and gun.
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System Operation 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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System Operation AFS #1 AFS #2 Power SOLV SW Fiber GFB 1 PS Optic GFB 2 PS Not Used Flow Solv Spare Flow A Flow B Dose A Dose B Valve Overrides Spare Dump Valve A Dump Valve B Optional Solenoid GFB 1 Locations GFB 2...
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System Operation Solenoid Solenoid Identification Identification Label Label TI12826a Solvent Solenoid Overrides . 66: 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 Sampling Valve...
System Operation Purging If using an electrostatic gun shut off the electrostatics before flushing the gun. Read Warnings, page 8. Follow the Grounding instructions in your system Installation manual. 2. Set the solvent supply pressure regulator at a pres- To avoid splashing fluid in the eyes, wear eye protec- sure high enough to completely purge the system in tion.
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System Operation Purging Using Recipe 0 Purging Fluid Supply System Recipe 0 is typically used: Follow this procedure before: • in multiple color systems to purge out material lines • the first time material is loaded into equipment* without loading a new color •...
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System Operation 3. Adjust the solvent fluid supply pressure. Use the lowest possible pressure to avoid splashing. 4. Remove the Fluid Station cover to access the sole- noid valves. See F . 65. 5. Purge as follows: • Single color/single catalyst systems: Purge component A side.
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System Operation Purging Sampling Valves and Tubes 8. Close sampling valves. Follow this procedure after meter calibration. NOTE: Select Abort on Calibration screen to cancel current calibration and close dose or purge valves. 1. Press the Standby key on the Booth Control. 9.
Meter Calibration Meter Calibration 4. Place the beakers (minimum size - 250 cc) in hold- ers. Put the sampling tubes into the beakers. NOTE: If tubes need replacing, use 5/32 in. or 4 mm OD tubing. To avoid splashing fluid in the eyes, wear eye protec- tion.
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11. After the volume for A, B, or Solvent is entered, the ProMix 2KS controller calculates the new flow meter c. To begin operation, see Start Up, page 49. K-Factor and shows it on the Calibration Screen.
Color Change Color Change Color Change Procedures Color Change Sequences . 69 through F . 86 illustrate various color change Multiple Color Systems sequences. See Table 9 to determine which figure to ref- erence, based on the recipe change and system config- 1.
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Color Change Color Purge/Dump First Purge Step M0-M1 Step P0-P1 Select the First Purge Source (air, solvent, or 3rd valve) • This sequence flushes out the color with solvent, and First Purge Time. For most applications, air is from the color valve to the Dump A valve. selected.
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Color Change Table 9: Color Change Chart Reference Number of Starting Ending Color Catalyst Dump 3rd Purge Gun Flush Recipe Recipe Change Change Valves Valve Boxes Refer to Fig. . 70 . 69 . 72 0, 1, or 2 . 71 0, 1, or 2 .
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Color Change ProMix 2KS Recipe Change Chart 1: A1 to A2, B1 to B2 with Dump Valves Valve Time-Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Color Purge Time P0->P1 Color Fill Time P1->P2 Catalyst Purge Time P2->P3...
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Color Change ProMix 2KS Recipe Change Chart 3: A1 to A2, same B with Dump Valves Valve Time-Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Color Purge Time P0->P1 Color Fill Time P1->P2 CC Purge/Fill Timers are independent of Mixed Material Purge Timers.
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Color Change ProMix 2KS Recipe Change Chart 5: B1 to B2, same A with Dump Valves Valve Time-Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Catalyst Purge Time P0->P1 Catalyst Fill Time P1->P2 CC Purge/Fill Timers are independent of Mixed Material Purge Timers.
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Color Change ProMix 2KS Recipe Change Chart 7: A1 to A2, B1 to B2 with Dump Valves, 1 GFB Valve Time-Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Color Purge Time P0->P1 Color Fill Time P1->P2...
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Color Change ProMix 2KS Recipe Change Chart 9: A1-A2, same B without Dump Valves, 1 GFB Valve Time-Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Air Chop Time Solvent Chop Time...
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Color Change ProMix 2KS Recipe Change Chart 11: Recipe 0 OR 61 to Recipe X with Dump Valves Valve Time-Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Air Purge Solvent Purge...
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Color Change ProMix 2KS Recipe Change Chart 13: Recipe 0 OR 61 to Recipe X without Dump Valves Valve Time-Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Air Purge Solvent Purge...
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Color Change ProMix 2KS Recipe Change Chart 15: Same A, Same B Valve Time-Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B Air Chop Time Solvent Chop Time First Purge (one of these)
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Color Change ProMix 2KS Recipe Change Chart 17: Recipe 0 OR 61 to Recipe X with Dump Valves and 3rd Flush Valve Valve Time-Sequence Dump A Dump B Color Change Solvent Catalyst Change Solvent Color Change A Catalyst Change B...
They are saved in E-24 Tank S Low Alarm Page 81 the date/time stamped log, which can be viewed on a PC, using the ProMix 2KS Web Interface (see manual E-25 Auto Dump Complete Alarm Page 81 313386).
Alarm Troubleshooting Alarm Troubleshooting Table 11. Alarm Troubleshooting E-1: COMM_ERROR Cause Solution No power to the EasyKey. Connect power to EasyKey. No power to Fluid Station. The intrinsically safe power Verify that the cable is correctly connected. See Installa- cable between the EasyKey and Fluid Station is not con- tion manual.
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Slow actuation of the component A or B valves. This can Manually operate the Dispense A and B solenoid valves be caused by: as instructed in the ProMix 2KS Repair-Parts manual to check operation. • Air pressure to the valve actuators is too low.
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Slow actuation of the component A or B valves. This can Manually operate the Dispense A and B solenoid valves be caused by: as instructed in the ProMix 2KS Repair-Parts manual to check operation. • Air pressure to the valve actuators is too low.
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(such as fans and conveyors). 3. Check if the ProMix 2KS is reading any fluid flow. 4. If the ProMix 2KS shows there is fluid flow and there are no leaks from the gun or any other seals or fit- tings, the flow meters are probably being affected by pressure pulsations.
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Alarm Troubleshooting Table 11. Alarm Troubleshooting E-7: DOSE_TIME_A_ALARM and E-8: DOSE_TIME_B_ALARM E-7: gun trigger input is active (AFS or Integration) and no A meter pulses are detected during the dose time selected. E-8: gun trigger input is active (AFS or Integration) and no B meter pulses are detected during the dose time selected.
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E-11: PURGE_VOLUME_ALARM Cause Solution ProMix 2KS solvent flow switch is not activated while Verify that the gun is not shut off and that the solvent flow purging. switch is activated while purge is taking place. Minimum flush volume is set too high.
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Alarm Troubleshooting Table 11. Alarm Troubleshooting E-15: SYSTEM_IDLE_WARNING Cause Solution Mix input is high, but the gun has not been triggered for 2 If not painting, clear alarm and resume operation. minutes. If painting, shut down and inspect fluid meter and air flow switch.
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Alarm Troubleshooting Table 11. Alarm Troubleshooting E-21: MATERIAL_FILL_ALARM Cause Solution For systems with minimum mixed material fill volume Check for restrictions or leaks in the fluid supply system. entered, the system detects that fill volume is not achieved during mixed material fill time. Check if the fill volume is properly configured: •...
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 DOSE A COLOR 4 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...
Air filter inlet size ....... 3/8 npt(f) 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.
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