Operation
®
ProMix 2KE
3A0869J
EN
Meter-Based Plural Component Proportioner
Self-contained, electronic plural component paint proportioner. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
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
Port
Part No.
Series
Description
psi (MPa, bar)
24F084
A
1 color/1 catalyst
3000 (27.58, 275.8)
24F085
24F086
24F087
A
A
A
3 colors/1 catalyst
1 color/1 catalyst
3 colors/1 catalyst
3000 (27.58, 275.8)
3000 (27.58, 275.8)
3000 (27.58, 275.8)
Approvals*
II 2 G
#
53
0359
Ex ia px IIA T3 Ta = 0°C to 54°C
FM10 ATEX 0025 X
Intrinsically safe and purged
equipment for
Class I, Division 1, Group D, T3
Ta = 0°C to 54°C
*
ProMix 2KE hazardous location equipment manufactured in the United States, with serial number beginning with
A or 01, has ATEX, FM, and CE approvals, as noted. Equipment manufactured in Belgium, with serial number
beginning with M or 38, has ATEX and CE approvals, as noted.
Approved for Non-Hazardous Location
Maximum Working Pressure
psi (MPa, bar)
USB
Part No.
Series
Description
Port Approvals*
24F080
A
1 color/1 catalyst
3000 (27.58, 275.8)
3000 (27.58, 275.8)
3000 (27.58, 275.8)
3000 (27.58, 275.8)
#
53
24F081
24F082
24F083
A
A
A
3 colors/1 catalyst
1 color/1 catalyst
3 colors/1 catalyst
*
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.
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Warnings
Related Manuals
Manual
Description
Manual
Description
3A1244
Graco Control Architecture
Module Programming
16G353 Alternator Conversion Kit
16G351 Electric Power Conversion Kit
ProMix 2KE Stand Kits
3A0870
313599
308778
312781
312782
312784
406714
ProMix 2KE, Repair/Parts
Coriolis Meter, Instructions/Parts
G3000 Flow Meter, Instructions/Parts
Fluid Mix Manifold, Instructions/Parts
Dosing Valve, Instructions/Parts
Gun Flush Box Kit 15V826
3A1323
3A1324
3A1325
3A1332
3A1333
313542
24H255 3-Color Valve Stack Kit
24H253 USB Module Kit
Rebuild Kit for High Pressure
Dispense Valve
Beacon Tower
406823
Dispense Valve Seat Kit
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.
4
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Warnings
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric
shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
INTRINSIC SAFETY
Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe equipment
will create a hazardous condition and can cause fire, explosion, or electric shock. Follow local regulations
and the following safety requirements.
• Only models with model numbers 24F084-24F087, utilizing the air-driven alternator, are approved for
• 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.
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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.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating area
of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of
toxic fumes, and burns. This equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
6
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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.
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Glossary of Terms
Glossary of Terms
Coriolis Meter - a non-intrusive flow meter often used in
low flow applications or with light viscosity, shear sensi-
tive, or acid catalyzed materials. This meter uses vibra-
tion to measure flow.
Overdose Alarm - when either the resin (A) or catalyst
(B) component dispenses too much material and the
system cannot compensate for the additional material.
Potlife Time - the amount of time before a material
Dose Size - the amount of resin (A) and catalyst (B) that
becomes unsprayable.
is dispensed into an integrator.
Potlife Volume - the amount of material that is required
to move through the mix manifold, hose and applicator
before the potlife timer is reset.
Dose Time Alarm - the amount of time that is allowed
for a dose to occur before an alarm occurs.
Dynamic Dosing - Component A dispenses constantly.
Component B dispenses intermittently in the necessary
volume to attain the mix ratio.
Purge - when all mixed material is flushed from the sys-
tem.
Purge Time - the amount of time required to flush all
Grand Total - a non-resettable value that shows the
mixed material from the system.
total amount of material dispensed through the system.
Ratio Tolerance - the settable percent of acceptable
variance that the system will allow before a ratio alarm
occurs.
Intrinsically Safe (IS) - refers to the ability to locate cer-
tain components in a hazardous location.
Idle - if the gun is not triggered for 2 minutes the system
enters Idle mode. Trigger the gun to resume operation.
Sequential Color Change - the process when a color
change is initiated and the system automatically flushes
the old color and loads a new color.
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.
Sequential Dosing - Components A and B dispense
sequentially in the necessary volumes to attain the mix
ratio.
K-factor - an assigned value that refers to the amount
Standby - refers to the status of the system.
of material per pulse that passes through a meter.
Mix - when cross-linking of the resin (A) and catalyst (B)
occurs.
8
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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
Table 1: Component Description
Component
Description
Control Box
•
•
•
•
•
•
•
•
•
Advanced Fluid Control Module
Power supply or alternator
Solenoid valves
Air flow switch(es)
Optional USB Module
Audible alarm
Optional pressure switch for gun flush box
Mix manifold, which includes the fluid integrator and static mixer.
Color/catalyst valve stacks, includes pneumatically operated dose valves for material A1
and B, additional dose valves A2 and A3 (optional), as well as solvent valves.
Meters
Fluid Module
•
Display Module Used to set up, display, operate, and monitor the system. Used for daily painting functions
including choosing recipes, reading/clearing alarms, and placing the system in Spray,
Standby, or Purge mode.
Installation
•
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.
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.
There must be a shutoff valve between each fluid
supply line and the ProMix 2KE system.
A 100 mesh minimum fluid filter must be installed on
component A and B fluid supply lines.
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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
USB MODULE
2' CAN CABLE
ALTERNATOR
MODULE
CABLE ASSEMBLY
FLUID
CONTROL
MODULE
20" CAN CABLE
CABLE ASSEMBLY
FLOW
METER A
FLOW
METER B
G3000
G3000HR
S3000
G3000
G3000HR
S3000
FIG. 1. Hazardous Location Installation
10
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Installation
Non-Hazardous Locations
USER INTERFACE
MODULE
10' CAN CABLE
50' OPTION
USB MODULE
LINE POWER
FILTER
POWER
SUPPLY
CABLE ASSEMBLY
FLUID
CONTROL
MODULE
CAN CABLE
CABLE ASSEMBLY
FLOW
METER A
FLOW
METER B
G3000
G3000
G3000HR
S3000
G3000HR
S3000
CORIOLIS
CORIOLIS
FIG. 2. Non-Hazardous Location Installation
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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
2. Snap the Display Module
into the bracket.
sized for your system.
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
•
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.
4. The other end of the cable comes from the factory
connected as shown, depending on the configura-
tion of your system:
•
Wall Power Systems
with USB Module:
Connect the CAN cable
to P3 on the USB Mod-
ule.
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.
P3
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
12
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Installation
3. For each gun in the system, connect a separate
Air Connections
clean air supply line to the air inlet of the air flow
switch. This air line supplies gun atomizing air. The
air flow switch detects air flow to the gun and signals
the controller when the gun is being triggered.
tion).
1. Tighten all ProMix 2KE system air and fluid line con-
nections as they may have loosened during ship-
ment.
2. Connect the main air supply line to the main air inlet.
This air line supplies the solenoids and all pneu-
matic control valves.
Atomizing
air outlets
Main Air
Inlet
Atomizing
air inlets
Solenoid
air inlet
TI15709a
FIG. 4. Atomizing Air Connection
TI15729a
FIG. 3. Main Air Connection
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Installation
Fluid Supply
•
Multiple color system: connect supply lines to the
component A2 and A3 dose valve inlets (DVA2,
DVA3). See FIG. 6.
Requirements
NOTE: Solvent supplied by a single source can cause
cross contamination and damage to the system. Install
check valves or use separate solvent sources.
• Do not exceed the pressure rating of the lowest
rated component. See the identification label.
NOTE: Paint Recirculating System Only
• 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.
•
If you are recirculating paint, use the standard inlet
on Dose Valve A1 (A2, A3) or Dose Valve B.
Remove the plug directly opposite it on the dose
valve for the recirculation outlet. The second port is
on the back of the valve and must be reached from
inside the control box.
ProMix 2KE models are available to operate air spray or
air-assisted systems with a capacity of up to 3800
cc/min.
•
•
•
Fluid supply pressure tanks, feed pumps, or circu-
lating systems can be used.
Second port
Materials can be transferred from their original con-
tainers or from a central paint recirculating line.
See manual 313599 for Coriolis meter installation
and operation instructions.
NOTE: The Coriolis meter can be used only on non-IS
systems 24F080-24F083. When installed on these sys-
tems, the meter’s hazardous location intrinsically safe
status is voided.
ti16338a
•
If you are using dynamic dosing, see Fluid Connec-
FIG. 5. Paint Recirculation Port
•
Another option is to use a tee fitting to
recirculate.
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.
NOTE: Verify that all unused fluid ports on the color
change valve stack are plugged before operation. An
open port will leak fluid.
3. Connect the component B line to the component B
dose valve inlet (DVB).
Fluid Connections
1. See FIG. 6. Connect the solvent supply line to the
1/4 npt(f) solvent valve inlets (SVA and SVB).
NOTE: The component A and B fluid meter inlets have
fluid check valves to prevent backflow from fluid supply
pressure fluctuations. Backflow can cause ratio inaccu-
racies.
2. Connect the component A supply line(s).
•
Single color system: connect component supply
line to the component A1 dose valve inlet (DVA1).
4. Connect the gun fluid supply line between the static
mixer (SM) outlet and the gun fluid inlet.
14
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Installation
FI
SVB
SVA
DVB
DVA1
DVA2 and
DVA3 (behind)
CVB
CVA
MA
MB
ti15699a
SM
Key:
MA
Component A Meter
MB
DVB Component B Dose Valve
SVB Solvent Valve B
CVB Meter B Check Valve
Component B Meter
DVA1 Component A Dose Valve
DVA2 Second Color/Catalyst Valve
DVA3 Third Color/Catalyst Valve
SVA Solvent Valve A
SM
FI
Static Mixer
Fluid Integrator Assembly
CVA Meter A Check Valve
FIG. 6. Fluid Controls, Sequential Dosing
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Installation
.
Set Up the Fluid Manifold for Dynamic
Dosing
C
N3
F
N2
D
see page 53.
NOTE: When using dynamic dosing it is very important
to maintain a constant, well-regulated fluid supply. To
obtain proper pressure control and minimize pump pul-
sation, install a fluid regulator on the A and B supply
lines upstream of the meters.
N1
SM
G
If you will be operating using dynamic dosing, the fluid
manifold must be set up properly for your application.
Order the 15U955 Injection Kit (accessory).
1. See FIG. 7. Remove the screws (A) and static mixer
bracket assembly (B).
B
2. Loosen the static mixer nut (N1). Remove and retain
the static mixer (SM).
A
3. Loosen the u-tube nuts (N2 and N3). Discard the
u-tube (C) and the static mixer fitting (D).
ti16334a
4. Remove and retain the 1/4 npt(m) fitting (F).
Remove the integrator (G) and discard
FIG. 7. Disassemble Integrator and Static Mixer
5. See FIG. 8. Remove the remaining parts from the
restrictor housing (H). Retain the plug (J) and base
(K). Discard all the used o-rings.
6. Rotate the restrictor housing (H) 180° so the set-
screw (S) is at top left, as shown in FIG. 8. Remove
and retain the two setscrews (S). The position of
these screws will be reversed when reassembled.
7. Install one larger o-ring (L1*) in the housing (H).
Screw the injection cap (M*) into the housing.
8. Determine the desired flow range for your applica-
tion. Select the appropriate size restrictor for your
selected flow and ratio, using the Dynamic Dosing
Restrictor Selection Graphs on pages 66-70, as a
guide. Install the restrictor (R*) in the base (K).
9. Assemble the smaller o-ring (L2*), restrictor (R*)
and base (K), one larger o-ring (L1*), and plug (J) as
shown.
10. Install the two setscrews. Install the long setscrew
(S) at the front of the housing, for ease of access.
16
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Installation
11. Screw the static mixer (SM) into the injection cap
(M*). Install the retained fitting (F) on the static
mixer tube and secure with the nut (N1).
*
These parts are included in the
15U955 Injection Kit.
J
H
L1*
K
R*
L2*
L1*
S
M*
SM
N1
F
ti16335a
FIG. 8. Install 15U955 Injection Kit
12. Follow instructions under Fluid Connections on
page 14.
NOTE: Use a minimum 20 ft (6.1 m) x 1/4 in. (6 mm) ID
gun fluid supply hose when using dynamic dosing. If the
material is harder to integrate, use a longer hose.
13. Tune the fluid pressure and flow.
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Installation
Tubing Chart and Diagrams
Starting Ending Tube OD
Type
Color
Description
Point
Point
in. (mm)
Air
Air
Air
Air
Air
Air
Air
Air
Air
Air
Air
Air
Air
Air
Air
Fluid
Fluid
Air
Air
Green
Green
Green
Green
Green
Green
Red
Red
Red
Red
Red
Solvent Valve A On
Dose Valve A1 On
Solvent Valve B On
Dose Valve B On
Dose Valve A2 On
Dose Valve A3 On
Solvent Valve A Off
Dose Valve A1 Off
Solvent Valve B Off
Dose Valve B Off
Dose Valve A2 Off
Dose Valve A3 Off
1G
2G
3G
4G
5G
6G
1R
2R
3R
4R
5R
6R
1G
2G
3G
4G
5G
6G
1R
2R
3R
4R
5R
6R
A1
A2
A3
A4
A5
A6
A7
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)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.156 (4.0)
0.25 (6.3)
Red
-----
Main Air to Pressure Gauge A1
Natural Solenoid Air
Natural Main Air to Filter
-----
-----
A2
A3
A4
A5
A6
0.25 (6.3)
Valve Stack A to Meter A
Valve Stack B to Meter B
Alternator Air Exhaust*
0.375 (9.5)
0.375 (9.5)
0.5 (12.7)
Black
Natural Air Regulator to Alternator* A7
0.375 (9.5)
*
Used only on IS models.
* IS Models
A1
A7*
A6*
A3
ti16773a
GFB1-S
ATOM-1
GFB1-P
ti16771a
ti13861a
(Pressurized air line)
5R 6R
1R
2R 3R 4R
GFB1-A
ti16770a
1G
GFB1-C
GFB1-S
2G
4G
3G
6G
5G
GFB1-C
ti13863a
18
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Installation
See Manual 312784 for full
setup instructions for a gun
flush box.
A5
A4
B Side
A Side
GFB1-A
ATOM-1
ATOM-2
ti16767a
A Side
B Side
A2
1G
4G
4R
2G
2R
5R
5G
3G
3R
6G
1R
6R
ti16768a
ti16769a
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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.
Neutral
Ground
ti16391a
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.
FIG. 9. Control Box Electrical Connection
Not included with system:
•
•
Power supply cord compatible to your local power
configuration. Wire gauge size must be 8-14 AWG.
TERMINAL
BLOCK
L
L
N
GRND
The input power access port is 22.4 mm (0.88 in.) in
diameter. It accepts a bulkhead strain relief fitting or
conduit.
POWER
SUPPLY
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
2. Connect electrical cord to the terminal block as
SWITCH
ROCKER
1
3. Close the Control Box. Restore power.
FIG. 10. Electrical Schematic
20
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Installation
Feed Pumps or Pressure Pots
Grounding
Connect a ground wire and clamp from a true earth
ground to the pumps or pots. See pump or pressure pot
manual.
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.
Air and Fluid Hoses
Use grounded hoses only.
Spray Gun
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.
•
•
Non-Electrostatic: Ground the spray gun through
connection to a Graco-approved grounded fluid sup-
ply hose.
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
AC
Power
Follow local code.
Ground
Screw
Object Being Sprayed
Follow local code.
All Solvent Pails Used When Purging
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.
TI15712a
FIG. 11. Ground Screw and Power Switch
Gun Flush Box
Connect a ground wire from the Gun Flush Box ground
lug to a true earth ground.
Check Resistance
Flow Meters
Verify that the meter cables are connected as shown in
cause incorrect signals.
To ensure proper grounding, resistance between
components and true earth ground must be less than
1 ohm.
NOTE: The Coriolis meter can be used only on non-IS
systems 24F080-24F083. When installed on these sys-
tems, the meter’s hazardous location intrinsically safe
status is voided.
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Installation
Key:
1
2
3
4
Control Box ground screw
Control Box ground wire
Gun Flush Box ground screw
Gun Flush Box ground wire
5
5
6
Power cable, Display
Module/Control Box
1
True Earth Ground - check your
local code for requirements.
2
6
3
4
ti16466a
FIG. 12. Grounding
22
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Display Module
Display Module
Screen number
Error code
Potlife state
Active recipe
LCD Display
Ratio
Operation mode; see
Potlife timers
Navigation keys
Flow rate
Enter key
Soft keys
Navigation Keys
Error Reset
Key
Standby Key
ti16319a
Setup Key
FIG. 13. 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 46. 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.
Error Reset: Use to clear alarm
so cause can be fixed. Also use
to cancel a data entry field.
Key
Function
Setup: Press to enter or exit
Setup mode.
Standby: Stops the current
operation and puts the system
into standby.
Enter: Press to choose a field to
update, to make a selection, or
to save a selection or value.
Soft keys: Press to select the
specific screen or operation
shown on the display directly
above each key.
Left/Right Arrows: Use to move
from screen to screen.
Up/Down Arrows: Use to move
among fields on a screen, items
on a dropdown menu, or digits
in a settable field.
3A0869J
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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 5, page
57, 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
Potlife
Purge
Purge
Length
Color Change
Dispense A
Dispense B
Batch
Reset Counter
Start
Volume
Pressure
Stop/Standby
Flow Rate High/Low
Job Number
User Number
Calibrate
Forced
Park
Locked
24
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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 31. For further detail on individual screens, see Run Mode Details, page
•
•
•
Recipe 1-1 (Screen 28) and 1-2 (Screen 29)
control Material 1/Color 1 parameters and flush.
Run Mode
The run mode has two screen sections that control the
mixing operations.
Recipe 2-1 (Screen 30) and 2-2 (Screen 31)
control Material 2/Color 2 parameters and flush.
Mix (Screens 2-4, 38)
Recipe 3-1 (Screen 32) and 3-2 (Screen 33)
control Material 3/Color 3 parameters and flush.
•
•
•
•
Spray (Screen 2) controls most mixing opera-
tions.
Maintenance (Screens 24-26)
Batch (Screen 3) controls dispense of a set vol-
ume.
•
Maintenance 1 (Screen 24) controls mainte-
nance timer actual and target for Meter A, Meter
B, Solvent Valve A, and Solvent Valve B.
Totals (Screen 4) displays grand and batch
totals for materials A1 (A2, A3) and B.
•
Maintenance 2 (Screen 25) controls dose
Job Number (Screen 38) displays job number
and user number
valves A1 and B maintenance timer actual and
target. Dose valves A2 and A3 are included if 3
colors are selected on Configure 1 (Screen 18).
Error Log (Screens 5-14)
•
Maintenance 3 (Screen 26) controls fluid and air
filter maintenance timers, actual and target.
•
•
10 screens, 5 errors per page
Displays date, time, and error
Calibration (Screens 22 and 23)
Setup Mode
1-Color
The setup mode has four screen sections that allow an
authorized user to choose the exact settings needed for
the system:
•
Calibration 1 (Screen 22) controls k factors
(cc/pulse) for Meter A and Meter B.
•
Calibration 2 (Screen 23) allows the user to per-
form a calibration.
Configure (Screens 18-21)
3-Color
•
•
Configure 1 (Screen 18) controls system type
(pump or meter), dosing type (sequential or
dynamic dosing), gun flush box enable, number
of guns (1 or 2), and system color configuration
(1 or 3).
Calibration 1 (Screen 22) controls k factors
(cc/pulse) for Meter B and for Meter A using col-
ors A1, A2, and A3.
•
Calibration 2 (Screen 23) allows the user to per-
form a calibration.
•
•
•
Configure 2 (Screen 19) controls hose length
and diameter for one or two guns and flow rate
region for dynamic dosing.
Troubleshooting Mode
Configure 3 (Screen 20) controls language (for
optional USB Module), date format, date, time,
password setting, and backlight timer.
The troubleshooting mode has three screen sections
that allow an authorized user to troubleshoot system
Configure 4 (Screen 21) controls units for dis-
tance and volume.
System Inputs (Screen 35)
Membrane Test (Screen 36)
Recipe (Screens 27-33)
•
Recipe 0 (Screen 27) includes timers for the
system first, second, and third flush and a third
flush material selection.
System Outputs and Manual Activation (Screen 37)
3A0869J
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Display Module
Ranges for User Inputs
This table is a one-sheet reference of the data range accepted for each user input. See the page indicated in the
table for further screen information, if needed.
Page
Screen
User Input
Target Volume
Range/Options
1 to 9999 cc
Default
0 cc
Run Mix Batch (3)
Run Job Number
Password (16)
Configure 1 (18)
000000000 to 999999999
0000 to 9999
000000000
0000 (disabled)
Meters
User Number
Password
46
Meters; 50cc Pump; 75cc Pump; 100cc
Pump; 125cc Pump; 150cc Pump
System Type
46
Configure 1 (18)
50 cc Sequential
Dosing Type
Dynamic (A B)
50cc Sequential (A-B 50cc)
100cc Sequential (A-B 100cc)
On or Off
46
46
46
46
Configure 1 (18)
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
1 or 3 colors
1 color
Number of Colors
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)
46
Configure 3 (20)
Chinese; Dutch; English; French; German;
Italian; Japanese; Korean; Portuguese;
Russian; Spanish; Swedish;
English
USB Log Language
46
46
46
46
46
46
46
Configure 3 (20)
Configure 3 (20)
Configure 3 (20)
Configure 3 (20)
Configure 3 (20)
Configure 4 (21)
Configure 4 (21)
mm/dd/yy; dd/mm/yy; yy/mm/dd
mm/dd/yy
Set at factory
Set at factory
0000 (disabled)
0 minutes
Date Format
Date
01/01/00 to 12/31/99
00:00 to 23:59
Time
0000 to 9999
Password
Backlight Timer
Distance Units
Volume Units
Ratio
0 to 99 minutes
Feet/inches or Meters/cm
Liters; Gallons US; Gallons Imperial
Feet/inches
Gallons US
1:1
Recipe 1-1 (28)
Recipe 2-1 (30)
Recipe 3-1 (32)
Recipe 1-1 (28)
Recipe 2-1 (30)
Recipe 3-1 (32)
Recipe 1-1 (28)
Recipe 2-1 (30)
Recipe 3-1 (32)
Recipe 0 (27)
0:1 to 30:1
Note: Enter 0 to dispense A only.
47
1 to 99 percent
5 percent
60 minutes
60 seconds
Ratio Tolerance
Potlife Timer
0 to 240 minutes
Note: If set to 0, potlife alarm is disabled.
0 to 240 seconds
Note: If set to 0, the valve(s) will not flush.
Flush Times - First (A purge),
Second (B purge), or Third
(using A or B, selected by user)
Recipe 1-2 (29)
Recipe 2-2 (31)
Recipe 3-2 (33)
Maintenance 1 (24)
0 to 2,000,000 L / 0 to 528,344 gal
0 to 9,999,999
0
Meter A or Meter B
Maintenance 1 (24)
Maintenance 2 (25)
Maintenance 3 (26)
Calibration 1 (22)
Calibration 2 (23)
0
0
Solvent Valve A or B
0 to 9,999,999
Dose Valve A1, A2, A3, or B
Fluid Filter A or B, or Air Filter
Meter A1, A2, A3, or B K-Factor
Actual Dispensed Volume
0 to 9999 days
0 days
0.119 cc/pulse
0 cc
0 to 0.873 cc/pulse
0 to 9999 cc
26
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Display Module
.
.
.
FIG. 14. Run Mode Screen Map
3A0869J
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Display Module
Set Password to 9909 (See Configure
3, Screen 20), then enter it here.
Password
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
Mem-
brane
Test
Mem-
brane
Test
Push to enter forced
mode, (System Outputs 2)
System Outputs 2
To Membrane Test
To Setup Home
Membrane Test
FIG. 17. Troubleshooting Screen Map
30
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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 2.
I = ON
Table 2: Pre-Operation Checklist
Checklist
System grounded
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. 18. Power Switch
Fluid supply containers filled
2. Graco logo will display after five seconds, followed
by Run Mix Spray (Screen 2).
Check all supply containers - A1 (A2 and A3, if
present), B, and solvent.
Dose valves set
Check that the dose valves are set correctly. Start
with the settings recommended in Valve Set-
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. 19. Run Mix Spray (Screen 2)
Initial System Setup
Solenoid pressure set
1. Change optional setup selections to desired param-
eters, as described in Configure 1-4 (Screens
18-21), page 46.
75-100 psi inlet air supply (0.5-0.7 MPa, 5.2-7
bar)
2. Set recipe and flush information as described in
Power On
1. IS Systems (Alternator Power Supply): Set pump
air regulators to minimum setting. Open main air
valve to start air-powered alternator. Main air pres-
sure is displayed on gauge. Display Module screen
will display after five seconds.
3. Set maintenance timers for meters, solvent valves,
dose valves, fluid filters and air filters, as described
3A0869J
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Basic Operation
9. Press
. The system will purge, then load mixed
Prime the System
material to the gun. If the gun flush box is not used,
trigger the gun into a grounded metal pail until the
system returns to Standby.
screen information, if needed.
Meter Calibration
1. Adjust the main air pressure. Most applications
require about 80 psi (552 kPa, 5.5 bar) air pressure
to operate properly. Do not use less than 75 psi
(517 kPa, 5.2 bar).
2. If this is the first time starting up the system, or if
lines may contain air, purge as instructed in Purg-
weight oil, which should be flushed out to avoid
contaminating your material.
Calibrate the meter:
•
The first time the system is operated.
•
Whenever new materials are used in the system,
especially if the materials have viscosities that differ
significantly.
3. From Run Home (Screen 1), press
sure that the system is in Standby mode.
. Make
•
•
As part of regular maintenance to retain meter accu-
racy.
Standby
Whenever a flow meter is serviced or replaced.
NOTE:
•
Meter factors on Calibration 1 (Screen 22) are
updated automatically after the calibration pro-
cedure is completed. You also may manually
edit them if desired.
Standby
•
All values on this screen are in cc or cc/pulse,
regardless of the units set in Configure 4
(Screen 21).
4. Adjust component A and B fluid supplies
as needed for your application. Use low-
est pressure possible.
1. Before calibrating Meter A or Meter B, prime the
32.
NOTE: Do not exceed the maximum rated
working pressure shown on the system identification
label or the lowest rated component in the system.
2. If the display is on a Run Mode screen, press
to access setup screens.
5. Open the fluid supply valves to the
system.
6. If using an electrostatic gun, shut
off the electrostatics before spray-
ing.
3. Press
to display Calibration 1 (Screen 22).
K-factors are shown for B and A1 (A2, A3 if pres-
ent).
7. If using a gun flush box, place the gun in the box
and close the lid.
8. Use
to change to desired color recipe.
32
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Basic Operation
10. After the volume for A1 (A2, A3) or B is entered, the
ProMix 2KE controller calculates the new k-factor
and shows it on Calibration 1 (Screen 22) and Cali-
bration 2 (Screen 23).
4. Press
5. Press
to move to Calibration 2 (Screen 23).
to highlight the meter you wish to cali-
. An X displays in the box.
brate. Press
11. Before you begin production, clear the system of
solvent and prime it with material.
6. Press
to start the calibration on the checked
a. Go to Mix mode.
meter (A with fluid A1, A2, or A3, or B). Press
to cancel the calibration.
b. Trigger the gun into a grounded metal pail until
mixed material flows from the gun nozzle.
7. Trigger gun into a graduated cylinder. Dispense a
minimum of 200-300cc of material.
Spraying
NOTE: Stop triggering the gun when desired amount is
screen information, if needed.
reached. Do not press
, as it will cancel the calibra-
tion.
8. The volume that the ProMix 2KE measured displays
on the Display Module.
cally based on calibration results. Make additional
manual changes, if desired, as described in Cali-
Volume measured
by system displays
here.
Enter dispensed
volume here.
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
FIG. 20. Dispensed Volume Comparison
9. Compare the amount on the Display Module to the
amount in the graduated cylinder.
loaded, the system returns to Standby. Press
again to spray the active recipe.
NOTE: For maximum accuracy, use a gravimetric
(mass) method to determine the actual volumes dis-
pensed.
•
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
correct.
NOTE: If the value is substantially different, repeat the
calibration process until the dispensed volume and mea-
sured volume match.
3A0869J
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Basic Operation
3. Adjust the flow rate. The fluid flow rate shown on the
Display Module screen is for either component A or
B, depending on which dose valve is open.
Purging
screen information, if needed.
.
Active
recipe
Flow
rate
Purge the system:
•
•
•
•
•
•
at the end of potlife
breaks in spraying that exceed the potlife
overnight shutdown or end of shift
the first time material is loaded into equipment
servicing
shutting down equipment for an extended period of
time
FIG. 21. Flow Rate Display
If the fluid flow rate is too low: increase air pres-
sure to component A and B fluid supplies or
increase the regulated fluid pressure of mixed
material.
1. Press
on Run Mix Spray (Screen 2) or
from any screen to put the system in Standby.
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.
2. Trigger the gun to relieve pressure.
3. If you are using a high pressure gun, engage the
trigger lock. Remove spray tip and clean tip sepa-
rately.
4. Turn on atomizing air to the gun. Check the spray
pattern as instructed in your spray gun manual.
4. If using an electrostatic gun shut off the electrostat-
ics before flushing the gun.
NOTE:
•
•
Pressure adjustments of each component will vary
with fluid viscosity. Start with the same fluid pres-
sure for component A and B, then adjust as needed.
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.
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.
6. If using a gun flush box, place the gun into the box
and close the lid.
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.
7. Press
on Run Mix Spray (Screen 2). The
purge sequence automatically starts.
If the gun flush box is not used, trig-
ger the gun into a grounded metal
pail until the purge sequence is com-
plete.
When done purging, the system automatically
switches to Standby mode.
34
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Basic Operation
8. If the system is not completely clean, repeat step 6.
Color Change Procedures
1. Place the gun in the gun flush box if used, and close
the lid.
NOTE: If necessary, adjust purge sequence times
so only one cycle is required.
9. Trigger the gun to relieve pressure. Engage trigger
lock.
2. Press
on Run Mix Spray (Screen 2) or
from any screen to put the system in Standby.
10. If spray tip was removed, reinstall it.
3. Use the scroll keys,
or
, to select the new
11. Adjust the solvent supply regulator back to its nor-
mal operating pressure.
color. Press
to begin the color change
sequence.
NOTE: The system remains full of solvent.
4. If a gun flush box is not used, trigger
the gun into a grounded metal pail
until the color change sequence is
complete. If your system has two
guns, trigger both guns at the same
time.
NOTE: 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.
NOTE: The color change timer does not start until
the gun is triggered and fluid flow is detected. If no
flow is detected within 2 minutes, the color change
operation aborts. The Display Module enters
Color Change
Color Change Sequence
Standby
mode at the previous color.
Step 1. Color Purge. The system flushes out the color
with solvent. The selected color change solvent valve
opens during Purge Time and closes when the time
expires.
Error SG occurs if the gun flush box is open.
Error SAD1 or SAD2 occurs if the AFS is on.
5. Trigger the gun (or guns) while the system flushes
the current color, purges with solvent, and loads the
new color.
Step 2. Catalyst Purge. The system flushes out the
catalyst with solvent. The catalyst change solvent valve
opens during Purge Time and closes when the time
expires.
NOTE: If your system uses 2 guns, you must trigger
both guns simultaneously during the entire color purge,
solvent purge, and load color sequence.
Step 3. Final Purge. The system fills the line with the
selected purge media (usually solvent). The selected
purge valve opens during the Final Purge Time and
closes when the time expires.
NOTE: If you do not see clear solvent flow, the system
did not flush successfully. Stop the color change. Look
for a clog in the line or increase the flush time.
Step 4. Catalyst Fill. The system fills the line with new
catalyst. The new catalyst valve opens during the Fill
Time and closes when the fill volume is reached.
6. During color change, the Recipe icon blinks on and
off, and you’ll see the number of the current color
and the new color. When the color change is com-
plete, Standby is highlighted.
Step 5. Color Fill. The system fills the line with new
color. The new color valve opens during the Fill Time
and closes when the fill volume is reached.
7. When you are ready to spray, remove the gun from
the gun flush box if used, and close its door.
Step 6. Mixed Material Fill. The system fills the line
with mixed material. The system begins mixing compo-
nents A and B until the fill volume expires.
NOTE: The gun flush box door must be closed for
the atomizing air valve to open.
8. Press
to start spraying.
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Basic Operation
Pre-Mix Fill
Purge/Color Change Detail
Premix fill sequence (right after purge sequence) loads
60 cc of the A1, A2, or A3 and B1, from the color stack,
to the mix manifold.
Purge/Flush
The Purge Sequence flushes the lines from the A & B
color stacks though the mix manifold and out to the
gun(s).
In the premix fill sequence, a SFA1/SFA2/SFA3/SFB1
alarm (Premix fill, low flow) is generated if there are less
than 10 ccs in 60 seconds.
"A" has a pre-assigned (not selectable) valve. "B" has a
pre-assigned (not selectable) valve.
SHA1/SHA2/SHA3/SHB1 alarm (Not enough premix fill
volume) is generated if there are less than 50 ccs in 60
seconds.
If you choose a third flush option, it can be "A" or "B"
(not "A" and "B"). You do not have an option to select
something other than "A" or "B" valve. For example, if
"A" was water and "B" was solvent. The third flush
options would have to be "A" water or "B" solvent. You
couldn't assign a third option like air.
NOTE: Premix fill always starts with the “B” side.
Mix Fill
The mix fill sequence (right after premix fill) loads A1,
A2, or A3: B1 mixed material (Ratio specified by user)
out to the gun(s). It loads 110% of the volume of the
hoses plus the volume of the manifold: (hose 1 + hose 2
+ manifold) x 1.1
The following should be the only selectable flush
sequence options:
A, B, 0
A, B, A
A, B, B
A, 0, A
0, B, A 0, B, B
A, 0, B
0, B, 0
SM (mix fill low flow) is generated if there are less than
50ccs in 60 seconds during a mix fill sequence.
There are 4 basic purge sequences as follows:
1. Selecting the purge button on the pendant. The
purge sequence from the recipe that you are cur-
rently in is used. The system is left full of solvent.
SN (Not enough mix fill volume) is generated if less than
the mix fill volume is loaded in 5 minutes during a mix fill
sequence.
2. Color Change from A1, A2 or A3 to A1, A2 or A3.
The purge sequence from the recipe you are leaving
is used. After the purge sequence completes, the
premix fill, from the recipe that you are going to,
starts (blinking recipe number, etc).
3. Color Change from A1, A2 or A3 to Zero. The recipe
zero purge sequence is used. The system is left full
of solvent.
4. Color change from Zero to Zero. The recipe zero
purge sequence is used. The system is left full of
solvent.
NOTE: Color Change from Zero to A1, A2 or A3. The
system does not do a purge sequence. It immediately
starts the premix fill sequence.
A SPSA/SPSB alarm (Not enough volume during purge)
is generated when the end of a purge phase is reached
(Time specified by user), and the system has not totaled
at least 10cc of material.
36
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Basic Operation
2. Shut off the A1 (plus A2 and A3, if using multiple
colors) and B fluid supply pumps/pressure pots.
Pressure Relief Procedure
3. Remove the Control Box cover.
4. With the gun triggered, push the manual override on
the A1 (A2, A3) and B dose valve solenoids to
To reduce the risk of skin injection, relieve pressure
when you stop spraying, before changing spray tips,
and before cleaning, checking, or servicing
equipment.
6. Shut off the fluid supply to solvent valves A and B.
NOTE: The following procedure relieves all fluid and air
pressure in the ProMix 2KE system.
7. With the gun triggered, push the manual override on
the A and B solvent valve solenoids to relieve sol-
sure is reduced to 0.
1. Press
on Run Mix Spray (Screen 2) or
from any screen to put the system in Standby.
8. Reinstall the Control Box cover.
Manual overrides
Solvent Valve A
Solenoid
Gun Flush Box Solenoid
location, if used.
Dose Valve
A1 Solenoid
ti15730a
Solvent Valve B
Solenoid
Dose Valve B
Solenoid
Dose Valve A1 and A2
Solenoid location, if used
FIG. 22. Solenoid Valves in Control Box
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Basic Operation
Lock Mode
Shutdown
NOTE: Do not change system type, number of guns,
hose length, hose diameter, dosing type, or number of
colors when material is loaded in the system. Change
these inputs only if system hardware is changed.
2. Close main air shutoff valve on air supply line and
on ProMix 2KE.
3. Non-IS Systems: Shut off ProMix 2KE power
(0 position). NOTE: The system will restart in
Recipe 0.
If you change one of these inputs, the system locks so
that you cannot spray or mix. The lock icons display.
Lock
icons
FIG. 23. System Lock Mode
Power down and power back up again to clear the lock
and put the new settings into effect. The lock ensures
that the selection was intended and prevents operation
with incorrect settings.
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. 24.
E
TI11581a
FIG. 24. Valve Adjustment
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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
See example in FIG. 25. The job log records total vol-
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, mix ratio, and the recipe used.
Job total volumes are in cubic centimeters. A log entry is
made whenever a new job is initiated, which occurs
when batch totals are cleared, when the job number is
incremented from Run Job Number (Screen 38), or
when a color change is performed. Job information is
displayed on the Display Module only through use of
the optional USB Module.
See example in FIG. 26. The error log records all errors
generated by the system, up to 500. It records the date,
time, error number, error code, and error type for each
error that occurs. Without the USB, the user can access
the 50 most recent errors via the Display Module.
NOTE: For both the Job Log and the Error Log, when
the log is full, new data automatically overwrites old
data. When data in either log is downloaded via the
USB, it remains in the module until it is overwritten.
FIG. 25. Sample Job Log
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Use of Optional USB Module
FIG. 26. 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. 27. 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: All USB logs are saved in Unicode (UTF-16) for-
mat. If opening the log file in Microsoft Word, select Uni-
code encoding.
3. Data download begins automatically. An LED on the
flash drive blinks until the download is complete.
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
FIG. 28. USB Port
5. Insert USB flash drive into USB port of computer.
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Run Mode Details
Run Mode Details
•
•
Press a soft key button to select one of the main
Run Mode screen sections: Mix or Errors
Run Mix Spray (Screen 2)
.
Run Mix Spray (Screen 2) displays at startup or if
is selected from Run Home (Screen 1). Use the Mix
Spray screen to control most mixing operations.
Press
to enter the Setup screens.
Run Mix Batch (Screen 3)
1 Gun
Target ratio
Gun status
Material
Run Mix Batch (Screen 3) displays if
is selected
from Run Mix Spray (Screen 2). Use the Mix Batch
screen to dispense set volumes. Target volume can be
set from 1 to 9999 cc.
Actual
ratio
Flow rate
Potlife
time
Target ratio
Material
Actual ratio
Mix
Standby
2 Guns
Purge
Home
Target volume
Actual volume
Start
Stop
Home
Potlife for
each gun
FIG. 31. Run Mix Batch (Screen 3)
•
Press
to set the target dispense volume. Use
to change each digit, then to move
to the next digit. Press when finished.
FIG. 29. Run Mix Spray (Screen 2)
•
Press
to toggle between Run Mix Spray
(Screen 2), Run Mix Batch (Screen 3), Run Mix
Totals (Screen 4), and Run Job Number (Screen
38).
•
Press
to toggle between Run Mix Spray
(Screen 2), Run Mix Batch (Screen 3), Run Mix
Totals (Screen 4), and Run Job Number (Screen
38).
•
Press
to access Run Home (Screen 1).
Run Home (Screen 1)
Screen Number
Mix
Errors
FIG. 30. Run Home (Screen 1)
42
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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 selected
Run Job Number (Screen 38) displays if
is
from Run Mix Batch (Screen 3). Use this screen to view
grand and batch totals for material A1, A2, A3, and
material B, and to clear batch totals if desired.
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
Grand total
Job number
User number
Increment job
Home
Home
Clear batch totals/
increment job
FIG. 34. Run Job Number (Screen 38)
FIG. 32. 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
to return
to the Run Totals (Screen 4) without clearing.
digit. Press
when finished.
on to clear the batch totals, or on
•
•
Press
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. 33. Confirm Clear Batch Totals
Press to toggle between Run Mix Spray
•
(Screen 2), Run Mix Batch (Screen 3), Run Mix
Totals (Screen 4), and Run Job Number (Screen
38).
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Run Mode Details
Run Log Errors (Screens 5-14)
Run Log Errors (Screens 5-14) display if
is
selected from Run Home (Screen 1). It displays the last
50 errors in the log. (Screen 5 displays errors 1 to 5;
Screen 6 displays errors 6 to 10, etc.).
Error codes
Error icons
FIG. 35. Run Log Errors (Screen 5)
•
Use
icons. See Table 5, page 57, for an explanation of
the different error codes.
44
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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)
Configure
Recipe Settings
Calibration
From any Run screen, press
to access the pass-
FIG. 37. Setup Home (Screen 17)
word screen. Password (Screen 16) displays if a pass-
word has been set. Set the password to 0000 to prevent
the Password Screen from displaying. See Configure 3
(Screen 20), page 46, to set or change the password.
•
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
Configure 1-4 (Screens 18-21)
FIG. 36. Password (Screen 16)
Configure 1 (Screen 18) displays if
is selected on
•
Press
Press
to enter the password (0000 to 9999).
to move between digits. Press
Setup Home (Screen 17). This screen allows users to
set up the system type (pump or meter), the type of dos-
ing (sequential or dynamic), number of guns (1 or 2),
and the system color configuration (1 or 3).
to change a digit. Press
when field is
correct. Setup Home (Screen 17) displays.
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.
•
•
Press
Mode.
to toggle between Run Mode and Setup
NOTE: If your application requires only 2 colors, the
system is still configured for 3 colors. Select 3 from the
dropdown menu.
Select
to display Run Home (Screen 1). Enter-
ing an incorrect password also displays Run Home
(Screen 1).
lowing for a description of each type of dosing, to help
you select the best option for your system. The options
are:
Setup Home (Screen 17)
Setup Home (Screen 17) displays if
is selected on
•
•
A-B 50cc
any screen and the system is not locked, or when a cor-
rect password is entered on Password (Screen 16). The
Setup Home screen displays the software versions of
the boards in the Display Module, Advanced Fluid Con-
trol Module, and the USB Module (if applicable).
(Select for sequential dosing, 50cc dose size.)
A-B 100cc
(Select for sequential dosing, 100cc dose size.)
•
A
B
(Select for dynamic dosing.)
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Setup Mode Details
Gun 1 hose
length
System
type
Gun flush
box
Gun 2
hose
length
Number
of guns
Gun 1 hose
diameter
Dosing
type
Gun 2 hose
diameter
Number
of colors
Home
Home
FIG. 40. Configure 2 (Screen 19)
FIG. 38. Configure 1 (Screen 18)
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 and volume.
•
•
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
to move to the next field.
USB log
language
Press
to move through Configure 2 (Screen
19), Configure 3 (Screen 20), and Configure 4
(Screen 21).
Date
format
Password
Date
NOTE: If you change system type (meter to pump),
number of guns, dosing type, or number of colors, a ver-
Backlight
timer
ification screen appears. Use
press on the to make the change, or on the
return to Configure 1 (Screen 18) without making a
to highlight and
Time
to
Configure 3
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.
Distance
units
Volume
units
Home
Configure 4
FIG. 41. Configure 3 (Screen 20) and Configure 4
(Screen 21)
FIG. 39. Confirm Change of System Type
Configure 2 (Screen 19) allows users to set for each gun
the hose length (0.1 to 45.7 m, 0.3 to 150 ft) and hose
diameter (0.1 to 1 inch). The system uses this 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. A change
in any of these fields will trigger the lock. See NOTE in
previous paragraph.
46
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Setup Mode Details
Recipe 0 (Screen 27)
Recipe 1-2 (Screen 29)
The Recipe Screens allow the user to set up the basic
Note about Settings of 0: If a Flush time is set to 0,
that valve will not flush.
recipes. Recipe 0 (Screen 27) displays if
is selected
on Setup Home (Screen 17). Recipe 0 allows users to
set up a full flush, independent of recipe purge timers,
with no material load. It includes timers for first, second
for flush timer details.
Recipe 1-2 (Screen 29) includes timers for first, second
and third flush for A1 (color 1). In 3-Color systems, Rec-
ipe 2-2 (Screen 31) and Recipe 3-2 (Screen 33) allow
users to set flush timers for the additional materials A2
and A3 (colors 2 and 3).
•
•
•
First flush: Always an A side purge, using the A side
flush material from the A purge valve.
Third flush time
(uses material
set in next field)
Second flush: Always a B side purge, using the B
side flush material from the B purge valve.
Recipe
number
Third
flush
source
First flush
time (A purge)
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).
Second flush
time (B purge)
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. 42. Recipe 0 (Screen 27)
Recipe 1-1 (Screen 28)
Note about Settings of 0: If Ratio is set to 0, the sys-
tem will dispense the A material only. If Potlife Time is
set to 0, the potlife alarm is disabled.
Third flush time
(uses material
set in next field)
Press
to move through the Recipe screens. The
Recipe
number
Recipe Screens allow the user to set up the basic rec-
ipe: Recipe 1-1 (Screen 28) is for A1 (color 1) and B. In
3-Color systems, Recipe 2-1 (Screen 30) is for A2 (color
2) and B, and Recipe 3-1 (Screen 32) is for A3 (color 3)
and B. These screens include the ratio of Material A1
(A2, A3) to Material B (0 to 30), ratio tolerance (1 to 99
percent), and potlife time (0 to 240 minutes).
First flush
time (A purge)
Third
flush
source
Second flush
time (B purge)
FIG. 44. Recipe 1-2 (Screen 29)
Recipe
number
Potlife
•
Press
to highlight the desired field and press
to move between dig-
to select. Press
timer
its. Press
to change a digit. Press
when
field is correct.
Ratio
Ratio
Home
tolerance
•
Press
to move through the Recipe screens.
FIG. 43. Recipe 1-1 (Screen 28)
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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 meters
and solvent valves (Maintenance 1, Screen 24), dose
valves (Maintenance 2, Screen 25), and fluid filters and
air filters (Maintenance 3, Screen 26). Timers for meters
are settable from 0 to 2,000,000 L or 0 to 528,344 gal-
lons. Timers for valves are settable from 0 to 9,999,999
counts. Timers for filters are settable from 0 to 9999
days.
Recommended Maintenance
Component
Frequency
Solvent Valves 1,000,000 cycles
Fluid Filter
5 days,
daily check is recommended
Air Filter
Pumps
30 days
250,000 cycles
1,000,000 cycles
5,000 gallons
Solvent valves
Meters
Dose Valves
Meters
Maintenance
actual and
target
Home
Maintenance 1
Clear totals
Dose
valves
Maintenance 2
Air filter
Fluid Filters
Days
Maintenance 3
FIG. 45. Setup Maintenance 1-3 (Screens 24-26)
•
Press
to move through the three mainte-
nance screens.
•
Press
highlighted. A confirmation screen appears. Use
to highlight and press on the to clear
the batch totals. No other button press will clear the
totals. Press on the to return to the active
Maintenance Screen without clearing.
to clear the maintenance total that is
48
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Setup Mode Details
Calibration 1 and 2 (Screens 22
and 23)
instructions.
•
•
Press
to highlight the meter you wish to cali-
. An X displays in the box.
brate. Press
Press
to start the calibration on the checked
meter (A with fluid A1, A2, or A3, or B). Press
to cancel the calibration.
Calibration 1 (Screen 22) displays if
is selected on
Setup Home (Screen 17). This screen displays the k
factor (cc/pulse) for Meter A with fluid A1 (A2 and A3, if
present) and Meter B. The system starts at the default
factor(s) for the meters. Factor values update automati-
cally as needed based on calibration results from Cali-
bration 2 (Screen 23). Factor values also can be set on
this screen, from 0 to 0.873 cc/pulse.
•
•
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
to change a digit. Press
when
field is correct.
Use
to toggle between Calibration 1
(Screen 22) and Calibration 2 (Screen 23).
Meter k
factors
Troubleshooting (Screens
35-37)
Home
Screens for testing system controls can be accessed by
setting the password to 9909. See Configure 3 (Screen
20), page 46, to set or change the password.
FIG. 46. Calibration 1 (Screen 22)
Press
to display Calibration 2 (Screen 23). This
screen allows the user to perform a calibration. It dis-
plays Meter A (with fluid A1, A2, and A3) and Meter B
k-factors, the target dispense volume, the actual dis-
pense volume (settable from 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.
Selected
material
Meter B
k factor
Troubleshooting
screen options
appear here.
Meter A
k factors
Active
Recipe
Target
dispense
volume
Actual
dispense
volume
Cancel Meter
Calibration
Home
Start Meter A
or Meter B
Calibration
FIG. 48. Setup Home with Troubleshooting
FIG. 47. Calibration 2 (Screen 23)
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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
Outputs (Screen 37). An X displays in the box to show
an electrical state of On for the dose valves (B, and A1,
A2, and A3), solvent valves (B and A), the gun trigger,
active, press
to display Troubleshooting System
Inputs (Screen 35). An X displays in the box to indicate if
Air Flow Switch 1 or 2 is on and if the gun is in the Gun
Flush Box. This screen also displays Meter A and Meter
B pulses. The fields relating to pump function can be
ignored.
and the alarm. Press
to start Forced Mode. A sec-
ond set of check boxes displays. Manually actuate the
valves, alarm, or gun trigger. For properly working com-
ponents, an X will display in the corresponding second
Pump B up
or down
(not used)
Pump
Pressures
(not used)
Air Flow
Switch on
box upon actuation. Press
to exit Forced Mode.
Moving to any other screen also will exit Forced Mode.
Dose
Valves
Solvent
Valves
Meter
Pulses
Gun
Trigger
Gun in Gun
Flush Box
Pump A up
or down
(not used)
Alarm
FIG. 49. Troubleshooting System Inputs (Screen 35)
Start
Forced
Mode
•
Press , then again to move to Trouble-
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
Stop
Forced
Mode
active, press
, then
again. Membrane Test
, then
(Screen 36) displays. You could also press
FIG. 51. Troubleshooting System Outputs (Screen
37)
again. This screen allows an authorized user to test
the buttons on the Display Module membrane. When in
this screen, all buttons lose their predefined functions,
and the soft keys are not defined. When a properly
working button is pressed, an X appears in the box.
FIG. 50. Membrane Test (Screen 36)
Press
three times to return to Setup Home (Screen
17). Direct access to any other screen is not possible.
50
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Dosing Options
Dosing Options
d. Dose Valve B (DVB) opens, and fluid flows into
the integrator and is aligned proportionately with
component A.
Sequential Dosing
Components A and B dispense sequentially in the nec-
essary volumes to attain the mix ratio.
e. Flow Meter B (MB) monitors the fluid volume
dispensed and sends electrical pulses to the
ProMix 2KE controller.
1. The operator presses
to begin operation.
f. When the target volume is dispensed, Dose
Valve B closes.
2. The ProMix 2KE controller sends signals to activate
the solenoid valves. The solenoid valves activate
Dose Valves A1 (A2 or A3, depending on recipe
selection) and B. Fluid flow begins when the gun is
triggered.
4. The components are pre-mixed in the integrator,
then uniformly blended in the static mixer (SM).
NOTE: To control output from the static mixer to the
gun, install an optional fluid pressure regulator.
3. Components A1 and B are introduced into the fluid
integrator (FI) one at a time as follows.
5. Components A and B are alternately fed into the
integrator as long as the gun is triggered.
a. The A side dose valve (DVA1, DAV2, or DVA3)
opens, and fluid flows into the integrator.
6. If the gun is not triggered for two minutes, the sys-
tem switches to Idle mode, which closes off the mix
manifold dose valves.
b. Flow Meter A (MA) monitors the fluid volume
dispensed and sends electrical pulses to the
ProMix 2KE controller. The controller monitors
these pulses and signals.
7. When the gun is triggered again, the ProMix 2KE
continues the process where it left off.
c. When the target volume dispenses, Dose Valve
A closes.
NOTE: Operation can be stopped at any time by
NOTE: The dispense volume of component A and B
is based on the mix ratio and dose size set by the
user and calculated by the ProMix 2KE controller.
pressing
switch.
or shutting off the main power
Table 3: Sequential Dosing Operation
Dose 2
Ratio = 2.0:1
A = 2
Dose 1
Dose 3
B = 1
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Dosing Options
FI
SVB
SVA
DVA1
DVB
DVA2 and
DVA3 (behind)
MA
MB
SM
ti15699a
Key:
MA
Component A Meter
MB
Component B Meter
DVA1 Component A Dose Valve
DVA2 Second Color/Catalyst Valve
DVA3 Third Color/Catalyst Valve
SVA Solvent Valve A
DVB Component B Dose Valve
SVB
SM
FI
Solvent Valve B
Static Mixer
Fluid Integrator
FIG. 52. Fluid Module, Sequential Dosing
52
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Dosing Options
Dynamic Dosing
Overview
Select Dynamic Dosing
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.
1. On the Display Module press
to access Setup
Home (Screen 17). Select
1 (Screen 18).
to display Configure
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. 55 for a
schematic diagram of the process.
2. Select A B from the dosing type drop down menu.
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.
Dynamic Dosing System Parameters
The following parameters affect dynamic dosing perfor-
mance:
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.
•
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.
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.
•
•
Component B Flow: Ensure that the supply pump is
sized to provide sufficient and uninterrupted flow.
FIG. 53 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.
Component A Pressure: Ensure precise pressure
regulation. It is recommended that the component A
pressure be 5-15% lower than the component B
pressure.
•
Component B Pressure: Ensure precise pressure
regulation. It is recommended that the component B
pressure be 5-15% higher than the component A
pressure.
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.
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. In systems with color
change, install the regulator downstream of the
color/catalyst valve stack.
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.
Select a Component B Restrictor Size
Monitor system performance by watching the Display
Module for warning messages which provide informa-
tion on system performance, and adjust pressures
accordingly. See Table 5 on page 57.
appropriate restrictor size based on the desired flow and
mix ratio.
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Dosing Options
B Pressure
Too Low
B Pressure
Too Low
B Pressure
Too High
B Pressure
Too High
A Pressure
B Pressure
A Pressure
B Pressure
FIG. 53. 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. 54. A/B Control Range with Too Large a
Restrictor
ToStatic
Component A (continuous flow)
Proportioned Material
Mixer
Component B (pulsed injection)
FIG. 55. Schematic Diagram of Dynamic Dosing Operation
Table 4: Dynamic Dosing Troubleshooting Guide
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.
54
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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.
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
44, to view the last 50 errors, with date and time stamps.
System Alarms
System alarms alert you of a problem to help prevent
off-ratio spraying. If an alarm occurs, operation stops
and the following occurs:
To reset errors, see Table 7 and Alarm Troubleshoot-
•
•
Alarm buzzer sounds.
Status bar on the Display Module shows the alarm
pressing
.
icon
and code.
•
Alarm is saved in the date/time stamped log.
Air Flow Switch (AFS) Function
Error Code Indicator
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 AFS functions with the flow meters to ensure
that system components are functioning correctly.
For example, if a flow meter fails or clogs, pure resin or
catalyst could spray indefinitely if the ProMix 2KE does
not detect the condition and intervene, which is why the
AFS is so important.
If the ProMix 2KE detects through the AFS signal that
the gun is triggered, yet there is no fluid flow through the
meter, a Dose Time Alarm (QTA1 or QTB1) occurs after
40 seconds and the system shuts down.
FIG. 56. Display Module Alarm Codes
System Advisory/Record Codes
Operating Without Air Flow Switch
Table 6 lists the advisory and record codes. Advisories
and records do not stop operation or sound an alarm. If
an advisory occurs, the Status bar on the Display 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.
It is not recommended to run without an air flow switch.
If a switch fails, replace it as soon as possible.
Airless Gun
It is not recommended to use an airless gun with the
ProMix 2KE. Two issues can arise from operating with-
out an air flow switch:
•
Without a gun trigger/air flow switch input the Pro-
Mix 2KE does not know it is spraying and will not
generate a Dose Time Alarm. This means there is
no way to detect a failed meter. You could spray
pure resin or catalyst for 2 minutes without knowing.
Record - no icon
Alarm icon
Advisory icon
FIG. 57. Error Log Icons
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System Errors
•
Since the ProMix 2KE does not know it is spraying
because there is no gun trigger/air flow switch input,
it will go into System Idle every 2 minutes when in
Mix mode.
System Idle Notice (IDLE)
This warning occurs if the ProMix 2KE is set to Mix
and 2 minutes have elapsed since the system last
received the air flow switch signal (gun trigger). The Gun
Idle icon
is displayed.
In applications using the AFS, 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.
56
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System Errors
Error Codes
Table 5: System Alarm/Advisory/Record Codes
Table 5: System Alarm/Advisory/Record Codes
Code Description
Details
Code Description
Details
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
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Alarm Codes - Alarm sounds, system stops, icon dis-
plays until problem is solved and alarm is cleared.
CA
Communication Error
43
43
43
43
43
CAU1 USB Communication Error
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
ES
System defaults loaded
Record Codes - No alarm, system continues operating,
no icon displays on active screen.
SPSA Purge Volume Error A
SPSB Purge Volume Error B
EL
EC
ES
ET
System powered on
N/A
N/A
N/A
SFA1 PreMix Error - Color
SFA2
SFA3
43
43
System setup changed
System defaults loaded
System performed an autodump after N/A
a potlife
SFB1 PreMix Error - Catalyst
SHA1 PreFill Error - Color
EQU1 USB Drive connected while in Standby N/A
SHA2
SHA3
SHB1 PreFill Error - Catalyst
SM
SN
MixFill Start Error
44
44
44
MixFill Complete Error
QPD1 Potlife Error - Gun 1
QPD2 Potlife Error - Gun 2
R1
R4
Ratio Low Error
Ratio High Error
44
45
46
QDA1 Overdose A, B Dose too Short
QDA2
QDA3
QDB1 Overdose B, A Dose too Short
QTA1 Dose Time A Error
47
QTA2
QTA3
QTB1 Dose Time B Error
QLAX Leak Error A
QLBX Leak Error B
47
48
P6A1
P6B1
Pressure Transducer Error A
Pressure Transducer Error B
Advisory Codes - No alarm, system continues operat-
ing, icon displays on active screen until cleared
MFA1 Meter A maintenance due
MFB1 Meter B maintenance due
MEA1 Mix valve A1 maintenance due
MEA2 Mix valve A2 maintenance due
MEA3 Mix valve A3 maintenance due
N/A
N/A
N/A
N/A
N/A
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System Errors
Alarm Troubleshooting
Alarm and Description
Cause
The CAN cable between the Display
Solution
CA
Verify that the cable is correctly con-
Communication Error
The Display Module is not
communicating with the
Advanced Fluid Control
Module.
Module and the Advanced Fluid Control nected.
Module is not connected.
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 module (See Alterna-
tor Module Power Output). If the
proper voltage is not detected, trou-
bleshoot the Alternator Module.
Check that the Advance Fluid Control
Module (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- Replace the cable (16E890)
noid/meter cables connected to the
AFCM.
The AFCM power supply may be bad, as Replace the module.
indicated by the status LEDs (red, yellow,
green) being off. Verify the power supply
works by disconnecting from the AFCM
and connecting to another module, either
the Display Module or USB Module.
The DM and the AFCM have different ver- Install the latest software from token kit
sions of software installed.
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.
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.
Put system in standby and reconnect or
replace the USB cable.
58
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System Errors
Alarm and Description
EQU2
Cause
Solution
Put system in Standby. Insert the USB
Most USB drives do not conform to IS
USB Drive Error
standards, so it is hazardous to use one drive only in a non-hazardous environ-
The USB drive has been
inserted when the system is
not in Standby.
while the system is running.
ment.
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.
•
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.
SPSA or SPSB
Check components and clean, repair, or
replace as necessary.
Solvent line, valve, or meter is plugged
or stuck.
Purge Volume Error
Insufficient volume during first
10 seconds of A or B purge
sequence.
Check and repair pump. See pump
manual for repair procedures and
replacement parts.
Solvent pump is not working.
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
during 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.
valve as needed.
Inspect air line for kinks, damage, or
loose connections. Repair or replace as
needed.
Air leak in atomizing air line.
SFA1, SFA2, SFA3 or SFB1
PreMix Error
Check components and clean, repair, or
replace as necessary.
Gun, line, valve, or meter is plugged or
stuck.
In systems with a gun flush
box, insufficient quantity of
resin/color (SFA1, SFA2, or
SFA3) or catalyst (SFB1) is
detected during the 10-second
PreMix sequence.
Check and repair pump. See pump
manual for repair procedures and
replacement parts.
Check air line path. See System Pneu-
that solenoid is working.
Feeder pump or solvent pump is not
turned on or is not working.
Air lines or solenoids are plumbed incor-
rectly or solenoids are not working.
Increase fluid pressure.
SHA1, SHA2, SHA3 or SHB1 Flow rate is too low.
PreFill Error
Total PreFill sequence volume
is not reached for color
(SHA1, SHA2, or SHA3) or
catalyst (SHB1) during the
5-minute PreFill sequence.
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System Errors
Alarm and Description
Cause
Solution
SM
Verify trigger is being pulled. Adjust as
needed.
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.
Clean line, tip, or filter.
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
34.
Have not sprayed enough volume to
keep fresh mixed fluid in the mix mani-
fold, hose, and gun.
Check that hose length and diameter
have been entered correctly. See Con-
Spray the required volume to restart the
potlife timer.
60
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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
spraying for some time, the pressures
from the fluid supplies could be unbal-
anced.
Adjust component A and B fluid supply
regulator pressures until they are about
equal. If the pressures are already
about equal, verify that component A
and B dose valves are operating prop-
erly.
Slow actuation of the component A or B Manually operate the Dose Valve A1
valves. This can be caused by:
(A2, A3) and B solenoid valves by
pressing and releasing solenoid valve
override buttons. Valves should snap
open and shut quickly.
•
Air pressure to the valve actuators is
too low.
•
Increase air pressure. Air pressure
must be 75-120 psi (0.52-0.84 MPa,
5.2-8.4 bar); 120 psi is recom-
mended.
•
•
Something is restricting the solenoid
or tubing and interrupting valve actu-
ation air.
•
•
There may be dirt or moisture in the
air supply. Filter appropriately.
Dose Valve A1 (A2, A3) is turned in
too far.
for adjustment guidelines.
Dose Valve B is open too far.
•
•
Fluid pressure is high and air pres-
sure is low.
•
•
Adjust air and fluid pressure. See
recommended air pressure above.
Fluid Seal in valve has failed.
See corresponding valve manual
for repair instructions.
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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
spraying for some time, the pressures
from the fluid supplies could be unbal-
anced.
Adjust component A and B fluid supply
regulator pressures until they are about
equal. If the pressures are already
about equal, verify that component A
and B dose valves are operating prop-
erly.
Slow actuation of the component A or B Manually operate the Dose Valve A1
valves. This can be caused by:
(A2, A3) and B solenoid valves to check
operation.
•
Air pressure to the valve actuators is
too low.
•
Increase air pressure. Air pressure
must be 75-120 psi (0.52-0.84 MPa,
5.2-8.4 bar); 120 psi is recom-
mended.
•
•
•
Something is restricting the solenoid
or tubing and interrupting valve actu-
ation air.
•
•
•
There may be dirt or moisture in the
air supply. Filter appropriately.
Dose Valve B is turned in too far.
Dose Valve A1 (A2, A3) is open too
far.
Fluid pressure is high and air pres-
sure is low.
for adjustment guidelines.
Adjust air and fluid pressure. See
recommended air pressure above.
62
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System Errors
Alarm and Description
Cause
Solution
QDA1, QDA2, QDA3
Overdose A
Valve seal or needle/seat are leaking.
Repair the valve.
Flow meter fluctuations caused by pres- Check for pressure pulsations:
The A dose has overshot and,
when combined with B, is too
large for the mix manifold
capacity.
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.
sure pulsations.
1. Close all the manifold valves.
2. Turn on the circulating pumps and
all the booth equipment (such as
fans and conveyors).
3. Check if the ProMix 2KE is reading
any fluid flow.
4. If the ProMix 2KE shows there is
fluid flow and there are no leaks
from the gun or any other seals or
fittings, the flow meters are proba-
bly being affected by pressure pul-
sations.
5. Close the fluid shutoff valve
between the fluid supply system
and the flow meter. The flow indica-
tion should stop.
6. If necessary, install pressure regu-
lators or a surge tank on the fluid
inlets to the ProMix 2KE to reduce
the fluid supply pressure. Contact
your Graco distributor for informa-
tion.
Slow actuation of component A or B
valves.
See Ratio Low Error and Ratio High
Error, pages 61-62.
Running a high mix ratio and a high flow It may be necessary to restrict the flow
rate.
rate through the component B dose
valve by adjusting its hex nut.
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System Errors
Alarm and Description
Cause
Solution
QTA1, QTA2, QTA3, or
QTB1
Dose Time Error
System is in Mix mode and gun is only
partially triggered, allowing air but no fluid
to pass through gun.
Fully trigger the gun.
The gun trigger is active, but
no A pulses (QTA1, QTA2,
QTA3) or no B pulses (QTB1)
are detected during the dose
time selected.
Fluid flow rate is too low.
Increase flow rate.
Flow meter or cable failed or flow meter
clogged.
To check meter sensor operation,
remove meter cap to expose sensor.
Pass a ferrous metal tool in front of the
sensor.
TI12792a
If there is a meter or cable failure, you
will see a large difference between the
amount of fluid dispensed and the flow
meter volume displayed by the Display
Module. Clean or repair meter as nec-
essary.
Slow actuation of component A or B
valves.
See Ratio Low Error and Ratio High
Error, pages 61-62.
The supply pump is not turned on.
Turn on the supply pump.
There is an air leak downstream from the Check the air lines for leaks and repair.
air flow switch.
The air flow switch is stuck open.
Clean or replace air flow switch.
QLAX or QLBX
Leak Error
Pressure on circulation system is fluctu- Replace check valve in front of meter.
ating and generating meter pulses.
Meter A (QLAX) or Meter B
(QLBX) measures fluid with all
valves closed.
Valve is leaking.
Replace valve seat, valve, or valve
seal.
Gun, manifold, or line is leaking.
Repair leak downstream of meters.
64
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Dynamic Dosing Restrictor Selection Graphs
Dynamic Dosing Restrictor Selection Graphs
Use the graphs on pages 66- 70 as a guide to determine
the correct restrictor size for your desired flow and mate-
rial viscosity. Table 6 lists the available restrictor sizes.
Table 6: 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.
3A0869J
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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. 58. Dynamic Dosing Performance (1:1 Ratio, 90 centipoise fluid, 100 psi A side pressure)
66
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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. 59. Dynamic Dosing Performance (5:1 Ratio, 90 centipoise fluid, 100 psi A side pressure)
3A0869J
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Dynamic Dosing Restrictor Selection Graphs
psi
(bar, MPa)
800
(55, 5.5)
Key
700
#2 Restrictor
(48, 4.8)
#3 Restrictor
#4 Restrictor
#7 Restrictor
(41, 4.1)
600
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. 60. Dynamic Dosing Performance (10:1 Ratio, 90 centipoise fluid, 100 psi A side pressure)
68
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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
200
(14, 1.4)
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. 61. Dynamic Dosing Performance (20:1 Ratio, 90 centipoise fluid, 100 psi A side pressure)
3A0869J
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Dynamic Dosing Restrictor Selection Graphs
psi
(bar, MPa)
200
(14, 1.4
180
Key
(12.4, 1.2
#2 Restrictor
#3 Restrictor
#4 Restrictor
#7 Restrictor
160
(11, 1.1)
140
9.7, 0.9)
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. 62. Dynamic Dosing Performance (30:1 Ratio, 90 centipoise fluid, 100 psi A side pressure)
70
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Dynamic Dosing Restrictor Selection Graphs
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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
72
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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
3A0869J
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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
74
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Schematics
Hazardous Location Electrical Schematic (continued)
J8
J7
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
1
2
3
4
5
CAN_L
+V_CAN
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
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 (-)
+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
3A0869J
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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
P1
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
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
J1
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
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
76
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Schematics
Non-Hazardous Location Electrical Schematic (continued)
J7
J8
CAN_L
+V_CAN
CAN_L
1
2
3
4
5
1
2
3
4
5
+V_CAN
V_CAN_RTN
CAN_H
V_CAN_RTN
CAN_H
FLUID
CONTROL
MODULE
SHIELD
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
3A0869J
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Technical Data
Technical Data
ProMix 2KE, Meter-Based Systems
US
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)
100 psi
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
up to ± 1%, user selectable
1/4 npt(f)
On-ratio accuracy
Fluid inlet sizes
Fluid outlet size (static mixer)
External power supply requirements
1/4 npt(f)
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
200 lb
5° to 50°C
91 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
Fluid flow rate range
G3000, G250 Meter
G3000HR, G250HR Meter
Coriolis Meter
S3000 Solvent Meter (accessory)
Noise level
0.02 to 1.00 gal/min
0.01 to 0.50 gal/min
0.005 to 1.00 gal/min
0.01 to 0.50 gal/min
75 to 3800 cc/min
38 to 1900 cc/min
20 to 3800 cc/min
38 to 1900 cc/min
Sound pressure level
below 70 dBA
Sound power level
Below 85 dBA
Materials of construction
Wetted materials on all models
303, 304 SST; Tungsten carbide (with nickel binder);
perfluoroelastomer; PTFE
3A0869J
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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 3A0869
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 J, June 2015
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