Installation ® ProMix 2KS 312775F EN Plural Component Proportioner Manual system for proportional mixing of plural component coatings. For professional use only. For use in explosive atmospheres (except the EasyKey). Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. See page 4 for model information, including maximum working pressure. Equipment approval labels are on page 3. Some components shown are not included with all systems.
Contents Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Equipment Approvals . . . . . . . . . . . . . . . . . . . . . . . 3 System Configuration and Part Numbers . . . . . . . 4 Configurator Key . . . . . . . . . . . . . . . . . . . . . . . . . 4 Standard Features . . . . . . . . . . . . . . . . . . . . . . . 5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Manuals Related Manuals Equipment Approvals Component Manuals in English Equipment approvals appear on the following labels which are attached to the Fluid Station and EasyKey™. See FIG. 1 on page 4 for label locations.
System Configuration and Part Numbers System Configuration and Part Numbers Configurator Key The configured part number for your equipment is printed on the equipment identification labels. See FIG. 1 for location of the identification labels. The part number includes one digit from each of the following six categories, depending on the configuration of your system.
System Configuration and Part Numbers Hazardous Location Approval Models using a G3000, G3000HR, or intrinsically safe Coriolis meter for both A and B meters are approved for installation in a Hazardous Location - Class I, Div I, Group D, T3 or Zone I Group IIA T3. Maximum Working Pressure Maximum working pressure rating is dependent on the fluid component options selected. The pressure rating is based on the rating of the lowest rated fluid component. Refer to the component pressure ratings below.
Accessories Accessories Accessory Gun Flush Box Gun Insert Selection 15V354 Third Purge Valve Kit 15V536 Solvent Flow Switch Kit 15V213 Power Cable, 100 ft (30.5 m) 15G710 Fiber Optic Cable, 100 ft (30.
Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation 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.
Warnings WARNING SKIN INJECTION HAZARD High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. • Tighten all fluid connections before operating the equipment. • 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.
Important Two-Component Material Information Important Two-Component Material Information Isocyanate Conditions 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. Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufficient ventilation in the work area.
Component Identification and Definition Component Identification and Definition EK CCM* Air Controls/ Filter BC* PS* BCV FO* MS ACV ST MA MB * See the ProMix 2KS Repair-Parts manual for optional cable lengths. FM GFB TI12504a FIG. 2. Manual System, shown with G3000 Meters, Color/Catalyst Change, One Gun Flush Box, and Accessory Solvent Flow Meter Table 1: Component Descriptions Component Description EasyKey (EK) Used to set up, display, operate, and monitor the system.
Component Identification and Definition Table 1: Component Descriptions Component Fluid Manifold (FM) Description • • • • • Flow Meters (MA, MB, MS) Pneumatically Operated Dose Valves for component A and B Purge Valves for solvent and air purge Sampling Valves for calibrating the flow meters and performing ratio checks Shutoff Valves for component A and B to close their fluid passages to the mix manifold, to allow for accurate calibration and ratio checks Mix Manifold, which includes the fluid integrato
Location Location Intrinsically Safe Installation Requirements Location Requirements See FIG. 3 on page 13. 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 area. See the identification label (FIG. 1) on the EasyKey or fluid station for the intrinsic safety rating for your model. 1.
Location FM08ATEX0074 SYSTEM ASSEMBLY CERTIFICATE NON-HAZARDOUS LOCATION ONLY ProMix 2KS EasyKey Interface Safety Barrier FM08ATEX0072 ASSOCIATED APPARATUS 250 VAC Maximum Supply Voltage HAZARDOUS (CLASSIFIED) LOCATION CLASS I, DIV I, GROUP D, T3 (US AND CANADA) CLASS I, ZONE I GROUP IIA T3 (ATEX ONLY) TAUB = -20°C TO 50°C 10’ I/S Power and Communication Cable (40’ extension option) ProMix 2KS Smart Fluid Plate (Wall Panel or RoboMix 50’ I/S Power Cable (3’, 6’, 10’, 15’, 25’, 100’ options) FM08ATEX
General Information General Information • • Reference numbers and letters in parentheses in the text refer to numbers and letters in the illustrations. FIG. 2, page 10, shows the basic components of a manual system. Contact your Graco distributor for actual system designs. • 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 system.
Air Supply Air Connections See the System Pneumatic Schematic on page 29. 1. Tighten all ProMix system air and fluid line connections as they may have loosened during shipment. 2 Purge air line (AT) must be a separate air supply, connected to the check valve (CV). Do not connect the purge air line to the unit’s main air supply or to the air manifold. 2. Install a bleed-type air shutoff valve into the control air filter inlet on Wall Mount Fluid Station. FIG. 4.
Fluid Supply Fluid Supply Requirements Fluid Connections 1. Connect the solvent supply lines. Do not exceed the pressure rating of the lowest rated component. See the identification label (FIG. 1 on page 4). To reduce the risk of injury, including fluid injection, you must install a shutoff valve between each fluid supply line and the fluid manifold assembly. Use the valves to shut off fluid during maintenance and service.
Fluid Supply DVA DVB FI MB MS MA RVB AT TI12556b APV RVA SVA SM SPV SVB Key: MA DVA RVA SVA MB DVB RVB Component A Meter Component A Dose Valve Component A Sampling Valve Component A Shutoff Valve Component B Meter Component B Dose Valve Component B Sampling Valve SVB MS SPV APV SM FI AT Component B Shutoff Valve Solvent Meter (accessory) Solvent Purge Valve Air Purge Valve Static Mixer Fluid Integrator Air Purge Valve Air Supply Tube FIG. 6.
Fluid Supply Setup the Fluid Manifold for Dynamic Dosing If you will be operating using dynamic dosing, the fluid manifold must be setup properly for your application. Order the 15U955 Injection Kit (accessory). 5. See FIG. 9. Remove the remaining parts from the restrictor housing (H). Retain the plug (J) and base (K). Discard all the used o-rings, 1. Remove the screws (A) and static mixer bracket assembly (B). See FIG. 8. 2. Loosen the static mixer nut (N1). Remove and retain the static mixer (SM). 6.
Fluid Supply 10. Install the two setscrews and o-rings (L3*). Install the long setscrew (S) at the front of the housing, for ease of access. 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). 12. Follow instructions under Fluid Connections on page 16. 13. Tune the fluid pressure and flow as explained in the ProMix 2KS Operation Manual.
Fluid Supply Solvent Meter Accessory The ProMix 2KS Solvent Push feature requires installation of the accessory solvent meter (MS). Order Graco Part No. 280555 S3000 Solvent Meter Kit. See manual 308778. NOTE: You must assemble the meter sensor to the meter body before connecting the cable to the sensor for the meter to function properly. 1. See FIG. 11. Install the solvent meter (MS) on the side of the fluid station, using the bracket and hardware provided with the meter.
Electrical Electrical Requirements Connect Main Power 1. Provide power to the EasyKey. Install a bulkhead strain relief or conduit bulkhead through the EasyKey port . See FIG. 13. All electrical wiring must be completed by a qualified electrician and comply with all local codes and regulations. Enclose all cables routed in the spray booth and high traffic areas in conduit to prevent damage from paint, solvent, and traffic. 2. See FIG.
Electrical Connect EasyKey to Fluid Station Control There are two 50 ft (15.2 m) cables to route between the EasyKey and Fluid Station Control: the Fluid Station Power Cable and the Fiber Optic Cable. 1. Connect the appropriate Fluid Station Power Cable end to the EasyKey connector VDC . See FIG. 13. 2. Connect the other cable end to the Fluid Station Control connector VDC (J10). See FIG. 15. 3. The Fiber Optic Cable is shipped from the factory attached to the Fluid Station connector . See FIG. 13.
Electrical Fluid Station Control Board Switch Settings On the 2KS fluid station control board, set switch S1 to ON (down) or OFF (up), as shown in FIG. 15. J4 (Fiber Optic Output - blue) J6 (Fiber Optic Input - black) J10 (Power Input) VDC J11 (Color Change Module) Set Switch S1 as shown below. J7 (Booth Control) TI15224a Set switch S1 to ON (down) if system has Booth Control OR Color Change, or neither. TI15223a Set switch S1 to OFF (up) if system has Booth Control AND Color Change. FIG. 15.
Electrical Connect Color Change Module To install the color change module(s), see manual 312787. Connect a 5-pin electrical cable from the labeled connection port (J11) on the fluid station control Set switches S3-S6 on the color change board(s) as shown in Table 2 and FIG. 16, depending on the number of color change boards and color change modules being used in your system. For wiring between the color change board and the solenoids, see the color change module electrical schematic, FIG. 17.
Electrical Switch S3-S6 Positions ON ON OFF OFF S4 S6 TI13661a S5 J7 S3 J11 FIG. 16.
Electrical WIRING DIAGRAM COLOR 8 (21) COLOR 7 (20) COLOR 6 (19) COLOR 5 (18) COLOR 4 (17) COLOR 3 (16) COLOR 2 (15) COLOR 1 (14) COLOR FLUSH (13) +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM J8 J15 J14 J9 J16 J10 COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COLOR 9 (22) COLOR 10 (23) COLOR 11 (24) COLOR 12 (25) CATALYST 4 (26) CATALYST 3 (27) CATALYST 2 (28) CATALYST 1 (29) CATALYST FLUSH (
Electrical Grounding Feed Pumps or Pressure Pots Your system must be grounded. Read Warnings, page 7. For intrinsic safety, ground wires for the EasyKey, Fluid Station, Booth Control, and Gun Flush Box must all be connected to the same true earth ground. See FIG. 18, page 28. Ground the ProMix system as instructed here and in the individual component manuals. A ground wire and clamp, part no. 223547, is available from Graco.
Electrical Color Change Module Wall Mount Fluid Station 9 10 Booth Control 8 3 Key: 4 Gun Flush Box EasyKey 1 EasyKey ground screw 2 EasyKey ground wire 3 Fluid Station ground screw 4 Fluid Station ground wire 5 True Earth Ground - check your local code for requirements 6 Gun Flush Box ground wire connection point 7 Gun Flush Box ground wire 8 Power Cable, Booth Control/Fluid Station 9 Color Control Module ground screw 10 Color Control Module ground wire (Part No. 223547).
Schematic Diagrams Schematic Diagrams System Pneumatic Schematic COLOR CHANGE CONTROL A B SE BE CLO 2 TU 5/3 N E OP DOSE A VALVE 12 VDC 4-WAY SOLENOID A B SE BE CLO 2 TU 5/3 N E OP DOSE B VALVE 12 VDC 05 AIR INPUT 4-WAY SOLENOID CONTROL AIR 3/8 AIR FILTER MANUAL DRAIN 5 MICRON WALL MOUNT ONLY A B 4-WAY SOLENOID A B 12 VDC A B AIR EXHAUST MUFFLER PURGE AIR SE BE CLO 2 TU 5/3 N E OP PURGE A VALVE SE BE CLO 2 TU 5/3 EN OP PURGE B VALVE SE BE CLO 2 TU 5/3 N E OP PURGE C VALVE (OPTIONAL
Schematic Diagrams System Electrical Schematic NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS system. Some components shown are not included with all systems.
Schematic Diagrams System Electrical Schematic NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS system. Some components shown are not included with all systems.
Dimensions and Mounting Hole Layouts Dimensions and Mounting Hole Layouts Wall Mount Fluid Station A Mounting plate only shown, for clarity C B D TI14134a E TI11894b NOTE: Height is shown from top of panel to fluid shutoff valves, and does not include the effect of variable fluid integrator heights. Width of panel does not include optional color/catalyst valve stacks. Module EasyKey A Overall Width in. (mm) Overall Depth in. (mm) B Overall Height in.
Dimensions and Mounting Hole Layouts EasyKey C E B D TI11891a A Booth Control Module Booth Control Bracket E B D TI11892a A 312775F TI12909a C 33
Dynamic Dosing Restrictor Selection Graphs Dynamic Dosing Restrictor Selection Graphs Use the graphs on pages 35- 39 as a guide to determine the correct restrictor size for your desired flow and material viscosity. Table 3 lists the available restrictor sizes. Table 3: Restrictor Sizes Example: Application: air spray system with a 5:1 mix ratio Fluid Supply: 1:1 pumps at 100 psi (7 bar, 0.7 MPa) Flow Rate: 300 cc/min at the gun Select the Restrictor Size: choose either the .040 or .
Dynamic Dosing Restrictor Selection Graphs psi (bar, MPa) Differential Pressure between A and B 4000 (276, 27.6) Key 3500 (241, 24.1) #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) See Detail View Below 500 (34, 3.4) 0 0 500 1000 1500 2000 2500 3000 3500 4000 Flow Rate (cc/min) Differential Pressure between A and B Detail View 1000 (69, 6.9) 750 (52, 5.2) 500 (34, 3.4) 375 (26 2.6) 250 (17, 1.
Dynamic Dosing Restrictor Selection Graphs psi (bar, MPa) Differential Pressure between A and B 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) See Detail View Below 200 14, 1.4) 0 0 500 1000 1500 2000 2500 3000 3500 4000 Flow Rate (cc/min) Detail View Differential Pressure between A and B 400 (28, 2.8) 300 (21, 2.1) 200 (14, 1.4) 100 (7, 0.7) 50 (3.4, 0.
Dynamic Dosing Restrictor Selection Graphs psi (bar, MPa) 800 (55, 5.5) Differential Pressure between A and B Key 700 (48, 4.8) #2 Restrictor #3 Restrictor #4 Restrictor #7 Restrictor 600 (41, 4.1) 500 (34, 3.4) 400 (28, 2.8) 300 (21, 2.1) 200 (14, 1.4) See Detail View Below 100 (7, 0.7) 0 0 500 1000 1500 2000 2500 3000 3500 4000 Flow Rate (cc/min) Differential Pressure between A and B Detail View 200 (14, 1.4) 150 (10, 1.0) 100 (7, 0.7) 50 (3.4, 0.
Dynamic Dosing Restrictor Selection Graphs psi (bar, MPa) Differential Pressure between A and B 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) See Detail View Below 50 (3.4, 0.34) 0 0 500 1000 1500 2000 2500 3000 3500 4000 Flow Rate (cc/min) Detail View Differential Pressure between A and B 100 (7, 0.7) 75 (5.2, 0.52) 50 (3.4, 0.34) 25 (1.7, 0.17) 0 0 500 1000 Flow Rate (cc/min) FIG. 22.
Dynamic Dosing Restrictor Selection Graphs psi (bar, MPa) 200 (14, 1.4 Differential Pressure between A and B 180 (12.4, 1.2 Key #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) See Detail View Below 20 (1.4, 0.14) 0 0 500 1000 1500 2000 2500 3000 3500 4000 Flow Rate (cc/min) Differential Pressure between A and B Detail View 40 (2.8, 0.28) 30 (2.1, 0.21) 20 (1.4, 0.14) 10 (0.7, 0.
Dynamic Dosing Restrictor Selection Graphs 40 312775F
Technical Data Technical Data Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . Base system: 4000 psi (28 MPa, 280 bar) Low pressure color change: 300 psi (2.1 MPa, 21 bar) High pressure color change: 3000 psi (21 MPa, 210 bar) Coriolis meter: 2300 psi (16.1 MPa, 161 bar) Maximum working air pressure . . . . . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7 bar) Air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 - 100 psi (0.5 - 0.7 MPa, 5.
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.