Installation ® ProMix 3KS 313881B EN Plural Component Proportioner Manual and Automatic systems for proportional mixing of plural component coatings. For professional use only. Approved for use in explosive atmospheres (except the EasyKey and 3KS Power Supply Module). 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.
Contents Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Equipment Approvals . . . . . . . . . . . . . . . . . . . . . . . 3 System Configuration and Part Numbers . . . . . . . 4 Configurator Key . . . . . . . . . . . . . . . . . . . . . . . . . 4 Standard Features . . . . . . . . . . . . . . . . . . . . . . . 5 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Component Identification and Definition . . . . . . . 8 Location . . . . . . . . . . . . . . . .
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 Power Supply Module. 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 digits from each of the following 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 A, B, and C 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.
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 symbol refers to procedure-specific risk. Refer back to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where applicable. WARNING FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode.
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.
Component Identification and Definition Component Identification and Definition See FIG. 2 and Table 1 for the system components. Components marked with a star (★) are available as part of the ProMix 3KS Kit. All other components are part of the ProMix 2KS System or are available as accessories. EK PSM★ CCM PS◆ PS★◆ BCV FO 3KS★ CCV★ BC ACV MB MA Fluid Hose to Gun 2KS ◆ See the ProMix 3KS Repair-Parts manual for optional cable lengths. MC★ 2KM 3KM★ TI14543a 6 ft (1.
Component Identification and Definition Table 1: Component Descriptions Component Description EasyKey (EK) Used to set up, display, operate, and monitor the system. The EasyKey accepts 85-250 VAC, 50/60 Hz line power and converts that power to acceptable low voltage and optical signals used by other system components. ★ 3KS Power Supply Module (PSM) Accepts 85-250 VAC, 50/60 Hz line power and converts that power to acceptable low voltage signals used by other system components.
Component Identification and Definition Table 1: Component Descriptions Component Flow Meters (MA, MB, ★MC, MS) Description Four optional flow meters are available from Graco: • G3000 is a general purpose gear meter typically used in flow ranges of 75-3800 cc/min. (0.02–1.0 gal/min.), pressures up to 4000 psi (28 MPa, 276 bar), and viscosities of 20–3000 centipoise. The K-factor is approximately 0.119 cc/pulse. • G3000HR is a high resolution version of the G3000 meter.
Location Location NOTE: To install the ProMix 2KS, see Installation Manual 312775 (manual systems) or 312778 (automatic systems). Intrinsically Safe Installation Requirements See FIG. 3 on page 12. Location Requirements 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.
Safety Barrier Safety Barrier 15T633* 15T634* 1/8” 3/8” 801-08-A-999-9-A-N-A-B-B-A-S 80A-04-A-SVW-9-A-N-A-B-B-A-S Endress+Hauser P/N * For P/N 15T633 order Coriolis Meter Kit 258150. For P/N 15T634 order Coriolis Meter Kit 258151. Graco P/N Size Flow Meter B A 3 2 Meter Position Signal Common 5 6 B J3 Terminal Signal Power 25 24 Meter Terminal Block No.
General Information General Information • Reference numbers and letters in parentheses in the text refer to numbers and letters in the illustrations. • FIG. 2, page 8, shows the basic components of a ProMix 3KS 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 the component C fluid supply line and the ProMix system.
Install the ProMix 3KS Upgrade Board Install the ProMix 3KS Upgrade Board 2. Unlock and open EasyKey door with its key. 3. Locate the display board (C). FIG. 5. 4. Remove one screw (E) and unplug the existing ProMix 2KS auto key board from the display board assembly. FIG. 5. • • • • • 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.
Install the ProMix 3KS Upgrade Board C PS UB J4 (on underside of upgrade board TI12496a RT1 Remove Screw (E) J3 (Upgrade Board Plug-in) FIG.
Air Supply Air Supply Requirements • Compressed air supply pressure: 75-100 psi (517-700 kPa, 5.2-7 bar). • Air hoses: use grounded hoses that are correctly sized for your system. 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. • Air regulator and bleed-type shutoff valve: include in each air line to fluid supply equipment.
Air Supply Air Connections 5. lnstall a bleed-type shutoff valve into the air purge valve inlet on the 2KS Wall Mount Fluid Station. See the System Pneumatic Schematic on page 34. 1. Tighten all ProMix system air and fluid line connections as they may have loosened during shipment. 6. Connect the air purge valve tubing (supplied) to a clean, dry air supply (install filters/dryers as needed). 2. Install a bleed-type air shutoff valve into the control air filter inlet on the 2KS Wall Mount Fluid Station.
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 Key: FI MC DVC RVC SVC CPV SM FI DVC Component C Meter Component C Dose Valve Component C Sampling Valve Component C Shutoff Valve Component C Purge Valve Static Mixer Fluid Integrator 1 3KS fluid inlet. Connect 6 ft (1.83 m) fluid supply line from 2KS fluid manifold static mixer outlet to 1/4 npt(m) fitting. 2 Connect gun fluid supply line to 1/4 npt fluid outlet. MC CPV RVC 1 SVC SM 2 TI14382a FIG. 7.
Electrical Electrical Requirements Connect Main Power 1. Provide power to the Power Supply Module. Install a bulkhead strain relief or conduit bulkhead through the Power Supply Module port . See FIG. 10. • • • • 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 completed by a qualified electrician and comply with all local codes and regulations.
Electrical Main Power Access Port AC Power Switch Ground Screw I/S Power TI14366a TI14372a FIG. 10. Power Supply Module Connections and AC Power Switch Connect Power Supply Module to ProMix 3KS Fluid Station Connect Color Change Module to ProMix 3KS Fluid Station 1. Connect one end of the 50 ft (15.2 m) Fluid Station Power Cable (Part No. 123271, red color coded) to the Power Supply Module I/S Power connector NOTE: Disconnect and discard the 3 ft (0.
Electrical J8 (Power Input from 2KS Fluid Station) J3 (Power Input from 3KS Power Supply Module) S1 OFF OFF ON ON TI15225a VDC J2 (Color Change Module) J1 (Booth Control) TI14373a FIG. 11. ProMix 3KS CAN Isolation Board Table 2: 3KS CAN Isolation Board Switch Settings Component Connector Diagnosis S1 J1, J2 If booth control is connected to J1 and color change module is connected to J2, set switch S1 to OFF.
Electrical Fluid Station Control Board Switch Settings See FIG. 12. On the 2KS fluid station control board, set switch S1 to ON (down) for all ProMix 3KS units. Set Switch S1 to ON (down) for all ProMix 3KS units. See views below Switch S1 ON TI15224a Switch S1 OFF TI15223a FIG.
Electrical Connect ProMix 2KS Fluid Station to ProMix 3KS Fluid Station Connect ProMix 3KS Solenoid Wiring Cable to ProMix 2KS Fluid Station Board See FIG. 14. At the ProMix 2KS Fluid Station, remove the knockout and install the solenoid cable strain relief See FIG. 14 and FIG. 15. The solenoid wiring cable is shipped attached to the ProMix 3KS Fluid Station. Connect the cable to the ProMix 2KS Fluid Station Board by (supplied).
Electrical Detail of ProMix 2KS Cable Connections to ProMix 3KS 10 ft (3.0 m), green color coded Solenoid Wiring Cable Strain Relief. See Table 3 on page 26 and System Electrical Schematic on pages 38 and 39. Apply labels (supplied) TI14379a FIG. 14. ProMix 2KS Cabling Connection Detail 10 ft (3.0 m), green color coded Detail of ProMix 3KS Cable Connections Solenoid Wiring Cable. See Table 3 on page 26 and System Electrical Schematic on pages 38 and 39. 50 ft (15.2m), red color coded 1 50 ft (15.
Electrical Table 3: Solenoid Wiring Cable Connections ProMix 2KS End (Board 255765) ProMix 3KS End Wire Color 26 Terminal Block Pin No. Description Wire Color Pin No.
Electrical 313881B 27
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 (J2) on the 3KS fluid station control board to the color change board. See FIG. 16. Set switches S3-S6 on the color change board(s) as shown in Table 4 and FIG. 16, depending on the number of color change boards and color change modules being used in your system.
Electrical Switch S3-S6 Positions ON ON OFF OFF S4 S6 TI13661a S5 J7 S3 J11 FIG. 16.
Electrical J7/J11 MANIFOLD CLR 8 CLR 7 CLR 6 CLR 5 CLR 4 CLR 3 CLR 2 CLR 1 SOL CLR 1 4 5 2 3 COLOR BOARD 1 (COLORS 1 THRU 12, CATALYST 1 THRU 4) +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 J15 5 6 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 J8 J14 J9 J16 J10 MANIFOLD 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC CLR 9 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC CLR 12 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC CAT 2 CLR 10 CLR 11 CAT 4 C
Electrical 313881B 31
Electrical Grounding Flow Meters Your system must be grounded. Read Warnings, page 6. For intrinsic safety, ground wires for the EasyKey, Power Supply Module, 2KS Fluid Station, 3KS Fluid Station, Booth Control, and Gun Flush Box must all be connected to the same true earth ground. See FIG. 18, page 33. 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 Booth Control 8 ProMix 2KS Wall Mount Fluid Station ProMix 3KS Fluid Station 9 10 3 Power Supply Module Key: 13 11 1 EasyKey ground screw 2 EasyKey ground wire 3 2KS Fluid Station ground screw 4 2KS 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 14 4 Gun Flus
Schematic Diagrams Schematic Diagrams System Pneumatic Schematic CC Board #1 COLOR CHANGE CONTROL COLOR VALVE STACKS AIR EXHAUST MUFFLER COLOR 1 COLOR 2 12 VDC COLOR 3 E UB 2T 5/3 N E OP A B 12 VDC 4-WAY SOLENOID SE O CL E B TU DOSE B VALVE 2 5/3 N E OP A B 12 VDC E 4-WAY SOLENOID OS 05 CL 3/8 AIR FILTER MANUAL DRAIN 5 MICRON WALL MOUNT ONLY CONTROL AIR A B COLOR 4 DOSE A VALVE COLOR 5 COLOR 6 1/4 TUBE 1/4 TUBE TO MANIFOLD O CL E B TU 2 5/3 N E OP PURGE A VALVE COLOR 7 C
Schematic Diagrams System Pneumatic Schematic CC Board #2 COLOR CHANGE CONTROL COLOR VALVE STACKS 3RD COMP. 1 3RD COMP. 2 3RD COMP. 3 3RD COMP. 4 1/4 TUBE 3RD COMP.
DISPLAY MEMBRANE SWITCH WITH RIBBON CABLE J2 J4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 3 4 5 6 7 8 9 10 11 DISPLAY BOARD P1 J6 RJ45 1 2 3 4 RJ45 J7 J8 J10 RJ45 1 2 3 4 5 6 1 2 3 4 J5 5 6 7 8 9 10 RJ45 J9 POWER HARNESS BARRIER BOARD POWER SUPPLY + + + + - POWER DIST.
313881B POWER HARNESS DC OK +24 VDC COMMON COMMON + + - BARRIER BOARD POWER SUPPLY 1 2 3 J4 +24VDC OPEN COMMON +12VDC I/S (RED) COM (BLACK) SHIELD 1 2 3 J5 HARNESS N L1 L1 N GND L1 85-250 VAC N 1 2 3 4 5 J1 1 2 PROMIX 3KS BARRIER/PS ENCLOSURE OPEN OPEN GND LUG TERMINAL BLOCK 1 POWER 2 ROCKER 1A SWITCH 1B 2A 2B 1 2 3 1 2 3 1 2 3 50' STD.
PROMIX 3KS PS & BARRIER INTERFACE TO FO IN (BLK) - J7 TO FO OUT (BLU) - J8 PROMIX 2KS EASYKEY INTERFACE NON-HAZARDOUS AREA CABLE (100' OPTION) (50' STD.
313881B See Table 3, page 26. +12VDC (RED) COM (BLK) SHIELD (BARE) 1 2 3 4 5 6 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 7 8 9 10 J15 1 2 3 4 5 6 1 2 3 4 5 6 +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM 2 3 5 3 2 5 4 1 J3 J8 J10 J16 J9 COM +12VDC COM +12VDC COM +12VDC 6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC 6' STD.
Dimensions and Mounting Hole Layouts Dimensions and Mounting Hole Layouts NOTE: See the table on page 41. 3KS Wall Mount Fluid Station A Mounting plate only shown, for clarity C B D E TI14377a TI14382a 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/component C valve stacks.
Dimensions and Mounting Hole Layouts A Overall Width in. (mm) Overall Depth in. (mm) B Overall Height in. (mm) 3KS Wall Panel 14.0 (355.6) 11.0 (279.4) Power Supply Module 10.2 (259.1) 6.7 (167.6) Module Mounting Dimensions, Width (C) x Height (D) in. (mm) E Mounting Hole Size in. (mm) Weight lb (kg) 18.8 (477.5) 13.0 x 12.0 (330.2 x 304.8) 0.5 (12.7) 50 (22.7) 11.5 (292.1) 8.0 x 10.75 (203.2 x 273.1) 0.3 (7.6) 22.2 (10.1) EasyKey See ProMix 2KS installation manual.
Dimensions and Mounting Hole Layouts 42 313881B
Technical Data Technical Data Maximum fluid working pressure . . . . . . . . . . . . . . . . . . . Base system: 3000 psi (21 MPa, 210 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.
