Operation
ProMix® 2KE
3A0868G
EN
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.
mum working pressure and approvals.
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Models
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 USB
Part No. Series Ratio Pumps
psi (MPa, bar)
Port
Approvals*
24F102
24F103
24F104
24F105
A
A
A
A
3:1 Merkur, A and B
23:1 Merkur, A and B
30:1 Merkur, A and B
45:1 Merkur, A and B
300 (2.1, 21)
2300 (15.8, 158)
3000 (20.6, 206)
4500 (31.0, 310)
II 2 G
Ex ia px IIA T3 Ta = 0°C to 54°C
FM10 ATEX 0025 X
Merkur A,
Merkur Bellows B
Merkur A,
Merkur Bellows B
24F106
24F107
24F108
A
A
A
3:1
300 (2.1, 21)
2300 (15.8, 158)
3500 (24.1, 241)
#
53
23:1
Intrinsically safe and purged equipment for
Class I, Division 1, Group D, T3
Ta = 0°C to 54°C
Merkur A,
Merkur Bellows B
35:1
24F109
24F110
24F111
24F112
A
A
A
A
3:1 Merkur, A and B
23:1 Merkur, A and B
30:1 Merkur, A and B
45:1 Merkur, A and B
300 (2.1, 21)
2300 (15.8, 158)
3000 (20.6, 206)
4500 (31.0, 310)
✔
✔
✔
✔
0359
See Special Conditions
for Safe Use in
Merkur A,
Merkur Bellows B
24F113
24F114
24F115
A
A
A
3:1
300 (2.1, 21)
2300 (15.8, 158)
3500 (24.1, 241)
✔
✔
✔
Merkur A,
Merkur Bellows B
23:1
Merkur A,
Merkur Bellows B
35:1
*
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.
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Models
Models (continued)
Approved for Non-Hazardous Location
Maximum Working
Part
No.
Pressure
psi (MPa, bar)
USB
Port
Series Ratio Pumps
Approvals*
24F088
24F089
24F090
24F091
A
A
A
A
3:1 Merkur, A and B
23:1 Merkur, A and B
30:1 Merkur, A and B
45:1 Merkur, A and B
300 (2.1, 21)
2300 (15.8, 158)
3000 (20.6, 206)
4500 (31.0, 310)
#
53
Merkur A,
3:1
24F092
24F093
24F094
A
A
A
300 (2.1, 21)
2300 (15.8, 158)
3500 (24.1, 241)
Merkur Bellows B
Merkur A,
Merkur Bellows B
23:1
Merkur A,
Merkur Bellows B
35:1
24F095
24F096
24F097
24F098
A
A
A
A
3:1 Merkur, A and B
23:1 Merkur, A and B
30:1 Merkur, A and B
45:1 Merkur, A and B
300 (2.1, 21)
2300 (15.8, 158)
3000 (20.6, 206)
4500 (31.0, 310)
✔
✔
✔
✔
Merkur A,
Merkur Bellows B
Merkur A,
Merkur Bellows B
24F099
24F100
24F101
A
A
A
3:1
300 (2.1, 21)
2300 (15.8, 158)
3500 (24.1, 241)
✔
✔
✔
23:1
Merkur A,
Merkur Bellows B
35:1
*
ProMix 2KE non-hazardous location equipment manufactured in the United States, with serial number beginning
with A or 01, has FM and CE approvals. Equipment manufactured in Belgium, with serial number beginning with
M or 38, has CE approval.
Related Manuals
Manual
Description
Manual
Description
406823
3A1244
Dispense Valve Seat Kit
3A0870
312781
312782
312784
312792
312793
312796
406714
ProMix 2KE, Repair/Parts
Graco Control Architecture
Module Programming
16G353 Alternator Conversion Kit
16G351 Electric Power Conversion Kit
ProMix 2KE Stand Kits
Fluid Mix Manifold, Instructions/Parts
Dosing Valve, Instructions/Parts
Gun Flush Box Kit 15V826
Merkur Displacement Pump
Merkur Bellows Displacement Pump
NXT Air Motor
3A1323
3A1324
3A1325
3A1333
313542
24H253 USB Module Kit
Beacon Tower
Rebuild Kit for High Pressure
Dispense Valve
4
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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.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are
present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
SPECIAL CONDITIONS FOR SAFE USE
• To prevent the risk of electrostatic sparking, the equipment’s non-metallic parts should be cleaned only
with a damp cloth.
• The aluminum adapter plate may spark upon impact or contact with moving parts, which may cause
fire or explosion. Take precautions to avoid such impact or contact.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric
shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
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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
• Be sure your installation complies with national, state, and local codes for the installation of electrical
apparatus in a Class I, Group D, Division 1 (North America) or Class I, Zones 1 and 2 (Europe)
Hazardous Location, including all of the local safety fire codes, NFPA 33, NEC 500 and 516, and
OSHA 1910.107.
• To help prevent fire and explosion:
• Do not install equipment approved only for a non-hazardous location in a hazardous location. See
model ID label for the intrinsic safety rating of your model.
• Do not substitute system components as this may impair intrinsic safety.
• Equipment that comes in contact with the intrinsically safe terminals must be rated for Intrinsic Safety.
This includes DC voltage meters, ohmmeters, cables, and connections. Remove the unit from the
hazardous area when troubleshooting.
• The equipment is intrinsically safe when no external electrical components are connected to it.
• Do not connect, download, or remove USB device unless unit is removed from the hazardous
(explosive atmosphere) location.
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
6
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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. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about
your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure and disconnect all power sources.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating area
of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of
toxic fumes, and burns. This equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
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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)
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 vis-
cosity. If used, this partially cured ISO will reduce perfor-
mance and the life of all wetted parts.
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.
NOTE: The amount of film formation and rate of crystal-
lization varies depending on the blend of ISO, the
humidity, and the temperature.
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 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.
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.
•
•
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.
Material Self-ignition
•
•
Never use solvent on one side if it has been con-
taminated from the other side.
Always lubricate threaded parts with ISO pump oil
or grease when reassembling.
Some materials may become self-igniting if applied
too thickly. Read material manufacturer’s warnings
and material MSDS.
Changing Materials
•
When changing materials, flush the equipment mul-
tiple times to ensure it is thoroughly clean.
Keep Components A and B
Separate
•
•
Always clean the fluid inlet strainers after flushing.
Check with your material manufacturer for chemical
compatibility.
Cross-contamination can result in cured material in
fluid lines which could cause serious injury or
damage equipment. To prevent cross-contamination
of the equipment’s wetted parts, never interchange
component A (resin) and component B (isocyanate)
parts.
8
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Glossary of Terms
Glossary of Terms
Dose Size - the amount of resin (A) and catalyst (B) that
Potlife Time - the amount of time before a material
is dispensed into an integrator.
becomes unsprayable.
Dose Time Alarm - the amount of time that is allowed
for a dose to occur before an alarm occurs.
Potlife Volume - the amount of material that is required
to move through the mix manifold, hose, and applicator
before the potlife timer is reset.
Dynamic Dosing - Component A dispenses constantly.
Component B dispenses intermittently in the necessary
volume to attain the mix ratio.
Pump Calibration Factor - the amount of material dis-
pensed per inch of pump travel.
Grand Total - a non-resettable value that shows the
Purge - when all mixed material is flushed from the sys-
total amount of material dispensed through the system.
tem.
Intrinsically Safe (IS) - refers to the ability to locate cer-
Purge Time - the amount of time required to flush all
tain components in a hazardous location.
mixed material from the system.
Idle - if the gun is not triggered for 2 minutes the system
enters Idle mode. Trigger the gun to resume operation.
Ratio Tolerance - the settable percent of acceptable
variance that the system will allow before a ratio alarm
occurs.
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.
Standby - refers to the status of the system.
Mix - when cross-linking of the resin (A) and catalyst (B)
occurs.
Overdose Alarm - when either the resin (A) or catalyst
(B) component dispenses too much material and the
system cannot compensate for the additional material.
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Overview
Overview
Usage
The ProMix 2KE is an electronic two-component paint
proportioner. It can blend most two-component paints. It
is not for use with quick-setting paints (those with a pot
life of less than 5 minutes).
•
•
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.
•
Has dynamic dosing capabilities. It dispenses mate-
rial A, monitors fluid flow, and dispenses material B
in doses to cause the mixture to stay on ratio.
•
For systems with one gun, an optional Gun Flush
Box provides an automated flushing system for a
manual spray gun.
Component Identification and Definition
Component
Description
Control Box
•
•
•
•
•
•
•
Advanced Fluid Control Module
Power supply or alternator
Solenoid valves
Air flow switch(es)
Optional USB Module
Audible alarm
Optional pressure switch for gun flush box
Fluid Module
•
•
Mix manifold, which includes the fluid integrator and static mixer.
Color/catalyst valve stacks, includes pneumatically operated dose valves for material A
and B, as well as solvent valves.
•
Pumps
Display Module Used to set up, display, operate, and monitor the system. Used for daily painting functions
including choosing recipes, reading/clearing errors, and placing the system in Spray,
Standby, or Purge mode.
Installation
General Information
•
Reference numbers and letters in parentheses in
the text refer to numbers and letters in the illustra-
tions.
•
•
Be sure all accessories are adequately sized and
pressure-rated to meet system requirements.
To protect the Display Module screens from paints
and solvents, clear-plastic protective shields are
available in packs of 10 (Part No. 24G821). Clean
the screens with a dry cloth if necessary.
10
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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.
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.
Hazardous (Classified) Locations
Class 1, Div 1, Group D, T3 (US and Canada)
Class 1, Zone 1, Group IIA, T3 (ATEX only)
USER INTERFACE
MODULE
10' CAN CABLE
50' OPTION
18 PSI
1.5 FCM
(MIN)
USB MODULE
2' CAN CABLE
ALTERNATOR
MODULE
FLUID
CONTROL
MODULE
20" CAN CABLE
LINEAR SENSOR/
REED SWITCH CABLE
LINEAR SENSOR/
REED SWITCH CABLE
"B" REED
SWITCH
"A" REED
SWITCH
"B" LINEAR
SENSOR
"A" LINEAR
SENSOR
"A" PRESSURE
TRANSDUCER
"B" PRESSURE
TRANSDUCER
FIG. 1. Hazardous Location Installation
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Installation
Non-Hazardous Locations
USER INTERFACE
MODULE
10' CAN CABLE
50' OPTION
USB MODULE
LINE POWER
FILTER
POWER
SUPPLY
FLUID
CONTROL
MODULE
CAN CABLE
LINEAR SENSOR/
REED SWITCH CABLE
LINEAR SENSOR/
REED SWITCH CABLE
"B" REED
SWITCH
"A" REED
SWITCH
"B" LINEAR
SENSOR
"A" LINEAR
SENSOR
"A" PRESSURE
TRANSDUCER
"B" PRESSURE
TRANSDUCER
FIG. 2. Non-Hazardous Location Installation
12
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Installation
Display Module
Air Supply
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.
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.
2. Snap the Display Module
into the bracket.
ti16672a
3. Connect one end of the CAN
cable (provided) to J6 on the
Display Module (either port).
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.
ti16604a
J6
4. The other end of the cable
•
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.
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.
P3
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.
ti16580a
•
Wall Power Systems
without USB Module:
Connect CAN cable to
J8 on the Advanced
Fluid Control Module.
•
Air line filter: a 10 micron or better air filter is rec-
ommended to filter oil and water out of the air supply
and help avoid paint contamination and clogged
solenoids.
J8
ti16579a
•
Alternator Power Sys-
tems (with or without
USB Module): Connect
CAN cable to J3 on the
alternator.
J3
ti16456a
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Installation
Air Connections
Fluid Supply
tion).
Requirements
1. Tighten all ProMix 2KE system air and fluid line con-
nections as they may have loosened during ship-
ment.
• Do not exceed the pressure rating of the lowest
rated component. See the identification label.
2. Connect the main air supply line to the main air inlet.
This air line supplies the solenoids, valves, and
pumps. See FIG. 3.
• To reduce the risk of injury, including fluid
injection, you must install a shutoff valve between
each fluid supply line and the mix manifold. Use
the valves to shut off fluid during maintenance
and service.
ProMix 2KE models are available to operate airless
(high pressure, 50 cc pumps only), air spray, or
air-assisted systems with a capacity of up to 3800
cc/min.
Main Air
Inlet
•
•
Fluid supply pressure tanks, feed pumps, or circu-
lating systems can be used.
ti15708a
Materials can be transferred from their original con-
tainers or from a central paint recirculating line.
FIG. 3. Air Supply Inlet
NOTE: The fluid supply must be free of pressure spikes,
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.
3. For each gun in the system, connect a separate
clean air supply line to the air inlet of the air flow
switch. This air supplies gun atomizing air. The air
flow switch detects air flow to the gun and signals
the controller when the gun is being triggered.
Fluid Connections
1. See FIG. 5, page 15. Connect the solvent supply line
to the 1/4 npt(f) solvent valve inlets (SVA and SVB).
2. Connect the component A supply line(s) to the com-
ponent A dose valve inlet (DVA).
Atomizing
air outlets
NOTE: Paint Recirculating System Only
•
If you are recirculating paint, use the standard inlet
on Dose Valve A or Dose Valve B. Remove the plug
directly opposite it on the dose valve for the recircu-
lation outlet. See FIG. 5.
Atomizing
air inlets
3. Connect the component B line to the component B
dose valve inlet (DVB).
Solenoid
air inlet
ti15709a
FIG. 4. Connect atomizing air
4. Connect the gun fluid supply line between the mix
manifold (MM) outlet and the gun fluid inlet.
14
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Installation
Component
Inlet
Solvent inlet
Remove plug;
recirculation outlet.
ti16755a
ti16754a
SVB
SVA
DVB
DVA
PB
PA
ti15697a
MM
Key:
PA Component A Pump
DVA Component A Dose Valve
SVA Solvent Valve A
PB Component B Pump
DVB Component B Dose Valve
SVB Solvent Valve B
MM Mix Manifold
FIG. 5. Fluid Connections
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Installation
Tubing Chart and Diagrams
Type
Color
Description
Starting Point Ending Point Tube OD in. (mm)
Air
Green
Green
Green
Green
Red
Solvent Valve A On
Dose Valve A On
Solvent Valve B On
Dose Valve B On
Solvent Valve A Off
Dose Valve A Off
Solvent Valve B Off
Dose Valve B Off
1G
2G
3G
4G
1R
2R
3R
4R
A1
A2
A3
A4
A5
1G
2G
3G
4G
1R
2R
3R
4R
A1
A2
A3
A4
A5
A6
A7
A8
A9
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.25 (6.3)
0.375 (9.5)
0.375 (9.5)
-----
Air
Air
Air
Air
Air
Air
Red
Red
Air
Red
Air
Natural Solenoid Air
Air
Air
Natural Air Regulator to Pump B
Natural Air Regulator to Pump A
Fluid
Fluid
Fluid
Fluid
Air
----
----
----
----
Pump B to Valve Stack B
Pump A to Valve Stack A
Valve Stack A to Mix Manifold A6
Valve Stack B to Mix Manifold A7
-----
-----
-----
Natural Air Regulator to Alternator*
Black Alternator Air Exhaust*
A8
A9
0.375 (9.5)
0.5 (12.7)
Air
*
Used only on IS models.
1R
1G
2R 3R 4R
*
IS Models
ti16770a
2G
4G
3G
GFB1-C
GFB1-S
ATOM-1
A8*
A9*
ti13861a
GFB1-P
(Pressurized air line)
GFB1-A
ti16771a
GFB1-C
GFB1-S
ti13863a
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Installation
GFB1-A
ATOM-1
ATOM-2
A2
A3
A Side
B Side
A1
A3
ti16772a
2G
2R
4G
4R
1R
1G
3R
3G
A4
A5
A Side
B Side
ti16765a
ti16766a
A4
A5
See Manual 312784 for full
setup instructions for a gun
flush box.
A7
A6
B Side
A Side
ti16764a
3A0868G
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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.
Line
Enclose all cables routed in the spray booth and high
traffic areas in conduit to prevent damage from paint,
solvent, and traffic.
Ground
Neutral
The ProMix 2KE operates with 85-250 VAC, 50/60 Hz
input power, with a maximum of 2 amp current draw.
The power supply circuit must be protected with a 15
amp maximum circuit breaker.
ti16391a
FIG. 6. Control Box Electrical Connection
Not included with system:
TERMINAL
BLOCK
•
•
Power supply cord compatible to your local power
configuration. Wire gauge size must be 8-14 AWG.
L
L
N
GRND
POWER
SUPPLY
The input power access port is 22.4 mm (0.88 in.) in
diameter. It accepts a bulkhead strain relief fitting or
conduit.
GRND
N
LINE POWER
FILTER
L
N
1. Verify that electrical power at the main panel is shut
off. Open Control Box cover.
2A
2
1A
SWITCH
ROCKER
2. Connect electrical cord to the terminal block as
1
3. Close the Control Box. Restore power.
FIG. 7. Electrical Schematic
18
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Installation
Grounding
Air and Fluid Hoses
Use grounded hoses only.
The equipment must be grounded. Grounding
reduces the risk of static and electric shock by
providing an escape wire for the electrical current
due to static build up or in the event of a short circuit.
Spray Gun
Follow the grounding instructions in your gun manual.
•
•
Non-Electrostatic: Ground the spray gun through
connection to a Graco-approved grounded fluid sup-
ply hose.
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 con-
nection according to local codes.
Electrostatic: Ground the spray gun through con-
nection 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.
AC
Power
Object Being Sprayed
Follow local code.
Ground
Screw
All Solvent Pails Used When Purging
TI15712a
Follow local code. Use only conductive metal pails/con-
tainers placed on a grounded surface. Do not place the
pail/container on a nonconductive surface, such as
paper or cardboard, which interrupts the grounding con-
tinuity.
FIG. 8. Ground Screw and Power Switch
Gun Flush Box
Connect a ground wire from the Gun Flush Box ground
lug to a true earth ground.
Check Resistance
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.
To ensure proper grounding, resistance between
components and true earth ground must be less than
1 ohm.
3A0868G
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Installation
Key:
1
2
3
4
5
6
7
8
9
Control Box ground screw
Control Box ground wire
Pump B ground screw
Pump B ground wire
10
Pump A ground screw
Pump A ground wire
1
Gun Flush Box ground screw
Gun Flush Box ground wire
True Earth Ground - check your
local code for requirements.
2
3
10 Power cable, Display
Module/Control Box
4
5
6
9
7
8
ti16467a
FIG. 9. Grounding
20
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Display Module
Display Module
Potlife state
Error code
Screen number
Active recipe
Ratio
Operation mode; see
page 22 for key
LCD display
Potlife timers
Navigation keys
Flow rate
Enter key
Soft keys
Navigation keys
Error Reset
key
Standby key
ti16319a
Setup key
FIG. 10. Display Module
Keys are used to input numerical data, enter setup
screens, navigate within a screen, scroll through
screens, and select setup values.
Display
Shows graphical and text information related to setup
and spray operations. The screen backlight is factory
set to remain on. The user may set a number of minutes
the screen can be inactive before the backlight dims.
See Configure 3 (Screen 20), page 44. Press any key
to restore.
NOTICE
To prevent damage to the soft key buttons, do not
press the buttons with sharp objects such as pens,
plastic cards, or fingernails.
NOTE: The Display Module and bracket can be
removed from the cover of the electrical box and
mounted remotely, if preferred.
Up/Down Arrows: Use to move
among fields on a screen, items
on a dropdown menu, or digits
in a settable field.
Key
Function
Setup: Press to enter or exit
Setup mode.
Error Reset: Use to clear alarm
so cause can be fixed. Also use
to cancel a data entry field.
Enter: Press to choose a field to
update, to make a selection, or
to save a selection or value.
Standby: Stops the current
operation and puts the system
into standby.
Left/Right Arrows: Use to move
from screen to screen.
Soft keys: Press to select the
specific screen or operation
shown on the display directly
above each key.
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Display Module
Icon Key
The following tables present a printable version of the information on the ProMix 2KE icon card. See Table 3, page
52, for a printable version of the error code information on the reverse side of the card.
General Icons
Spray Gun States
Screen Shortcuts
I
I
I
Icon
Description
Icon
Description
Icon
Description
Pump
Mix
Home
Meter
Mix Spray
In Flush Box
Purge
Spray
Dose Valve
Solvent Valve
Air Filter
Alarm Log
Run Pumps
System Configuration
Recipes
Purge in Flush Box
Standby
Fluid Filter
Gun Flush Box
Park Pumps
Flush Time
Hose Length
Hose Diameter
Ratio
Idle
Maintenance
Calibrate
Locked
Operation Modes
Softkeys
I
I
Icon
Description
Icon
Description
Standby
Mix/Spray
Mix
Standby
Purge
Purge
Potlife
Color Change
Dispense A
Dispense B
Batch
Reset Counter
Start
Length
Volume
Stop/Standby
Pressure
Air Flow Switch
Flow Rate High/Low
Job Number
User Number
Calibrate
Forced
Park
Locked
22
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Display Module
Screen Summary
NOTE: This summary is a one-page guide to the ProMix 2KE screens, followed by screen maps. For operating
instructions, see Basic Operation, page 29. For further detail on individual screens, see Run Mode Details, page
Recipe (Screens 28 and 29)
Run Mode
•
Recipe 1-1 (Screen 28) and 1-2 (Screen 29)
control Material 1/Color 1 parameters and flush.
The run mode has three screen sections that control the
mixing operations.
Maintenance (Screens 24-26)
Mix (Screens 2-4, 38)
•
•
•
Maintenance 1 (Screen 24) controls mainte-
nance timer actual and target for Pump A,
Pump B, Solvent Valve A, and Solvent Valve B.
•
•
•
•
Spray (Screen 2) controls most mixing opera-
tions.
Batch (Screen 3) controls dispense of a set vol-
ume.
Maintenance 2 (Screen 25) controls dose
valves A and B maintenance timers, actual and
target.
Totals (Screen 4) displays grand and batch
totals for materials A and B.
Maintenance 3 (Screen 26) controls fluid and air
filter maintenance timers, actual and target.
Job Number (Screen 38) displays job number
and user number
Calibration (Screens 22 and 23)
Error Log (Screens 5-14)
•
Calibration 1 (Screen 22) controls pump factors
for Pump A and Pump B.
•
•
10 screens, 5 errors per page.
Displays date, time, and error.
•
Calibration 2 (Screen 23) allows the user to per-
form a calibration.
Pump Control (Screen 15)
•
•
Manually start or stop a pump.
Park pumps for brief shutdowns.
Troubleshooting
The troubleshooting mode has three screen sections
that allow an authorized user to troubleshoot system
Setup Mode
The setup mode has four screen sections that allow an
authorized user to choose the exact settings needed for
the system:
System Inputs (Screen 35)
Membrane Test (Screen 36)
System Outputs and Manual Activation (Screen 37)
Configure (Screens 18-21)
•
•
Configure 1 (Screen 18) controls system type
(pump or meter), gun flush box enable, and
number of guns (1 or 2).
Configure 2 (Screen 19) controls hose length
and diameter for one or two guns, flow rate
region setting, and air flow switch enable or
disable.
•
•
Configure 3 (Screen 20) controls language (for
optional USB Module), date format, date, time,
password setting, and backlight timer.
Configure 4 (Screen 21) controls units for dis-
tance, volume and pressure.
3A0868G
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Display Module
Ranges for User Inputs
This table is a one-sheet reference of the data range/options accepted for each user input and the default setting.
See the page indicated in the table for further screen information, if needed.
Page
Screen
User Input
Target Volume
Range/Options
1 to 9999 cc
Default
0 cc
Run Mix Batch (3)
40 Run Job Number (38)
000000000 to 999999999
0000 to 9999
000000000
0000 (disabled)
Meters
User Number
Password
Password (16)
Configure 1 (18)
Meters; 50cc Pump; 75cc Pump; 100cc Pump;
125cc Pump; 150cc Pump
On or Off
System Type
Configure 1 (18)
Configure 1 (18)
Configure 2 (19)
Configure 2 (19)
Configure 2 (19)
Off
1 gun
Gun Flush Box Enable
Number of Guns
1 or 2 guns
0.1 to 45.7 m / 0.3 to 150 ft
0.1 to 1 inch
1.53 m / 5.01 ft
0.25 inches
High
Gun 1 or Gun 2 hose length
Gun 1 or Gun 2 hose diameter
Flow Rate Region
High (250 cc/min or higher) or
Low (<250 cc/min)
On or Off
44
Configure 2 (19)
Configure 3 (20)
On
Air Flow Switch
Chinese; Dutch; English; French; German; Ital-
ian; Japanese; Korean; Portuguese;
Russian; Spanish; Swedish;
mm/dd/yy;
English
USB Log Language
44
Configure 3 (20)
mm/dd/yy
Date Format
dd/mm/yy;
yy/mm/dd
44
44
44
44
44
44
44
Configure 3 (20)
Configure 3 (20)
Configure 3 (20)
Configure 3 (20)
Configure 4 (21)
Configure 4 (21)
Configure 4 (21)
Recipe 1-1 (28)
01/01/00 to 12/31/99
Set at factory
Set at factory
0000 (disabled)
0 minutes
Feet/inches
Gallons US
psi
Date
00:00 to 23:59
0000 to 9999
Time
Password
Backlight Timer
Distance Units
Volume Units
Pressure Units
Ratio
0 to 99 minutes
Feet/inches or Meters/cm
Liters; Gallons US; Gallons Imperial
psi; Bar; MPA
0:1 to 30:1
Note: Enter 0 to dispense A only.
1 to 99 percent*
1:1
Recipe 1-1 (28)
Recipe 1-1 (28)
5 percent
Ratio Tolerance
Potlife Timer
0 to 240 minutes
Note: If set to 0, potlife alarm is disabled.
60 minutes
Recipe 1-2 (29)
0 to 240 seconds
Note: If set to 0, the valve(s) will not flush.
60 seconds
Flush Times- First (A purge),
Second (B purge), or Third
(using A or B, chosen by user)
Maintenance 1 (24)
Maintenance 1 (24)
0 to 9,999,999
0 to 9,999,999
0
0
Pump A or Pump B
Solvent Valve A or Solvent
Valve B
Maintenance 2 (25)
Maintenance 3 (26)
Calibration 1 (22)
0 to 9,999,999
0 to 9999 days
5 to 50 cc/in
0
Dose Valve A or Dose Valve B
Fluid Filter A or B, or Air Filter
Pump A or Pump B Factor
0 days
50cc: 10 cc/in.
75cc: 15 cc/in.
100 cc: 20 cc/in.
125cc: 25 cc/in.
150cc: 30 cc/in.
0 cc
Calibration 2 (23)
1 to 9999 cc
Actual Dispensed Volume
*
The system will attempt to hold whatever accuracy is entered. For some ratios and applications, testing shows that actual sys-
24
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Display Module
.
.
.
FIG. 11. Run Mode Screen Map
3A0868G
25
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Display Module
Password
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 Outputs 1
Set-Up Home
System Inputs
To
To
Screen
36
Screen
36
Push to enter forced
mode, (System Outputs 2)
System Outputs 2
To Membrane Test
To Setup Home
Membrane Test
FIG. 14. Troubleshooting Screen Map
28
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Basic Operation
Basic Operation
Non-IS Systems (Wall Power Supplied): Turn the
AC Power Switch ON (I = ON, 0 = OFF).
Pre-Operation Tasks
Go through the Pre-Operation Checklist in Table 1.
Table 1: Pre-Operation Checklist
✓
Checklist
System grounded
I = ON
Verify all grounding connections were made. See
All connections tight and correct
TI16336a
Verify all electrical, fluid, air, and system connec-
tions are tight and installed according to the man-
ual instructions.
FIG. 15. Power Switch
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.
Dose valves set
Check that dose valves are set correctly. Start
with the settings recommended in Valve Set-
Fluid supply valves open and pressure set
Component A and B fluid supply pressures should
be equal unless one component is more viscous
and requires a higher pressure setting.
FIG. 16. Run Mix Spray (Screen 2)
Solenoid pressure set
Initial System Setup
1. Change optional setup selections to desired param-
eters, as described in Configure 1-4 (Screens
75-100 psi inlet air supply (0.5-0.7 MPa, 5.2-7
bar)
Power On
2. Set recipe and flush information as described in
1. IS Systems (Alternator Power Supply): Set pump
air regulators to minimum setting. Open main air
valve to start air-powered alternator. Main air pres-
sure is displayed on gauge.
3. Set maintenance timers for pumps, valves, fluid fil-
ters and air filters, as described in Maintenance 1-3
3A0868G
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Basic Operation
8. Open the fluid supply valve to the
pump.
Prime the System
screen information, if needed.
NOTE: If using an electrostatic gun,
shut off the electrostatics before
spraying.
9. If using a gun flush box, place the gun in the box
and close the lid. Press
cycles.
. The pump will run 12
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).
If the gun flush box is not used, trig-
ger the gun into a grounded metal
pail until the system returns to
Standby.
2. If this is the first time starting up the system, or if
lines may contain air, purge as instructed in Purg-
weight oil, which should be flushed out to avoid
contaminating your material.
10. Press
to stop the pump before 12 cycles are
completed. If the pump is not fully primed after 12
cycles, press again.
3. From Run Home (Screen 1), press
. Make
11. Repeat for Pump B.
sure that the system is in Standby mode.
Standby
4. Press
5. Press
to show the dropdown menu.
to highlight Pump A, then press
.
6. Put Pump A into supply pail.
7. Adjust air pressure to component A
pump for your application. Use lowest
pressure possible.
NOTE: Do not exceed the maximum rated working pres-
sure shown on the system identification label or the low-
est rated component in the system.
30
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Basic Operation
Pump Calibration
6. Press
to start the calibration on the checked
pump (A 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
Calibrate the pump:
reached. Do not press
, as it will cancel the calibra-
tion.
•
The first time the system is operated.
8. The volume that the ProMix measured displays on
the Display Module.
•
Whenever new materials are used in the system,
especially if the materials have viscosities that differ
significantly.
Volume measured
by system displays
here.
•
•
At least once per month as part of regular mainte-
nance.
Whenever a pump is serviced or replaced.
Enter dispensed
volume here.
NOTE:
•
Pump factors on Calibration 1 (Screen 22) are
updated automatically after the calibration pro-
cedure is completed. You also may manually
edit them if desired.
FIG. 17. Dispensed Volume Comparison
9. Compare the amount on the Display Module to the
amount in the graduated cylinder.
•
•
All values on this screen are in cc or cc/in.,
regardless of the units set in Configure 4
(Screen 21).
NOTE: For maximum accuracy, use a gravimetric
(mass) method to determine the actual volumes dis-
pensed.
During each calibration the dispense valve will
close during an up stroke and a down stroke (in
either order). This test is to verify that the pump
ball checks are seating properly and not leak-
ing. If leaking occurs, the system will alarm after
the calibration for that particular valve.
•
If the screen and actual volumes are different, press
to highlight the dispense volume field. Press
. Press
to move between digits. Press
when field is
to change a digit. Press
1. Before calibrating pump A or B, prime the system
correct.
NOTE: If the value is substantially different, repeat the
calibration process until the dispensed volume and mea-
sured volume match.
2. If the display is on a Run Mode screen, press
to access setup screens.
3. Press
to display Calibration1 (Screen 22).
Pump calibration factors are shown for Pump A and
Pump B.
4. Press
to move to Calibration 2 (Screen 23).
5. Press
brate. Press
to highlight the pump you wish to cali-
. An X displays in the box.
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Basic Operation
10. After the volume for A or B is entered, the ProMix
2KE controller calculates the new pump factor and
shows it on Calibration 1 (Screen 22) and Calibra-
tion 2 (Screen 23).
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.
11. Before you begin production, clear the system of
solvent and prime it with 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 reg-
ulated fluid pressure of mixed material.
a. Go to Mix mode.
b. Trigger the gun into a grounded metal pail until
mixed material flows from the gun nozzle.
4. Turn on atomizing air to the gun. Check the spray
pattern as instructed in your spray gun manual.
NOTE:
Spraying
•
•
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.
screen information, if 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.
cally based on calibration results. Make additional
manual changes, if desired, as described in Cali-
Adjust the flow rate.
NOTICE
Do not allow a fluid supply tank to run empty. It is pos-
sible 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.
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
Purging
loaded, the system returns to Standby. Press
again to spray the loaded recipe.
screen information, if needed.
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.
There are 2 purging procedures in this manual:
•
•
Purging Mixed Material
Purging Fluid Supply System
Flow
rate
Use the criteria listed for each procedure to determine
which procedure to use.
FIG. 18. Flow Rate Display
32
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Basic Operation
9. Trigger the gun to relieve pressure. Engage trigger
lock.
Purging Mixed Material
There are times when you only want to purge the fluid
manifold, such as:
10. If spray tip was removed, reinstall it.
•
•
•
•
end of potlife
11. Adjust the solvent supply regulator back to its nor-
mal operating pressure.
breaks in spraying that exceed the potlife
overnight shutdown or end of shift
before servicing the fluid manifold assembly, hose
or gun.
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 sys-
tem.
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.
Purging Fluid Supply System
3. If you are using a high pressure gun, engage the
trigger lock. Remove spray tip and clean tip sepa-
rately.
Follow this procedure before:
•
•
•
the first time material is loaded into equipment
servicing
shutting down equipment for an extended period of
4. If using an electrostatic gun shut off the electrostat-
ics before flushing the gun.
time
•
putting equipment into storage
5. Set the solvent supply pressure regulator at a pres-
sure 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.
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.
6. If using a gun flush box, place the gun into the box
and close the lid.
3. If you are using a high pressure gun, engage the
trigger lock. Remove spray tip and clean tip sepa-
rately.
7. Press
on Run Mix Spray (Screen 2). The
purge sequence automatically starts.
4. If using an electrostatic gun, shut off the electrostat-
ics before flushing the gun.
If the gun flush box is not used, trig-
ger the gun into a grounded metal
pail until the purge sequence is com-
plete.
5. Disconnect the component A and B fluid supplies at
the pump inlets, and connect solvent supply lines.
6. Adjust the solvent fluid supply pressure. Use the
lowest possible pressure to avoid splashing.
When done purging, the system automatically
switches to Standby mode.
7. Remove the Control Box cover to access the sole-
noid valves. See FIG. 19.
8. If the system is not completely clean, repeat step 6.
NOTE: If necessary, adjust purge sequence times
so only one cycle is required.
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Basic Operation
8. Purge as follows:
9. Reinstall the Control Box cover.
10. Shut off the solvent fluid supply.
•
Purge component A side. Press the manual
override on the Dose Valve A solenoid valve
and trigger the gun into a grounded metal pail.
11. Disconnect the solvent supply lines and reconnect
the component A and B fluid supplies.
•
Purge component B side. Press the manual
override on the Dose Valve B solenoid valve
and trigger the gun into a grounded metal pail
until clean solvent flows from the gun.
NOTE: The system remains full of solvent.
•
Repeat to thoroughly clean the mix manifold.
Manual overrides
Solvent Valve A
Solenoid
Dose Valve A
Solenoid
ti15730a
Gun Flush Box Solenoid
location, if used.
Solvent Valve B
Solenoid
Dose Valve B
Solenoid
FIG. 19. Solenoid Valves in Control Box
34
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Basic Operation
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.
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.
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 mini-
mizes valve response time. To open dose or purge
valves (for high viscosity materials), turn hex nut (E)
counterclockwise. To close dose or purge valves (for
low viscosity materials), turn clockwise. See FIG. 21.
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.
E
2. Follow procedure for Purging Fluid Supply Sys-
tem, page 33, if desired or necessary.
3. Shut off air supply to A and B pumps and solvent
supply pumps.
4. With the gun triggered, push the manual override on
the A and B dose and solvent valve solenoids to
relieve pressure. See FIG. 19. Verify that fluid pres-
sure is reduced to 0.
TI11581a
5. Reinstall the Control Box cover.
FIG. 21. Valve Adjustment
Lock Mode
Shutdown
NOTE: Do not change system type, number of guns,
hose length or hose diameter when material is loaded in
the system. Change these inputs only if system hard-
ware is changed.
2. Close main air shutoff valve on air supply line and
on ProMix 2KE.
3. Non-IS Systems: Shut off ProMix 2KE power
If you change one of these inputs, the system 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. The lock icons dis-
play.
(0 position).
Lock
icons
FIG. 20. System Lock Mode
3A0868G
35
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Use of Optional USB Module
Use of Optional USB Module
NOTE: User Number, Ratio, and Alarm 1-5 are dis-
played as of 2KE System Software version 1.03.001
(USB Cube Software version 1.10.001).
USB Logs
Job Log 1
Error Log 2
umes 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, and mix ratio. Job total vol-
umes are in cubic centimeters. A log entry is made
when a new job is initiated, which occurs when batch
totals are cleared, or when the job number is incre-
mented from Run Job Number (Screen 38). Job infor-
mation is displayed on the Display Module only through
use of the optional USB Module.
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. 22. Sample Job Log
36
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Use of Optional USB Module
FIG. 23. Sample Error Log
Setup
Language
dropdown
menu
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 Config-
ure 3 (Screen 20). Select your language from the lan-
guage dropdown.
FIG. 24. Select Language for USB Logs
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Use of Optional USB Module
6. The USB flash drive window automatically opens. If
it does not, open USB flash drive from within Win-
Download Procedure
dows® Explorer.
7. Open Graco folder.
Remove proportioner from hazardous location before
inserting, downloading, or removing the USB flash
drive.
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.
1. Press
on Run Mix Spray (Screen 2) or
9. Open DOWNLOAD folder.
from any screen to place the system in Standby.
10. Open folder labeled with the highest number. The
highest number indicates the most recent data
download.
NOTE: The system will not operate with a USB flash
drive in the port. If you insert the flash drive while spray-
ing, the system will stop and an alarm error will occur.
11. Open log file. Log files open in Microsoft® Excel® by
default. However, they can also be opened in any
2. Insert USB flash drive into USB port. Use only
Graco-recommended USB flash drives; see Rec-
text editor or Microsoft® Word.
NOTE:
3. Data download begins automatically. An LED on the
flash drive blinks until the download is complete.
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 mod-
ule flashes until the download is complete.
Recommended USB Flash
Drives
4. Remove flash drive from USB port.
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).
To help prevent fire and explosion, never leave the
USB flash drive in the USB port.
•
•
•
Crucial Gizmo!™ 4GB USB flash drive (model
JDO4GB-730)
Transcend JetFlash® V30 4GB USB flash drive
(model TS4GJFV30)
OCZ Diesel™ 4GB USB flash drive (model
OCZUSBDSL4G)
USB Port
TI15712a
FIG. 25. USB Port
5. Insert USB flash drive into USB port of computer.
38
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Run Mode Details
Run Mode Details
•
•
Press a soft key button to select one of the main
Run Mix Spray (Screen 2)
Run Mode screen sections: Mix
or Pump Control
Press to enter the Setup screens.
, Errors
,
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.
.
Gun status
Target ratio
1 Gun
Run Mix Batch (Screen 3)
Actual
ratio
Flow rate
Run Mix Batch (Screen 3) displays if
is selected
from the Run Mix Spray Screen. Use the Mix Batch
screen to dispense set volumes. Target volume can be
set from 1 to 9999 cc.
Potlife
time
Mix
Purge
Home
Standby
2 Guns
Target ratio
Actual ratio
Target volume
Actual volume
Potlife for
each gun
Stop
FIG. 28. Run Mix Batch (Screen 3)
Home
Start
FIG. 26. Run Mix Spray (Screen 2)
•
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).
•
Press
to toggle between Run Mix Spray
•
Press
to access Run Home (Screen 1).
(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. 27. Run Home (Screen 1)
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Run Mode Details
Run Mix Totals (Screen 4)
Run Job Number (Screen 38)
Run Mix Totals (Screen 4) displays if
is
Run Job Number (Screen 38) displays if
is
selected from the Run Mix Batch Screen. Use this
screen to view grand and batch totals for material A and
material B, and to clear batch totals if desired.
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.
Batch total
Job number
User number
Grand tota
Home
l
Home
Clear batch totals/
increment job
FIG. 31. Run Job Number (Screen 38)
FIG. 29. Run Mix Totals (Screen 4)
•
Press
to set the user number. Use
to
•
Press
to clear all batch totals. A verification
change each digit, then
to move to the next
screen appears. Use
to highlight and press
digit. Press
Press
when finished.
on the
to clear the batch totals, or on the
to return to Run Totals (Screen 4) without clearing.
•
•
increment the job number.
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).
FIG. 30. Confirm Clear Batch Totals
Run Log Errors (Screens 5-14)
•
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 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 1-5;
Screen 6 displays errors 6-10, etc.).
Error codes
Error Icons
FIG. 32. Run Log Errors (Screen 5)
•
Use
icons. See Table 3, page 52, for an explanation of
the different error codes.
40
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Run Mode Details
Run Pump Control (Screen 15)
Run Pump Control (Screen 15) displays if
is
selected from the Run Home Screen. Use this screen to
manually start and stop a pump.
Pump/Park selection
dropdown
Start
Stop
Home
FIG. 33. Run Pump Control (Screen 15)
•
•
Press
to show the dropdown menu.
Press
to highlight, then press
to select
a pump or the Park option.
•
•
If Pump A or Pump B is selected, use
start. The selected pump will run for 12 cycles. To
or
to
stop before the 12 cycles are completed, press
.
If Park is selected, use
to move the pump to the
bottom of the stroke to park it so pump rod is fully
enclosed in the lower and material can’t dry on shaft
during break or overnight.
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Setup Mode Details
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.
Software Version:
Display Module
Fluid Control Module
USB Module
Password (Screen 16)
From any Run screen, press
to access the pass-
Configure Recipe Maintenance Calibration
FIG. 35. Setup Home (Screen 17)
word screen. The Password Screen displays if a pass-
word has been set. Set the password to 0000 to prevent
Password (Screen 16) from displaying. See Configure 3
(Screen 20), page 44, to set or change the password.
•
Press a soft key button to select one of the four
Setup Mode screen sections:
Configure
, Recipe
.
, Maintenance
, or
Calibration
•
Press
Mode.
to toggle between Run Mode and Setup
FIG. 34. Password (Screen 16)
•
Press
Press
to enter the password (0000 to 9999).
to move between digits. Press
to change a digit. Press
when field is
correct. Setup Home (Screen 17) displays.
•
•
Press
Mode.
to toggle between Run Mode and Setup
Select
to display Run Home (Screen 1). Enter-
ing 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 the Password Screen. The
Setup Home screen displays the software versions of
the boards in the Display Module, Advanced Fluid Con-
trol Module, and the USB Module (if applicable).
42
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Setup Mode Details
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) and number of
guns (1 or 2).
NOTE: If 1 gun is selected, users can enable a gun flush
box (✓=yes; X=no). The gun flush box option is avail-
able only for 1-gun systems.
FIG. 37. 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 informa-
tion 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.
For all pump systems, the type of dosing is dynamic,
and the number of colors is 1. See Dynamic DosingDy-
Gun flush
box
System
type
Users also can configure the flow rate region and the air
flow switch. The flow rate region (High/Low) determines
the sensitivity of the overdose alarm:
Number
of guns
•
Select the High
cc/min or higher. The High setting has a 100cc over-
dose volume.
setting if your flow rate is 250
Home
FIG. 36. Configure 1 (Screen 18)
•
Select the Low
setting if your flow rate is less
•
Press
to display the dropdown menu for that field.
Press to choose from the menu options and
to set. Press
to highlight the desired field. Press
than 250 cc/min. The Low setting has a 50 cc over-
dose volume.
The air flow switch can be disabled here for airless
applications. Select to enable or to disable.
to move to the next field.
A change in any of these fields will trigger the lock. See
NOTE in previous paragraph.
•
Press
to move through Configure 2 (Screen
19), Configure 3 (Screen 20), and Configure 4
(Screen 21).
Gun 2
hose
length
Gun 1
hose
length
NOTE: If you change system type (pump to meter) or
number of guns, a verification screen appears. Use
Gun 2
hose
Gun 1
hose
to highlight and press
on the
to make the
diameter
diameter
change, or on the to return to Configure 1 (Screen
Air
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.
Flow rate
region
flow
switch
Home
FIG. 38. 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 pre-
ferred units for distance, volume, and pressure.
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Setup Mode Details
Recipe 1-2 (Screen 29)
Note about Settings of 0: If a Flush time is set to 0,
USB log
language
Date
format
that valve will not flush.
Password
Recipe 1-2 (Screen 29) includes timers for first, second
and third flush:
Date
Time
Backlight
timer
•
•
•
First flush: Always an A side purge, using the A side
flush material from the A purge valve.
Configure 3
Second flush: Always a B side purge, using the B
side flush material from the B purge valve.
Distance
units
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).
Pressure
units
Volume
units
Home
Configure 4
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.
FIG. 39. Configure 3 (Screen 20) and Configure 4
(Screen 21)
ethiordf 0flussehcownidths tthoesAkippuargfleus
v
h
a.lvFeorfoerx3a0mspelec,oenndtse.r
0
seconds for A, 30 seconds for B, 30 seconds for the third flush time, and select
A
for the third flush source. The system will skip the first
A
flush, go directly to the second flush with the
B
purge valve for 30 seconds followed by the
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.
Third flush time
(uses material
set in next field)
First flush time
(A purge)
Recipe
number
Recipe 1-1 (Screen 28) displays if
is selected on
Thirdflush
source
Setup Home (Screen 17). The Recipe Screens allow the
user to set up the basic recipe. Recipe 1-1 (Screen 28)
includes the ratio of Material A to Material B (0 to 30),
ratio tolerance (1 to 99 percent), and potlife time (0 to
240 minutes).
Second
flush time
(B purge)
Home
FIG. 41. Recipe 1-2 (Screen 29)
•
Press
to highlight the desired field and press
to move between dig-
to change a digit. Press when
to select. Press
Recipe
number
its. Press
Potlife
timer
field is correct.
Ratio
•
•
Press
screens.
to toggle between the Recipe
Ratio
tolerance
Home
FIG. 40. Recipe 1-1 (Screen 28)
Press
to return to Setup Home (Screen 17).
44
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Setup Mode Details
Maintenance 1-3 (Screens 24-26) Maintenance Recommendations
The following table shows recommended starting values
for maintenance. Maintenance needs will vary based on
individual applications and material differences.
Maintenance 1 (Screen 24) displays if
is selected
on Setup Home (Screen 17). The Maintenance Screens
display actual and target maintenance timers for pumps
and solvent valves (Maintenance 1, Screen 24), dose
valves (Maintenance 2, Screen 25), and fluid filters and
air filters (Maintenance 3, Screen 26). Maintenance tim-
ers for pumps and valves are settable from 0 to
9999999. Timers for filters are settable from 0 to 9999
days.
Recommended Maintenance
Component
Frequency
Solvent Valves 1,000,000 cycles
Fluid Filter
Air Filter
daily
monthly
Pumps
250,000 cycles
1,000,000 cycles
Solvent valves
Dose Valves
Pumps
Maintenance
actual and
target
Maintenance 1
Clear
Totals
Home
Dose
valves
Maintenance 2
Air filter
Fluid
filters
Days
Maintenance 3
FIG. 42. Setup Maintenance 1-3 (Screens 24-26)
•
Press
to move through the three mainte-
nance screens.
•
Press
to clear the maintenance total that is
highlighted. A verification 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.
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Setup Mode Details
Calibration 1 and 2 (Screens 22
and 23)
instructions.
•
•
Press
to highlight the pump you wish to cali-
. An X displays in the box.
brate. Press
Press
to start the calibration on the highlighted
pump (A or B). Press
to cancel the calibration.
Calibration 1 (Screen 22) displays if
is selected on
Setup Home (Screen 17). This screen displays the
pump factor for Pump A and Pump B. The factor is the
pump displacement per inch. The system starts at the
default factor for the pump size chosen on Configure 1
cally as needed based on calibration results from Cali-
bration 2 (Screen 23). Factor values also can be set on
this screen, from 5 to 50 cc/in.
NOTE: If you press
check to be sure that you have selected Pump A or
Pump B.
but calibration does not begin,
•
Press
to highlight the actual dispense vol-
ume field. Press
9999 cc). Press
to set the volume (from 0 to
to move between digits.
Press
field is correct.
to change a digit. Press
when
Pump B
Factor
•
Use
to toggle between Calibration 1
(Screen 22) and Calibration 2 (Screen 23).
PumpA
Factor
Home
Troubleshooting (Screens
35-37)
FIG. 43. Calibration 1 (Screen 22)
Press
to display Calibration 2 (Screen 23). This
Screens for testing system controls can be accessed by
setting the password to 9909. See Configure 3 (Screen
20), page 44, to set or change the password.
screen allows the user to perform a calibration. It dis-
plays Pump A and Pump B factors, the target dispense
volume, the actual dispense volume (0 to 9999 cc), and
the material to dispense.
After setting the password to 9909, press
to exit
Setup. Press to reenter Setup. Setup Home
(Screen 17) displays, with troubleshooting screen
options.
Pump B
Factor
Material to
dispense
Target
dispense
volume
Troubleshooting
screen options
appear here.
Pump A
Factor
Actual
dispense
volume
Start Pump
Calibration
Cancel Pump
Calibration
Home
FIG. 44. Calibration 2 (Screen 23)
FIG. 45. Setup Home with Troubleshooting
46
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Setup Mode Details
Troubleshooting System Inputs (Screen 35)
Troubleshooting System Outputs
(Screen 37)
From Setup Home (Screen 17) with Troubleshooting
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
Pump B is up or down, if Pump A is up or down, if Air
Flow Switch 1 or 2 is on, and if the gun is in the Gun
Flush Box. This screen also displays the pressure of
Pump A and Pump B. The fields relating to meter func-
tion can be ignored.
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 are used only for meter systems), solvent
valves (B and A), the gun flush box, and the alarm.
Press
to start Forced Mode. A second set of check
to highlight an output to
boxes displays. Use
Air Flow
test. Manually actuate the valve, alarm, or gun trigger
corresponding to the highlighted box. For properly work-
ing components, an X will display in the second box
Switch on
Pump B
up or
down
Pump
Pressures
upon actuation. Press
to exit Forced Mode. Moving
to any other screen also will exit Forced Mode.
Meter
Pump A
up or
down
Pulses
(not used)
Dose
Valves
Solvent
Valves
Gun in Gun
Flush Box
Gun
Trigger
FIG. 46. Troubleshooting System Inputs (Screen 35)
Alarm
•
Press , then again to move to Trouble-
Start
Forced
Mode
shooting System Outputs (Screen 37). Press
move to the Membrane Test (Screen 36).
to
Membrane Test (Screen 36)
From Setup Home (Screen 17) with Troubleshooting
active, press
, then
again. Membrane Test
, then
(Screen 36) displays. You could also press
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.
Stop
Forced
Mode
FIG. 48. Troubleshooting Screen Outputs (Screen 37)
FIG. 47. Membrane Test (Screen 36)
•
Press
three times to return to Setup Home
(Screen 17). Direct access to any other screen is
not possible.
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Setup Mode Details
Dynamic Dosing
In typical operation (ratios 1:1 and above), component A
dispenses constantly. Component B dispenses intermit-
tently in the necessary volume to attain the mix ratio.
Balancing A/B Pressure
If component B pressure is too high, it will push the com-
ponent A stream aside during B injection. The valve will
not open long enough, causing a Ratio High error.
General Operating Cycle, Dynamic Dosing
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.
Overview
Dynamic Dosing provides on-demand proportioning,
eliminating the need for an integrator and therefore min-
imizing undesired material contact. This feature is espe-
cially useful with shear-sensitive and waterborne
materials.
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.
A restrictor injects component B into a continuous
stream of component A. The software controls the dura-
tion and frequency of each injection. See FIG. 52 for a
schematic diagram of the process.
FIG. 50 shows the A to B pressure balance, read at the
proportioner inlet. It is recommended that the compo-
nent 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.
Dynamic Dosing System Parameters
The following parameters affect dynamic dosing perfor-
mance:
•
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.
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.
•
•
Component B Flow: Ensure that the supply pump is
sized to provide sufficient and uninterrupted flow.
In dynamic dosing, component A dose valve is con-
stantly on. Component B dose valve will cycle on and
off; one cycle every 0.5 – 1.0 seconds indicates proper
balance.
Component A Pressure: Ensure precise pressure
regulation. It is recommended that the component A
pressure be 5-15% lower than the component B
pressure.
Monitor system performance by watching the pressure
readings for each pump on Run Pump Control (Screen
15).
•
Component B Pressure: Ensure precise pressure
regulation. It is recommended that the component B
pressure be 5-15% higher than the component A
pressure.
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 pul-
sation, install a fluid regulator on the A and B supply
lines upstream of the meters.
FIG. 49. Monitor Pump Pressures
Select a Component B Restrictor Size
Warning messages also provide information on system
performance. Adjust pressures accordingly. See Table 2
on page 49.
If you cannot maintain the desired flow and spraying
ratio, you may need to select a different restrictor. Use
the charts on pages 61 to 65 to select an appropriate
restrictor size based on the desired flow and mix ratio.
48
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Setup Mode Details
e
)
e
g
l
g
n
l
a
n
R
a
l
R
o
o
r
o
l
t
t
B Pressure
Too Low
o
r
n
(
a
o
t
C
m
n
s
o
C
B Pressure
Too Low
B Pressure
Too High
B Pressure
Too High
A Pressure
B Pressure
A Pressure
B Pressure
FIG. 50. A/B Control Range with Properly Sized
Restrictor
NOTE: If the restrictor is too small, it may be
necessary to supply more differential pressure
than is available in your system.
FIG. 51. A/B Control Range with Too Large a
Restrictor
ToStatic
Mixer
Component A (continuous flow)
Proportioned Material
Component B (pulsed injection)
FIG. 52. Schematic Diagram of Dynamic Dosing Operation
Table 2: Dynamic Dosing Troubleshooting Guide
(for complete system troubleshooting, see Table 3 beginning on page 52)
Error Message
Ratio Low Error (R1)
Solution
•
•
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.
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System Errors
System Errors
NOTE: Do not use the fluid in the line that was dis-
pensed off ratio as it may not cure properly.
Record - no icon
Alarm icon
System Alarms
System alarms alert you of a problem and help prevent
off-ratio spraying. If an alarm occurs, operation stops
and the following occurs:
Advisory icon
FIG. 54. Error Log Icons
•
•
Alarm buzzer sounds.
Status bar on the Display Module shows the alarm
code.
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
40, to view the last 50 errors, with date and time stamps.
•
Alarm is saved in the date/time stamped log.
Error Code Indicator
To reset alarms, see Table 3, and Alarm Troubleshoot-
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 trig-
gered. The gun icon on the Display Module shows spray
when the AFS is activated.
FIG. 53. Display Module Alarm Codes
If a pump fails, pure resin or catalyst could spray indefi-
nitely if the ProMix 2KE does not detect the condition
and intervene, which is why the AFS is so important.
System Advisory/Record Codes
TABLE 3 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 Mod-
ule 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.
If the ProMix 2KE detects through the AFS signal that
the gun is triggered, yet one or both of the pumps are
not running, a Dose Time Alarm (QTA1 or QTB1) occurs
after 40 seconds and the system goes into Standby.
NOTE: Systems with a 45:1 pump ratio are designed for
use with an airless gun. These systems contain no air
flow switch and are set up so that they do not trigger a
System Idle Warning.
NOTE: For airless applications with other pump ratios,
the air flow switch can be disabled on Configure 2
(Screen 19).
50
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System Errors
System Idle Warning (IDLE)
This warning occurs if the ProMix 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. This warning is not active in
systems with a 45:1 pump ratio, using an airless gun.
In applications using the AFS, triggering the gun clears
the warning and you can start spraying again.
Without the AFS, triggering the gun does not clear the
alarm. To start spraying again, you must press
,
then
, then trigger the gun.
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System Errors
Error Codes
Table 3: System Alarm/Advisory/Record Codes
Code Description Details
Table 3: System Alarm/Advisory/Record Codes
Code Description
Details
Advisory Codes - No alarm, system continues operat-
ing, icon displays on active screen until cleared
Alarm Codes - Alarm sounds, system stops, icon dis-
plays until problem is solved and alarm is cleared.
MAA1 Pump A maintenance due
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
CA
Communication Error
54
54
MAB1 Pump B maintenance due
CAU1 USB Communication Error
MEA1 Mix valve A maintenance due
MEB1 Mix valve B maintenance due
MESA Solvent valve A maintenance due
MESB Solvent valve B maintenance due
MGA1 Fluid Filter A maintenance due
MGB1 Fluid Filter B maintenance due
MGP1 Air Filter maintenance due
EQU2 USB Installed when not in Standby
SG
Gun Flush Box Error
SAD1 Atomizing Air During Purge - Gun 1
SAD2 Atomizing Air During Purge - Gun 2
SFA1 PreMix Error - Color
SFB1 PreMix Error - Catalyst
SHA1 PreFill Error - Color
SHB1 PreFill Error - Catalyst
ES
System defaults loaded
SM
SN
MixFill Start Error
Record Codes - No alarm, system continues operating,
no icon displays on active screen.
MixFill Complete Error
QPD1 Potlife Error - Gun 1
QPD2 Potlife Error - Gun 2
EL
EC
EP
ET
System powered on
N/A
N/A
N/A
System setup changed
Pump park operation completed
R1
R4
Ratio Low Error
Ratio High Error
System performed an autodump after N/A
a potlife
QDA1 Overdose A, B Dose too Short
QDB1 Overdose B, A Dose too Short
EQU1 USB Drive connected while in Standby N/A
QTA1 Dose Time A Error
QTB1 Dose Time B Error
QLAX Leak Error A
QLBX Leak Error B
DJA1
DJB1
Linear Sensor Error - Pump A
Linear Sensor Error - Pump B
DKA1 Reed Switch Error - Pump A
DKB1 Reed Switch Error - Pump B
P4A1
P4B1
Pressure High Error - Pump A
Pressure High Error - Pump B
P6A1
P6B1
Pressure Transducer Error - Pump B
DDA1 Diving/Cavitation Error - Pump A
DDB1 Diving/Cavitation Error - Pump B
EFA1 Park Error - Pump A
EFB1 Park Error - Pump B
DFA1 Stall Up Error - Pump A
DFB1 Stall Up Error - Pump B
DGA1 Stall Down Error - Pump A
DGB1 Stall Down Error - Pump B
DHA1 No Stall Error - Pump A
DHB1 No Stall Error - Pump B
52
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System Errors
Alarm Troubleshooting
Alarm and Description
Cause
Solution
CA
The CAN cable between the Display Mod- Verify that the cable is correctly
ule and the Advanced Fluid Control Module connected.
is not connected.
Communication Error
The Display Module is not
communicating with the
Advanced Fluid Control
Module.
The CAN cable is cut or bent.
Verify that the cable has not been cut
or bent at a radius smaller than 1.6 in.
(40 mm).
The cable or connector failed.
Alternator Powered Systems:
Replace cable.
1. For any module that does not
have power, disconnect and
check the voltage on the cable
produced by the alternator mod-
ule (See Alternator Module Power
Output). If the proper voltage is
not detected, troubleshoot the
Alternator Module.
Check that the Advance Fluid Control Mod-
ule (AFCM), Display Module (DM), and
USB Module have power (green LED) and
are communicating (amber LED blinking)
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.
There may be a short in one of the sole-
noid/meter cables connected to the AFCM.
Replace the cable (16E890)
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.
Replace the module.
The DM and the AFCM have different ver- Install the latest software from token
sions of software installed.
kit 16D922 on all modules.
The red LED on the AFCM is on.
If on solid, replace module.
If blinking, contact your distributor.
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.
CAU1
The module has been removed.
Put system in standby and install the
USB Module.
Put system in standby and reconnect
or replace the USB cable.
USB Communication Error
The system detected a USB
Module at last power up, but
does not detect it currently.
The cable is disconnected or broken.
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System Errors
Alarm and Description
Cause
Solution
EQU2
Most USB drives do not conform to IS stan- Put system in Standby. Insert the
USB Drive Error
The USB drive has been
inserted when the system is
not in Standby.
dards, so it is hazardous to use one while
the system is running.
USB drive only in a non-hazardous
environment.
SG
The cover of the gun flush box is not
closed.
Close the cover and clear the alarm.
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.
Purge the system with solvent or
fresh mixed material:
For systems with a gun flush box, the gun is
not in the box when purge is active.
•
Solvent Purge - See Purging
Mixed Material on page 33. The
system purges until the preset
purge time is complete.
NOTICE
To prevent mixed material from
curing in the equipment, do not
shut off power. Follow one of
the solutions at right.
•
New Mixed Material Purge - Go
to Mix mode and spray the
required volume to restart the
potlife timer.
SAD1 or SAD2
Replace air flow switch.
Atomizing air is stuck on.
Atomizing Air During Purge
Atomizing air to Gun 1 (SAD1)
or Gun 2 (SAD2) is detected
when purge is selected or dur-
ing purge sequence.
Insert the gun into the Gun Flush Box.
Gun is not in Gun Flush Box.
Gun Flush Box air shutoff is not working.
Test using Troubleshooting Screens.
off valve as needed.
Inspect air line for kinks, damage, or
loose connections. Repair or replace
as needed.
Air leak in atomizing air line.
54
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System Errors
Alarm and Description
Cause
Solution
SFA1 or SFB1
PreMix Error
Check components and clean, repair,
or replace as necessary.
Gun, line, or valve is plugged or stuck.
In systems with a gun flush
box, insufficient quantity of
resin/color (SFA1) or catalyst
(SFB1) is detected during the
10-second PreMix sequence.
Refill fluid supply. Check and repair
pump. See pump manual for repair
procedures and replacement parts.
Pump(s) not working or out of fluid.
Check air line path. See System
67. Verify that solenoid is working.
Air lines or solenoids are plumbed incor-
rectly or solenoids are not working.
SHA1 or SHB1
PreFill Error
Increase fluid pressure.
Flow rate is too low.
Total PreFill sequence volume
is not reached for color
(SHA1) or catalyst (SHB1)
during the 5-minute PreFill
sequence.
SM
Verify trigger is being pulled. Adjust
as needed.
Clean line, tip, or filter.
Gun Flush Box is not triggering gun.
MixFill Start Error
In systems with a gun flush
box, insufficient volume of
mixed material is detected
during the 10-second mixed fill
sequence.
Line or gun is plugged or restricted.
Flow rate is too low.
Increase fluid pressure or decrease
restriction.
Clean valve or verify that solenoid is
triggering valve properly.
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
the mixed material for Gun 1
(QPD1) or Gun 2 (QPD2).
Purge the mixed material line. See
page 33.
Have not sprayed enough volume to keep
fresh mixed fluid in the mix manifold, hose,
and gun.
Check that hose length and diameter
have been entered correctly. See
Spray the required volume to restart
the potlife timer.
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System Errors
Alarm and Description
Cause
Solution
R1
There is too much restriction in the
system.
•
•
•
Check that the system is fully
loaded with material.
Ratio Low Error
The mix ratio is lower than the
set tolerance for an A to B
component volume compari-
son.
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
clogged.
•
Check that the fluid regulator is
set properly.
If the alarm occurs during start up, after
purging, the flow rate was probably too
high.
Restrict gun needle travel to slow
down the initial fluid delivery rate until
fluid hoses are loaded with material.
If the alarm occurred after you were spray- Adjust component A and B fluid sup-
ing for some time, the pressures from the
fluid supplies could be unbalanced.
ply regulator pressures until they are
about equal. If the pressures are
already about equal, verify that com-
ponent A and B dose valves are oper-
ating properly.
Slow actuation of the component A or B
valves. This can be caused by:
Manually operate the Dose Valve A
and B solenoid valves as instructed in
the ProMix 2KE Repair-Parts manual
to check operation.
•
•
Air pressure to the valve actuators is
too low.
•
Increase air pressure. Air pres-
sure must be 75-120 psi
(0.52-0.84 MPa, 5.2-8.4 bar); 120
psi is recommended.
Something is restricting the solenoid or • There may be dirt or moisture in
tubing and interrupting valve actuation
air.
the air supply. Filter appropri-
ately. Verify that solenoids are
operational.
•
•
Dose Valve B is turned in too far.
Dose Valve A is open too far.
Fluid pressure is high and air pressure
is low.
•
•
35, for adjustment guidelines.
Adjust air and fluid pressure. See
recommended air pressure
above.
56
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System Errors
Alarm and Description
Cause
Solution
R4
There is too little restriction in the system.
•
•
•
Check that the system is fully
loaded with material.
Ratio High Error
The mix ratio is higher than
the set tolerance for an A to B
component volume compari-
son.
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.
If the alarm occurs during start up, after
purging, the flow rate was probably too
high.
Restrict gun needle travel to slow
down the initial fluid delivery rate until
fluid hoses are loaded with material.
If the alarm occurred after you were spray- Adjust component A and B fluid sup-
ing for some time, the pressures from the
fluid supplies could be unbalanced.
ply regulator pressures until they are
about equal. If the pressures are
already about equal, verify that com-
ponent A and B dose valves are oper-
ating properly.
Slow actuation of the component A or B
valves. This can be caused by:
Manually operate the Dose Valve A
and B solenoid valves to check oper-
ation.
•
Air pressure to the valve actuators is
too low.
•
Increase air pressure. Air pres-
sure must be 75-120 psi
(0.52-0.84 MPa, 5.2-8.4 bar); 120
psi is recommended.
•
Something is restricting the solenoid or • There may be dirt or moisture in
tubing and interrupting valve actuation
air.
the air supply. Filter appropri-
ately.
•
•
Dose Valve B is turned in too far.
Dose Valve A is open too far.
Fluid pressure is high and air pressure
is low.
•
•
35, for adjustment guidelines.
Adjust air and fluid pressure. See
recommended air pressure
above.
QDA1
Valve seal or needle/seat are leaking.
Repair the valve.
Overdose A
Slow actuation of component A or B valves. See Ratio Low Error and Ratio High
The A dose has overshot and,
when combined with B, is too
large for the mix manifold
capacity.
Running a high mix ratio and a high flow
rate.
It may be necessary to restrict the
flow rate through the component B
dose valve by adjusting its hex nut.
QDB1
Overdose B
The B dose has overshot,
forcing an A dose that, when
combined with B, is too large
for the mix manifold capacity.
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System Errors
Alarm and Description
Cause
Solution
QTA1 or QTB1
Dose Time Error
System is in Mix mode and gun is only par- Fully trigger the gun.
tially triggered, allowing air but no fluid to
The gun trigger is active, but pass through gun.
no A pump (QTA1) or B pump
(QTB1) movement is detected
during the dose time selected.
Fluid flow rate is too low.
Increase flow rate.
Slow actuation of component A or B valves. See Ratio Low Error and Ratio High
A or B pump has no air pressure.
Verify that main air supply is turned
on and valves are open.
There is an air leak downstream from the
air flow switch.
Check the air lines for leaks and
repair.
The air flow switch is stuck open.
A or B dose valve leak
Clean or replace air flow switch.
Replace valve needle and seat.
QLAX or QLBX
Leak Error
Pump A (QLAX) or Pump B
(QLBX) is running with all
valves closed.
A or B pump is not seating and continues
to move/creep.
Replace pump packings, balls, and
seats.
DJA1 or DJB1
Verify that sensor is plugged in. Verify
that sensor and AFCM are opera-
tional. Verify cable connections.
Replace any malfunctioning compo-
nent.
Sensor not recognized by system.
Linear Sensor Error
System does not detect the
pump A (DJA1) or pump B
(DJB1) linear position sensor,
or has an invalid position read-
ing.
Replace magnet and holder on top
side of air motor piston.
Magnet fell off.
Verify that the sensor is threaded
down
Sensor readings are out of range.
completely.
DKA1 or DKB1
Reed Switch Error
Flip reed switch 180 degrees to align
with magnet in air valve.
Reed switch installed backward.
System does not detect the
pump A (DKA1) or Pump B
(DKB1) reed switch sensor, or
detects an invalid state.
Verify cable is connected on both
ends. Verify that reed switch, cable,
and AFCM are operational. Replace
any malfunctioning component.
Reed switches are stuck, or both reed
switches are on at once
Verify that magnet is installed prop-
erly and is operational.
Magnet in air valve not functioning prop-
erly.
P4A1 or P4B1
Reduce pressure on air supply to sys-
tem or pumps.
Pump air pressure is set too high.
Pressure High Error
System detects a high pres-
sure reading on pump A
(P4A1) or pump B (P4B1).
Relieve pressure if system has been
idle. Decrease environmental
temperature.
Thermal expansion occurring in lines.
Replace transducer. Verify that cable
and AFCM are operational.
Pressure transducer malfunction.
Pressure transducer malfunction.
P6A1 or P6B1
Replace transducer. Verify that cable
and AFCM are operational.
Pressure Transducer Error
System does not detect pres-
sure transducer A (P6A1) or
pressure transducer B (P6B1).
58
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System Errors
Alarm and Description
Cause
Fluid supply is empty.
Solution
DDA1 or DDB1
Refill fluid supply system.
Diving/Cavitation Error
Pump A (DDA1) or Pump B
(DDB1) is diving or cavitating.
Rebuild displacement pump and
replace packings, balls, and seats.
Tighten all fittings.
Displacement pump is not seating properly.
Air in fluid supply system.
Gun not open.
EFA1 or EFB1
Park Error
Trigger gun and allow fluid to flow
while pump is attempting to park.
Pump A (EFA1) or Pump B
(EFB1) does not park (does
not reach bottom change-
over).
Check and clear all fluid lines, gun tip,
and the mix manifold.
Fluid lines plugged.
Clean or rebuild dispense valve. Ver-
ify that solenoid is operational. Clear
air lines to valve.
Dispense valve malfunction.
DFA1 or DFB1
Stall Up Error
Pump A (DFA1) or Pump B
(DFB1) does not stall up dur-
ing the pump calibration and
stall test (keeps moving up
when dosing valve is closed).
Rebuild displacement pump and
replace packings, balls, and seats.
Displacement pump is not seating properly.
Dispense valve not seating/sealing.
Replace needle/seat on dispense
valve.
DGA1 or DGB1
Stall Down Error
Rebuild displacement pump and
replace packings, balls, and seats.
Replace needle/seat on dispense
valve.
Displacement pump is not seating properly.
Dispense valve not seating/sealing.
Pump A (DGA1) or Pump B
(DGB1) does not stall down
during the pump calibration
and stall test (keeps moving
down when dosing valve is
closed).
DHA1 or DHB1
No Stall Error
Rebuild displacement pump and
replace packings, balls, and seats.
Displacement pump is not seating properly.
Dispense valve not seating/sealing.
Pump A (DHA1) or Pump B
(DHB1) does not stall in either
direction during the pump cali-
bration and stall test (keeps
moving when dosing valve is
closed).
Replace needle/seat on dispense
valve.
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Dynamic Dosing Restrictor Selection Graphs
Dynamic Dosing Restrictor Selection Graphs
Use the graphs on pages 61- 65 as a guide to determine
the correct restrictor size for your desired flow and mate-
rial viscosity. Table 4 lists the available restrictor sizes.
Table 4: Restrictor Sizes
Size Code
Orifice Size
Part No.
Example:
2*
3*
0.020
0.030
0.040
0.050
0.060
0.070
0.080
15U936
15U937
15U938
15U939
15U940
15U941
16D554
Application: air spray system with a 5:1 mix ratio
4*
Fluid Supply: 1:1 pumps at 100 psi (7 bar, 0.7 MPa)
Flow Rate: 300 cc/min at the gun
5✓
6✓
7*
Select the Restrictor Size: choose either the 0.040
or 0.070 orifice, to ensure that the pressure differen-
tial 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.
8✓
*
These restrictors are included in Injection Kit
15U955.
✓ These restrictors are optional sizes, not included in
•
•
•
If the viscosity of component B is lower than the vis-
cosity of the chart used for selection you may need
to use a smaller restrictor or decrease the pressure
differential.
the Injection Kit.
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 pres-
sure differential.
In systems using an air-assisted gun, if the fluid
pressure of component A is higher than the compo-
nent A pressure from the charts you may need to
use a larger restrictor or increase the pressure dif-
ferential.
60
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Dynamic Dosing Restrictor Selection Graphs
psi
(bar, MPa)
4000
(276, 27.6)
3500
(241, 24.1)
Key
#2 Restrictor
#3 Restrictor
#4 Restrictor
#7 Restrictor
3000
(207, 20.7)
2500
(172, 17.2)
2000
(138, 13.8)
1500
(103, 10.3)
1000
(69, 6.9)
500
(34, 3.4)
0
0
500
1000
1500
2000
2500
3000
3500
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)
0
0
500
1000
FIG. 55. Dynamic Dosing Performance (1:1 Ratio, 90 centipoise fluid, 100 psi A side pressure)
3A0868G
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Dynamic Dosing Restrictor Selection Graphs
psi
(bar, MPa)
1400
(97, 9.7)
Key
1200
(83, 8.3)
#2 Restrictor
#3 Restrictor
#4 Restrictor
#7 Restrictor
1000
(69, 6.9)
800
(55, 5.5)
600
(41, 4.1)
400
(28, 2.8)
200
14, 1.4)
0
0
500
1000
1500
2000
2500
3000
3500
4000
Flow Rate (cc/min)
Detail View
400
(28, 2.8)
300
(21, 2.1)
200
(14, 1.4)
100
(7, 0.7)
50
(3.4, 0.34)
0
0
500
1000
FIG. 56. Dynamic Dosing Performance (5:1 Ratio, 90 centipoise fluid, 100 psi A side pressure)
62
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Dynamic Dosing Restrictor Selection Graphs
psi
(bar, MPa)
800
(55, 5.5)
Key
700
#2 Restrictor
#3 Restrictor
#4 Restrictor
(48, 4.8)
600
(41, 4.1)
#7 Restrictor
500
(34, 3.4)
400
(28, 2.8)
300
(21, 2.1)
200
(14, 1.4)
100
(7, 0.7)
0
0
500
1000
1500
2000
2500
3000
3500
4000
Flow Rate (cc/min)
Detail View
200
(14, 1.4)
150
(10, 1.0)
100
(7, 0.7)
50
(3.4, 0.34)
0
0
500
1000
FIG. 57. Dynamic Dosing Performance (10:1 Ratio, 90 centipoise fluid, 100 psi A side pressure)
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Dynamic Dosing Restrictor Selection Graphs
psi
(bar, MPa)
300
(21, 2.1)
250
(17.2, 1.72)
Key
#2 Restrictor
#3 Restrictor
#4 Restrictor
#7 Restrictor
(14, 1.4)
200
150
10.3, 1.03)
100
(7.0, 0.7)
50
(3.4, 0.34)
0
0
500
1000
1500
2000
2500
3000
3500
4000
Flow Rate (cc/min)
Detail View
100
(7, 0.7)
75
(5.2, 0.52)
50
(3.4, 0.34)
25
(1.7, 0.17)
0
0
500
1000
FIG. 58. Dynamic Dosing Performance (20:1 Ratio, 90 centipoise fluid, 100 psi A side pressure)
64
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Dynamic Dosing Restrictor Selection Graphs
psi
(bar, MPa)
200
(14, 1.4
180
(12.4, 1.2
Key
#2 Restrictor
#3 Restrictor
#4 Restrictor
160
(11, 1.1)
140
9.7, 0.9)
#7 Restrictor
120
8.3, 0.8)
100
(7, 0.7)
80
(5.5, 0.55)
60
(4.1, 0.41)
40
(2.8, 0.28)
20
(1.4, 0.14)
0
0
500
1000
1500
2000
2500
3000
3500
4000
Flow Rate (cc/min)
Detail View
40
(2.8, 0.28)
30
(2.1, 0.21)
20
(1.4, 0.14)
10
(0.7, 0.07)
0
0
500
1000
FIG. 59. Dynamic Dosing Performance (30:1 Ratio, 90 centipoise fluid, 100 psi A side pressure)
3A0868G
65
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Schematics
Schematics
Hazardous Location System Pneumatic Schematic
O P E N
5 / 3 2 T U B E
O P E N
5 / 3 2 T U B E
O P E N
5 / 3 2 T U B E
O P E N
5 / 3 2 T U B E
O P E N
5 / 3 2 T U B E
O P E N
5 / 3 2 T U B E
O P E N
5 / 3 2 T U B E
O S E
C L
O S E
C L
O S E
C L
O S E
C L
O S E
C L
O S E
C L
66
3A0868G
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Schematics
Non-Hazardous Location Pneumatic Schematic
O P E N
5 / 3 2 T U B E
O P E N
5 / 3 2 T U B E
O P E N
5 / 3 2 T U B E
O P E N
5 / 3 2 T U B E
O P E N
5 / 3 2 T U B E
O P E N
5 / 3 2 T U B E
O P E N
5 / 3 2 T U B E
O S E
C L
O S E
C L
O S E
C L
O S E
C L
O S E
C L
O S E
C L
3A0868G
67
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Schematics
Hazardous Location Electrical Schematic
J1
CAN_L
1
2
3
4
5
+V_CAN
V_CAN_RTN
CAN_H
SHIELD
P4
P1
J2
J3
P3
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
ALTERNATOR
MODULE
CAN_L
1
CAN_L
1
2
3
4
5
18 PSI
1.5 FCM
(MIN)
2
3
4
5
+V_CAN
V_CAN_RTN
CAN_H
+V_CAN
V_CAN_RTN
CAN_H
SHIELD
SHIELD
J2
1
2
3
4
5
6
7
8
9
1
V CAN
CAN_L
1
2
3
4
5
USB COMPONENT
MODULE
2
V CAN
USB BASE
MODULE
+V_CAN
V_CAN_RTN
CAN_H
3
V CAN
GRND
4
V CAN RTN
V CAN RTN
CHASSIS GND
CHASSIS GND
V CAN RTN
V CAN RTN
BIT 3
5
SHIELD
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
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
BIT 2
GND
SCK
SO
SI
V CAN
V CAN
V CAN
V CAN RTN
V CAN RTN
CAN L
CAN H
V CAN RTN
V CAN RTN
BIT 0
BIT 1
VTOKEN
LOFO
/HOLD
/CS
J6
J1
J7
CAN_L
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
1
2
3
4
5
+V_CAN
V_CAN_RTN
CAN_H
SHIELD
USER INTERFACE
MODULE
1
2
+
-
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
ALARM
2
3
3
4
4
5
6
5
7
6
8
MANIFOLD
9
7
BLACK
RED
10
11
12
13
14
8
PURGE A
DOSE A1
PURGE B
DOSE B
9
BLACK
RED
MEMBRANE
10
11
12
13
14
BLACK
RED
J4
LED_YELLOW
LED_BLUEA
LED_GREEN
UNUSED
1
2
3
4
5
6
7
8
9
BLACK
RED
LED_BLUEB
UNUSED
BLACK
RED
DOSE A2
DOSE A3
GFB #1
LED_RED
1
2
UNUSED
BLACK
RED
COM(LEDS)
3
BLACK
RED
J2
4
UNUSED
1
2
3
4
5
UNUSED
UNUSED
UNUSED
6
7
3X CABLE
8
9
PWR (RED)
10
11
12
13
14
FLOW METER A
COM (BLACK)
SIG (WHITE)
SHIELD/GRN
SIG
AIR FLOW SWITCH 1
COM
GFB 1 PRESSURE SWITCH/
AIR FLOW SWITCH 2
SIG
COM
3X CABLE
GROUND
TERMINAL
PWR (RED)
FLOW METER B
COM (BLACK)
SIG (WHITE)
SHIELD/GRN
68
3A0868G
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Schematics
Hazardous Location Electrical Schematic (continued)
J8
J7
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
1
2
3
4
5
CAN_L
+V_CAN
2
3
4
5
V_CAN_RTN
CAN_H
SHIELD
FLUID
CONTROL
MODULE
J5
J4
UNUSED
UNUSED
ALARM (+)
COMMON
PURGE A (+)
DOSE A1 (+)
1
1
2
3
4
5
AFS #1 (+)
COMMON
PURGE B (+)
DOSE B (+)
2
3
4
5
J13
J3
J12
+12 VDC
+12 VDC
FLOW METER A SIG
COMMON
1
2
3
4
5
1
2
3
4
5
FLOW METER B SIG
COMMON
GFB INPUT/AFS #2 (+)
GFB OUTPUT
DOSE A2 (+)
DOSE A3 (+)
J2
+5 VDC
AI (-)
+5 VDC
AI (-)
1
2
3
4
5
1
2
3
4
5
"B" PRESSURE
TRANSDUCER
"A" PRESSURE
TRANSDUCER
COMMON
AI (+)
COMMON
AI (+)
SHIELD
SHIELD
J14
J15
LINEAR SENS "A" SIG.
UNUSED
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
LINEAR SENS "B" 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_BTM (DOWN)
REED SWITCH_TOP (UP)
REED SWITCH_COM
LINEAR SENS "B" +5 VDC
LINEAR SENS "B" COM
UNUSED
J25
J11
J11
UNUSED
UNUSED
UNUSED
UNUSED
1
1
2
3
4
UNUSED
UNUSED
UNUSED
UNUSED
2
3
4
J25
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
1
2
3
4
"B" REED
SWITCH
"A" REED
SWITCH
5
6
7
8
9
10
11
12
13
14
"A" LINEAR
SENSOR
"B" LINEAR
SENSOR
FERRITE
FERRITE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
3A0868G
69
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Schematics
Non-Hazardous Location Electrical Schematic
J1
1
2
3
4
5
CAN_L
TERMINAL
BLOCK
+V_CAN
V_CAN_RTN
CAN_H
L
L
N
GRND
SHIELD
POWER
SUPPLY
GRND
N
LINE POWER
FILTER
L
N
P4
P3
1
2
3
4
5
CAN_L
CAN_L
1
2
3
4
5
+V_CAN
V_CAN_RTN
CAN_H
+V_CAN
V_CAN_RTN
CAN_H
2A
2
1A
SWITCH
ROCKER
SHIELD
SHIELD
P1
J2
1
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
1
V CAN
USB COMPONENT
MODULE
2
V CAN
USB BASE
MODULE
3
V CAN
4
V CAN RTN
V CAN RTN
CHASSIS GND
CHASSIS GND
V CAN RTN
V CAN RTN
BIT 3
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
BIT 2
GND
SCK
SO
SI
V CAN
V CAN
V CAN
V CAN RTN
V CAN RTN
CAN L
CAN H
V CAN RTN
V CAN RTN
BIT 0
BIT 1
VTOKEN
LOFO
/HOLD
/CS
J6
J7
CAN_L
1
2
3
4
5
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
+V_CAN
V_CAN_RTN
CAN_H
SHIELD
USER INTERFACE
MODULE
J1
1
2
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
+
ALARM
2
3
-
3
4
4
5
6
5
7
6
8
MANIFOLD
9
7
BLACK
RED
10
11
12
13
14
8
PURGE A
DOSE A1
PURGE B
DOSE B
9
MEMBRANE
BLACK
RED
10
11
12
13
14
BLACK
RED
J4
LED_YELLOW
LED_BLUEA
LED_GREEN
UNUSED
1
2
3
4
5
6
7
8
9
BLACK
RED
LED_BLUEB
UNUSED
BLACK
RED
DOSE A2
DOSE A3
GFB #1
LED_RED
1
2
UNUSED
BLACK
RED
COM(LEDS)
3
J2
BLACK
RED
4
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
7
3X CABLE
8
9
PWR (RED)
10
11
12
13
14
FLOW METER A
COM (BLACK)
SIG (WHITE)
SHIELD/GRN
SIG
AIR FLOW SWITCH 1
COM
GFB 1 PRESSURE SWITCH/
AIR FLOW SWITCH 2
SIG
COM
3X CABLE
GROUND
TERMINAL
PWR (RED)
FLOW METER B
COM (BLACK)
SIG (WHITE)
SHIELD/GRN
70
3A0868G
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Schematics
Non-Hazardous Electrical Schematic (continued)
J7
J8
CAN_L
1
CAN_L
1
2
3
4
5
+V_CAN
2
+V_CAN
V_CAN_RTN
CAN_H
V_CAN_RTN
CAN_H
SHIELD
3
4
5
FLUID
CONTROL
MODULE
SHIELD
J5
J4
UNUSED
ALARM (+)
COMMON
PURGE A (+)
DOSE A1 (+)
UNUSED
1
1
2
3
4
5
AFS #1 (+)
COMMON
PURGE B (+)
DOSE B (+)
2
3
4
5
J13
J12
+12 VDC
+12 VDC
FLOW METER A SIG
COMMON
DOSE A2 (+)
DOSE A3 (+)
1
2
3
4
5
1
2
3
4
5
FLOW METER B SIG
COMMON
GFB INPUT/AFS #2 (+)
GFB OUTPUT
J2
J3
+5 VDC
AI (-)
1
2
3
4
5
1
2
3
4
5
+5 VDC
AI (-)
"A" PRESSURE
TRANSDUCER
"B" PRESSURE
TRANSDUCER
COMMON
AI (+)
COMMON
AI (+)
SHIELD
SHIELD
J14
J15
LINEAR SENS "A" SIG.
UNUSED
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
LINEAR SENS "B" 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_BTM (DOWN)
REED SWITCH_TOP (UP)
REED SWITCH_COM
LINEAR SENS "B" +5 VDC
LINEAR SENS "B" COM
UNUSED
J25
J11
J11
UNUSED
UNUSED
UNUSED
UNUSED
1
1
2
3
4
UNUSED
UNUSED
UNUSED
UNUSED
2
3
4
J25
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
1
2
3
4
"B" REED
SWITCH
"A" REED
SWITCH
5
6
7
8
9
10
11
12
13
14
"A" LINEAR
SENSOR
"B" LINEAR
SENSOR
1
2
3
4
5
6
7
8
9
10
11
12
13
14
3A0868G
71
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Dimensions and Mounting
Dimensions and Mounting
14.76 in.
(37 cm)
1.0 in
(2.5 cm)
0.55 in
(1.4 cm)
12.76 in.
(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. (165 cm)
7 in.
(18 cm)
22.00 in.
(56 cm)
26.8 in.
(68 cm)
72
3A0868G
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Technical Data
Technical Data
ProMix 2KE
US
100 psi
Metric
Maximum fluid working pressure
Maximum working air pressure
Air supply
0.7 MPa, 7 bar
0.5 to 0.7 MPa, 5.2 to 7 bar
3/8 npt(f)
75 to 100 psi
Air filter inlet size
Air filtration for air logic (Graco-supplied)
Air filtration for atomizing air (user-supplied)
Mixing ratio range
5 micron (minimum) filtration required; clean and dry air
30 micron (minimum) filtration required; clean and dry air
0.1:1 to 30:1
20 to 5000 cps
100 mesh minimum
1/4 npt(f)
Viscosity range of fluid
Fluid filtration (user-supplied)
Fluid outlet size (static mixer)
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
Approximate weight
41° to 122°F
300 lb
5° to 50°C
136 kg
Environmental conditions rating
Fluids handled
indoor use, pollution degree (2), installation category II
one or two component:
•
•
•
•
•
solvent and waterborne paints
polyurethanes
epoxies
acid catalyzed varnishes
moisture sensitive isocyanates
On-ratio accuracy
1:1 to 10:1 Mixing Ratio
10.1:1 to 30:1 Mixing Ratio
Noise level
2%
5%
Sound pressure level
below 70 dBA
Below 85 dBA
Sound power level
Materials of construction
Wetted materials on all models
303, 304 SST; Tungsten carbide (with nickel binder);
perfluoroelastomer; PTFE
3A0868G
73
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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 reconnaissent avoir convenu que la
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.
Graco Information
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 reserves the right to make changes at any time without notice.
This manual contains English. MM 3A0868
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2010, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Revision G, June 2014
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