Repair-Parts ProMix® 2KS 312777E 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 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 manifold component.
System Configuration and Part Numbers 6 312777E
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 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.
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.
Grounding Grounding Your system must be grounded. See the Grounding instructions in your ProMix 2KS Installation manual. Pressure Relief Procedure NOTE: The following procedures relieve all fluid and air pressure in the ProMix 2KS system. Use the procedure appropriate for your system configuration. Check Resistance Relieve pressure when you stop spraying, before changing spray tips, and before cleaning, checking, or servicing equipment.
Pressure Relief Procedure Systems with Color Change and without Dump Valves Systems with Color/Catalyst Change and Dump Valves NOTE: This procedure relieves pressure through the sampling valve. NOTE: This procedure relieves pressure through the dump valves. 1. Complete all steps under Single Color Systems, page 11. 1. Complete all steps under Single Color Systems, page 11. 2. Close the A side shutoff valve (SVA), FIG. 3. Open the A side sampling valve (RVA). 2.
Pressure Relief Procedure Color Solenoid Identification Label Catalyst Color Solenoid Identification Label TI12826a Solvent Solenoid Overrides FIG.
Pressure Relief Procedure 14 312777E
Troubleshooting Troubleshooting Table 1: System Alarm Codes Code Description Follow Pressure Relief Procedure, page 11, before cleaning, checking, or servicing equipment. NOTE: Do not use the fluid in the line that was dispensed off ratio as it may not cure properly. Alarm Codes Table 1 lists the system alarm codes. See the system operation manual for complete information on alarm troubleshooting.
Troubleshooting Solenoid Troubleshooting NOTE: Refer to the Schematic Diagrams, page 30. F2 F1 J1 Power Fiber Optic CAN J13 CAN J12 1 J14 1 J15 GFB 2 GFB 1 Dump B J9 Dump A 1 Purge B Dose A Dose B Purge A Valve Overrides 3rd Purge J3 1 J8 Dump Valve A Dump Valve B GFB 1 Optional Solenoid Locations GFB 2 3rd Purge Valve Solenoid Dose Valve A Solenoid Dose Valve B Solenoid Purge Valve A Solenoid Purge Valve B Solenoid TI12652b FIG.
Troubleshooting NOTE: Refer to the Schematic Diagrams, page 30. If the dispense or purge valves are not turning on or off correctly, it could be caused by one of the following. Table 2: Solenoid Troubleshooting Cause 1. Air regulator pressure set too high or too low. Solution Check air pressure. 80-90 psi (550-630 kPa, 5.5-6.3 bar) is commonly used. Do not go below 70 psi (490 kPa, 4.9 bar) or above 120 psi (0.8 MPa, 8 bar), 2.
Troubleshooting Fluid Manifold Troubleshooting See FIG. 5. To remove the fluid manifold, see page 47. See manual 312781 for complete information on the fluid manifold.
Troubleshooting EasyKey Barrier Board Diagnostics See FIG. 6 and Table 3 to troubleshoot the EasyKey barrier board. Also see the EasyKey Electrical Schematic on page 31 and the System Electrical Schematic on pages 32 and 33. J4, Pin 1 J1, Pin 1 D5 F1 F2 F4 F3 D4 J5, Pin 1 FIG. 6: 255786 EasyKey Barrier Board Table 3: EasyKey Barrier Board Diagnostics Connector Description Diagnosis J1 AC Power Input n/a J4 24 Vdc Power Input to EasyKey Display Board D5 turns on.
Troubleshooting EasyKey Display Board Diagnostics See FIG. 7 and Table 4 to troubleshoot the EasyKey display board. Also see the EasyKey Electrical Schematic on page 31 and the System Electrical Schematic on pages 32 and 33.
Troubleshooting Table 4: EasyKey Display Board Diagnostics Connector/ Indicator Description Connector/ Indicator Description J1 Graphic Display Backlight J9 24 Vdc Power Input/Alarm Output J4 Ribbon Cable to Membrane J10 RS485 Communication Terminals J5 Inputs and Outputs D7 (green) J6 Remote I/O LED turns on when power is supplied to board J7 Fiber Optic Cable Input (black) J8 Fiber Optic Cable Output (blue) 312777E D11 (yellow) LED blinks (heartbeat) when board is operating P1 Eth
Troubleshooting 22 312777E
Troubleshooting Fluid Station Control Board Diagnostics See FIG. 8, FIG. 9, and Table 5 to troubleshoot the fluid station control board. Also see the System Electrical Schematic on pages 32 and 33. D18 D19 J4 (Fiber Optic Output - blue) F1 (Fuse) F2 (Fuse) J6 (Fiber Optic Input - black) D15 D45 J10 (Power Input) D16 J11 (Color Change Module) D46 D17 Set Switch S1 as shown below. J7 (Booth Control) D44 TI15223a D20 Set switch S1 to OFF (up) if system has Booth Control AND Color Change.
Troubleshooting Pin 1 AFS #1 J1 J10 AFS #2 Solvent Switch GFB 1 PS J4 J6 GFB 2 PS J11 J13 (Not Used) Pin 1 J12 Solvent Meter Spare Pin 1 Flow Meter A J3 Flow Meter B Pin 1 Dose Valve A Dose Valve B J9 Spare + G s + G s J7 + G s + G s + + + J14 J15 Pin 7 (plugged) + Dump Valve B + GFB 1 Pin 1 + GFB 2 + Dump Valve A + Spare + Pin 1 + 3rd Flush Valve + Purge Valve B (Solvent) Spare Pin 1 (plugged) + Purge Valve A (Air) Pin 7 (plugged) J8 FIG.
Troubleshooting Table 5: Fluid Station Control Board Diagnostics LED Connector and Pin Nos. Signal Description Diagnosis D15 J1, 1 & 2 Air Flow Switch 1 Turns on when gun 1 is triggered. D16 J1, 5 & 6 Solvent Flow Switch Turns on when solvent is flowing. D17 J1, 9 & 10 Gun Flush Box 2 Pressure Switch Turns on when a gun is in Gun Flush Box 2. D18 J10 Power Turns on when power is supplied to the board. D19 n/a Communication (yellow) Turns on when board is communicating with EasyKey.
Troubleshooting Booth Control Troubleshooting See FIG. 10 and Table 6 to troubleshoot the booth control board. Also see the System Electrical Schematic on pages 32 and 33. The booth control does not contain any servciceable parts and must be replaced as a complete unit. To replace the booth control, disconnect the cable from J7 on the fluid station control board. See FIG. 8 on page 23. Install the new booth control and connect the cable to J7.
Troubleshooting D2 D6 D7 D5 D3 D4 J11 (on rear of board) Bottom View of Booth Control TI12789a D10 D9 D8 FIG.
Troubleshooting Color Change Board Diagnostics See FIG. 11 and Table 7 to troubleshoot the color change board. Also see the System Electrical Schematic on pages 32 and 33. To replace the color change board, see manual 312787. J8, Pin 1 D33 D34 D43 D31 D44 D29 J9, Pin 1 J15, Pin 1 D39 D41 D32 D35 D38 J16, Pin 1 D27 D37 J14, Pin 1 D45 D30 D46 D28 J10, Pin 1 D36 D9 D10 D8 F1 (Fuse) J7 J11 FIG.
Troubleshooting Table 7: Color Change Board Diagnostics LED Connector and Pin Nos. Board 1 Signal Description Board 2 Signal Description Diagnosis D8 n/a Board OK Board OK Blinks (heartbeat) during normal operation. D9 n/a Communication (yellow) Communication (yellow) Turns on when board is communicating with ProMix 2KS. D10 J7 Power Power Turns on when power is supplied to the board.
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)
2777E DISPLAY BOARD P1 BARRIER BOARD J9 1 2 3 4 RJ45 DISPLAY BOARD RJ45 J5 J1 J4 24 VDC+ IN RED 18 AWG BLACK 18 AWG RED/BLACK/WHITE 22 AWG J5-1 J5-2 J5-3 SHIELD/GRND COMMON (BLACK) +12 VDC I/S (WHITE) UNUSED UNUSED J1-2 J1-1 UNUSED J1-4 J1-3 UNUSED J1-5 RED 18 AWG BLACK 18 AWG UNUSED J4-1 J4-2 J4-3 GREEN/BLACK/WHITE 22 AWG IS POWER 12 VDC + + + + - RED 18 AWG BLACK 18 AWG DC OK + - - 24 VDC+ HIGH VOLTAGE IN POWER SUPPLY 24 VDC+ OUTPUT GND LUG COMMON R
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.
Schematic Diagrams Tubing Schematic B3 13 B1 13 GFB1-P A2 GFB2-P A6 B7 B5 DB AT A4 DA A8 TI13857a B1 B3 B5 B7 GFB1-C TI13858a GFB2-C GFB1-A GFB2-A TI13862a A2 A4 A6 A8 DA DB GFB1-P GFB1-A ATOM-1 GFB1 GFB2 GFB1-C GFB1-S GFB2-P GFB2-A GFB2-C GFB2-S TI13863a 34 GFB1-S GFB2-S ATOM-1 TI13861a ATOM-2 ATOM-2 TI13860a 312777E
Schematic Diagrams Table 8: Tubing Chart Color Description Starting Point Ending Point Tube OD in. (mm) Tube Ref. No.
Service Service Before Servicing 3. Shut off ProMix 2KS power (0 position). FIG. 12. 4. If servicing EasyKey Display, also shut off power at main circuit breaker. • • • • • To avoid electric shock, turn off EasyKey power before servicing. Servicing EasyKey exposes you to high voltage. Shut off power at main circuit breaker before opening enclosure. All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.
Service Servicing EasyKey Updating Software To update software, upload new software from your PC using the basic web interface. See manual 313386. Replacing Display Board or Graphic Display 5. Disconnect graphic display power cable (J1) from the display board (210c). 6. Separate graphic display (210b) from display board (210c) [connector J2 on back of board]. 7. To assemble the new parts, align connector J2 on the display board (210c) with the socket on the graphic display (210b). Press them together.
Service Replacing Line Filter Replacing Power Switch 1. Follow Before Servicing, page 36. 1. Follow Before Servicing, page 36. 2. Unlock and open EasyKey door with its key. 2. Unlock and open EasyKey door with its key. 3. Note position of line filter input and output wires. See EasyKey Electrical Schematic, page 31. Disconnect wires and remove line filter (214l) from bracket (214m). See FIG. 14. 3. Note position of power switch wires. See EasyKey Electrical Schematic, page 31.
Service Replacing Barrier Board 8. Install the cover (214b) with 2 screws (214k), using the security tool. 9. Connect cables to J1, J4, and J5. 10. Close and lock EasyKey door with key. 11. Turn on power at main circuit breaker. NOTICE To avoid damaging circuit board when servicing, wear Part No. 112190 grounding strap on wrist and ground appropriately. 12. Turn EasyKey power on to test operation. Replacing Barrier Board Fuses 1. Follow Before Servicing, page 36. 2.
Service J4 (Power to Display Board) J1 (Power In) 214g 214g F2 F1 F4 F3 214h J5 (Power to Fluid Station) 214g Do not remove this screw 214h Front of Barrier Board, showing Fuses and Connectors 1 1 Z Apply thermal compound to surface of heatsink (Z). Back of Barrier Board, showing Heatsink (Z) FIG.
Service Replacing Air Filter Element Removing a pressurized air filter bowl could cause serious injury. Depressurize air line before servicing. Check the 5 micron air manifold filter daily and replace element (317a, Part No. 114228) as needed. 1. Close main air shutoff valve on air supply line and on unit. Depressurize air line. 317a TI13069a 2. Remove filter cover (A). See FIG. 17. 3. Unscrew filter bowl (B). 4. Remove and replace element (317a). 5. Screw filter bowl (B) on securely.
Service Wall Mount Fluid Station Preparation Servicing GFB Pressure Switch 1. Follow Before Servicing, page 36. 1. Follow Preparation, page 42. 2. Loosen the 4 screws (307), then remove the Wall Mount Fluid Station cover (322). FIG. 20. 2. See FIG. 19. Disconnect the GFB pressure switch (PS) wires from J1 pins 7-10 on the Control Board. Disconnect the air line. Remove the switch and hardware from the side of the fluid station. Servicing Air Flow Switch 3. Install a new GFB pressure switch.
Service 314 343 306 320 319 305 316 322 314 307 302 315 301 303 See Detail Below 340 341 318, 332 339 TI12425a 321 335 325 317 Solenoid Manifold Detail 309 311 308 323 342 328 330 328 313 324 331 312 TI12426a FIG.
Service Replacing Control Board 3. Remove 4 screws (303). Remove connector jam nuts on the outside of the enclosure (301). Remove control board (302). FIG. 20. 4. Install new control board (302) with 4 screws (303). 5. Connect cables to control board (302). FIG. 21. Insert fiber optic cable connectors into board connectors (J4, J6), matching blue with blue, black with black, and hand-tighten connectors. Do not pinch or kink the fiber optic cables; the cables require a 2 in. (51 mm) bend radius.
Service Replacing Solenoids 343 302 The Wall Mount Fluid Station has a minimum of 4 solenoids. If you have options installed, you have additional (optional) solenoids for each. See Table 9 and Schematic Diagrams, page 30. F2 F1 N To replace a single solenoid: 1. Follow Preparation, page 42, and shut off power at main circuit breaker. 2. Disconnect 2 solenoid wires (N) from control board (302). See FIG. 22 and System Electrical Schematic, page 33. 6 7 1 2 3 3.
Service Servicing Flow Meters 2. Secure meter (M) and plate (MP) to fluid station with screws (MS). NOTE: You must assemble the meter sensor to the meter body before connecting the cable to the sensor for the meter to function properly. Coriolis Meter 3. Connect meter cable (CC). See FIG. 23. 1. Follow Before Servicing, page 36. 4. Connect fluid line (P). 2. To remove and service the Coriolis meter, see manual 313599. 5. Calibrate meter as instructed in ProMix Operation manual.
Service Servicing Fluid Manifold 341 Removal 1. Follow Servicing Flow Meters, Removal steps 1-5, page 46. 2. Disconnect air and fluid lines from the manifold (4). 3. Holding onto the fluid manifold (4), loosen the three screws (341) holding the bracket (325) to the fluid station. Lift the fluid manifold (4) and pull it away from the panel. Service as instructed in the Fluid Mix Manifold manual 312781. 325 Installation 1. Secure the fluid manifold (4) and mounting plate (325) with three screws (341).
Service 48 312777E
Parts Parts Configurator Key The configured part number for your equipment is printed on the equipment identification labels. See the illustrations below 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. The digits in this table do not correspond to ref. nos. in the parts lists or parts drawings.
Parts ProMix 2KS Manual System Part No. MD0001 to MD7634, includes EasyKey with LCD display 2 10 2 5, 6 310 11 16 12 7 329 2 3 13b 8 13b (Ref) 9 4 2 Items 310 and 329 are part of the Wall Mount Fluid Station. See the parts list beginning on page 55 for descriptions.
Parts Ref. No. Configured Digit (see page 49) or part usage Part No.
Parts EasyKey Controls 277869 EasyKey, with Display 206 Detail of Display Interface Kit (210) 214c 214f 201 208 210a 210d 202 214h 214l, 214m 210b 210c (not part of kit) 210e 214g TI12554a 221 214a 211 214b TI12417b 214k 201 214d 214f 212 203 218 209 214l, 214m 214e, 214j 207 205, 206 213, 223, 206 52 204 215 221 211 TI13070b 312777E
Parts 277869 EasyKey, with Display Ref. No. Ref. No. Part No.
Parts Wall Mount Fluid Station 314 320 306 319 305 316 322 314 307 302 315 301 303 See Detail Below 340 339 341 325 321 318, 332 TI12425a 335 Control Board Fuses 343 317 Solenoid Manifold Detail 309 311 308 323 342 328 330 328 313 324 331 312 TI12426a TI12652b 54 312777E
Parts Wall Mount Fluid Station NOTE: Parts are shown on page 54, unless noted. Ref. No. 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 317a 318 319 320 321 322 323 324 325 327 Ref. No. Part No. Description 256529 ENCLOSURE 255765 BOARD, circuit n/a SCREW, machine, pan hd; 4-40 x 3/16 in. (5 mm) 119257 CONNECTOR, bar, ground 119162 CONNECTOR, plug, 6-position 116773 CONNECTOR, plug,10-position 113783 SCREW, machine, pan hd; 1/4-20 x 1/2 in.
Parts Color Change Accessory Kits Low Pressure Color Change Kits Kit Part No.
Technical Data Technical Data Maximum fluid working pressure . . . . . . . . . . . . . . . Base system: 4000 psi (27.58 MPa, 275.8 bar) Low pressure color change: 300 psi (2.07 MPa, 20.6 bar) High pressure color change: 3000 psi (21 MPa, 210 bar) Coriolis meter: 2300 psi (15.86 MPa, 158.6 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.
