312776L, Manual, ProMix 2KS Manual

Operation
ProMix ® 2KS 312776L

Plural Component Proportioner EN
Manual system for proportional mixing of plural component coatings.

For professional use only.
Approved for use in explosive atmospheres (except the EasyKey).
Important Safety Instructions See page 4 for model information, including maximum working
Read all warnings and instructions in this pressure. Equipment approval labels are on page 3. Some
manual. Save these instructions. components shown are not included with all systems.
TI12504a
# 53
2575 II 2 G
Contents
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Recipe Setup Screens . . . . . . . . . . . . . . . . . . . . 40
Equipment Approvals . . . . . . . . . . . . . . . . . . . . . . . 3 Recipe 0 Screens . . . . . . . . . . . . . . . . . . . . . . . 45
System Configuration and Part Numbers . . . . . . . 4 Calibration Screen . . . . . . . . . . . . . . . . . . . . . . . 47
Configurator Key . . . . . . . . . . . . . . . . . . . . . . . . . 4 System Operation . . . . . . . . . . . . . . . . . . . . . . . . . 48
Standard Features . . . . . . . . . . . . . . . . . . . . . . . 6 Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . 48
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sequential Dosing . . . . . . . . . . . . . . . . . . . . . . . 48
2KS Accessories . . . . . . . . . . . . . . . . . . . . . . . . . 6 Dynamic Dosing . . . . . . . . . . . . . . . . . . . . . . . . 48
2KS Acid Compatible Accessories . . . . . . . . . . . 6 Recipe (Color) Change . . . . . . . . . . . . . . . . . . . 48
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Solvent Push . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Important Two-Component Material Information . 9 Mix Fill Push . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Isocyanate Conditions . . . . . . . . . . . . . . . . . . . . . 9 General Operating Cycle, Sequential Dosing . . 48
Material Self-ignition . . . . . . . . . . . . . . . . . . . . . . 9 General Operating Cycle, Dynamic Dosing . . . . 50
Keep Components A and B Separate . . . . . . . . . 9 Mix Manifold Valve Settings . . . . . . . . . . . . . . . 53
Moisture Sensitivity of Isocyanates . . . . . . . . . . 10 Air Flow Switch (AFS) Function . . . . . . . . . . . . . 54
Changing Materials . . . . . . . . . . . . . . . . . . . . . . 10 Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Important Acid Catalyst Information . . . . . . . . . . 11 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Acid Catalyst Conditions . . . . . . . . . . . . . . . . . . 11 Pressure Relief Procedure . . . . . . . . . . . . . . . . 57
Moisture Sensitivity of Acid Catalysts . . . . . . . . 11 Purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . 12 Solvent Push Feature . . . . . . . . . . . . . . . . . . . . 65
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Mix Fill Push Feature . . . . . . . . . . . . . . . . . . . . . 66
Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Meter Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Component Identification and Definition . . . . . . 15 Color Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Booth Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Color Change Procedures . . . . . . . . . . . . . . . . . 69
EasyKey Display and Keypad . . . . . . . . . . . . . . . 20 Color Change Sequences . . . . . . . . . . . . . . . . . 69
Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Alarms and Warnings . . . . . . . . . . . . . . . . . . . . . . 82
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 System Alarms . . . . . . . . . . . . . . . . . . . . . . . . . 82
AC Power Switch . . . . . . . . . . . . . . . . . . . . . . . 21 System Warnings . . . . . . . . . . . . . . . . . . . . . . . 82
I/S Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Alarm Troubleshooting . . . . . . . . . . . . . . . . . . . . . 83
Audible Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . 94
Graco Web Interface Port . . . . . . . . . . . . . . . . . 21 System Pneumatic Schematic . . . . . . . . . . . . . . 94
Ethernet Connection . . . . . . . . . . . . . . . . . . . . . 21 System Electrical Schematic . . . . . . . . . . . . . . . 95
Run Mode Screens . . . . . . . . . . . . . . . . . . . . . . . . 22 EasyKey Electrical Schematic . . . . . . . . . . . . . . 97
Splash Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Meter Performance Data (G3000 on A and B) . . . 98
Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Meter Performance Data (G3000 on A, Coriolis
Totals Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 25 on B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Reset Total Screen . . . . . . . . . . . . . . . . . . . . . . 25 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Reset Solvent Screen . . . . . . . . . . . . . . . . . . . . 25 Graco Standard Warranty . . . . . . . . . . . . . . . . . . 102
Alarms Screens . . . . . . . . . . . . . . . . . . . . . . . . . 26 Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 102
Level Control Screen . . . . . . . . . . . . . . . . . . . . 26
Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Password Screen . . . . . . . . . . . . . . . . . . . . . . . 28
Set Up Home Screen . . . . . . . . . . . . . . . . . . . . 28
System Configuration Screens . . . . . . . . . . . . . 30
Option Screens . . . . . . . . . . . . . . . . . . . . . . . . . 34
Advanced Setup Screens . . . . . . . . . . . . . . . . . 36
2 312776L
Related Manuals
Related Manuals Equipment Approvals

Component Manuals in English Equipment approvals appear on the following labels
Manual Description which are attached to the Fluid Station and EasyKey™.
See FIG. 1 on page 5 for label locations.
312775 ProMix 2KS Manual System Installation
312777 ProMix 2KS Manual System Repair-Parts EasyKey and Fluid Station Label
312781 Fluid Mix Manifold ATEX Certificate is listed here
312782 Dispense Valve
312783 Color Change Valve Stacks ®
ProMix 2KS Intrinsically Safe (IS) System. Install
312787 Color Change Module Kit Electronic Proportioner per IS Control Drawing No. 289833.
EasyKey Interface IS Associated
312784 Gun Flush Box Kits Apparatus for use in non hazardous
C US
location, with IS Connection to Smart
310745 Gun Air Shutoff Kit FM08ATEX0074
II 2 G Intrinsically safe
Fluid Plate IS
Ex ia IIA T3 Apparatus for use in:
equipment for Class I,
312786 Dump Valve and Third Purge Valve Kits Div 1, Group D, T3 Class I, Division 1, Group D T3
Ta = -20°C to 50°C Hazardous Locations
312785 Network Communication Kits Read Instruction Manual
MAX AIR WPR Warning: Substitution of components
308778 G3000/G3000HR Flow Meter may impair intrinsic safety.
.7 7 100
313599 Coriolis Flow Meter MPa bar PSI
PART NO. SERIES SERIAL
MAX FLUID WPR
313290 Floor Stand Kit
MFG. YR. GRACO INC.
313542 Beacon Kit MPa bar PSI P.O. Box 1441
Minneapolis, MN
MAX TEMP 50°C (122°F) 55440 U.S.A.
313386 Basic Web Interface/Advanced Web Inter-
face
406799 15V256 Automatic System Upgrade Kit
406800 15V825 Discrete I/O Board Kit
Fluid Station Label
ProMix® 2KS FLUID PANEL

PART NO. SERIES SERIAL MFG. YR. MAX AIR WPR
.7 7 100
Intrinsically safe equipment MPa bar PSI
for Class I, Div 1, Group D, T3 GRACO INC.
C US Ta = -20°C to 50°C
Install per 289833 FM08ATEX0073 P.O. Box 1441
II 2 G Minneapolis, MN
Ex ia IIA T3 55440 U.S.A.
Artwork No. 293538
TI13581b
ATEX Certificate is listed here
EasyKey Label
ProMix® 2KS POWER REQUIREMENTS

PART NO. SERIES NO. MFG. YR. VOLTS 85-250 ~
Artwork No. 293467
AMPS 2 AMPS MAX

GRACO INC.
Intrinsically safe connections
for Class I, Div 1, Group D 50/60 Hz
P.O. Box 1441 C US Ta = -20°C to 50°C
Minneapolis, MN Install per 289833 II (2) G
55440 U.S.A. [Ex ia] IIA
Um: 250 V FM08ATEX0072
TI13582b
ATEX Certificate is listed here
312776L 3
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.
Manual
System Control and Display A and B Meter Color Valves Catalyst Valves Applicator Handling
M D = EasyKey with LCD 0 = No Meters 0 = No Valves 0 = No Valves 1 = One Air Flow
Display (single color) (single catalyst) Switch Kit
1 = G3000 (A and B)
1 = Two Valves 1 = Two Valves 2 = Two Air Flow
2 = G3000HR (A and
(low pressure) (low pressure) Switch Kits
B)
2 = Four Valves (low 2 = Four Valves 3 = One Gun Flush Box
3 = 1/8 in. Coriolis (A)
pressure) (low pressure) Kit
and G3000 (B)
3 = Seven Valves 3 = Two Valves 4 = Two Gun Flush Box
4 = G3000 (A) and 1/8
(low pressure) (high pressure) Kits
in. Coriolis (B)
4 = Twelve Valves
5 = 1/8 in. Coriolis (A)
(low pressure)
and G3000HR (B)
5 = Two Valves
6 = G3000HR (A) and
(high pressure)
1/8 in. Coriolis (B)
6 = Four Valves
7 = 1/8 in. Coriolis (A
(high pressure)
and B)
M E = EasyKey with LCD 1 = G3000 (A) and 0 = No Valves 0 = No Valves 1 = One Air Flow
(acid Display G3000A (B) (no color; need (single catalyst) Switch Kit
models) to order acid kit
2 = Two Air Flow
26A096-26A100;
Switch Kits
see page 6)
3 = One Gun Flush Box
Kit
4 = Two Gun Flush Box
Kits
4 312776L
®
ProMix 2KS Intrinsically Safe (IS) System. Install
Electronic Proportioner per IS Control Drawing No. 289833.
EasyKey Interface IS Associated
Apparatus for use in non hazardous
C US
location, with IS Connection to Smart
FM08ATEX0074 Fluid Plate IS
II 2 G Intrinsically safe
Ex ia IIA T3 Apparatus for use in:
equipment for Class I,
Class I, Division 1, Group D T3
Label Location Div 1, Group D, T3
Ta = -20°C to 50°C Hazardous Locations
Label Location
on Fluid Station Read Instruction Manual on EasyKey
MAX AIR WPR Warning: Substitution of components TI12418a
TI12423a
may impair intrinsic safety.
.7 7 100
PART NO. SERIES SERIAL
MPa bar PSI
Maximum Fluid MAX FLUID WPR Configured Part Number
Working Pressure MFG. YR. GRACO INC.
is listed here MPa bar PSI P.O. Box 1441
Minneapolis, MN
MAX TEMP 50°C (122°F) 55440 U.S.A.
FIG. 1: Identification Label
Hazardous Location Approval

Models using a G3000, G3000HR, G3000A, 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.
Example: Model MD2531 has a maximum working pressure of 3000 psi (21 MPa, 210 bar).
Check the identification label on the EasyKey or fluid station for the system maximum working pressure.
See FIG. 1.
ProMix Fluid Components Maximum Working Pressure

Base System (no meters [option 0], no color/catalyst change [option 0]). . . . . . . 4000 psi (27.58 MPa, 275.8 bar)
Meter Option 1 and 2 (G3000 or G3000HR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000 psi (27.58 MPa, 275.8 bar)
Meter Option 3, 4, 5, 6, and 7 (one or two Coriolis Meters) . . . . . . . . . . . . . . . . . 2300 psi (15.86 MPa, 158.6 bar)
Meter Option 8 (G3000 and G3000A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000 psi (27.58 MPa, 275.8 bar)
Color Change Option 1, 2, 3 and 4 and
Catalyst Change Option 1 and 2 (low pressure valves) . . . . . . . . . . . . . . . . . . . . . . . 300 psi (2.07 MPa, 20.6 bar)
Color Change Option 5 and 6 and
Catalyst Change Option 3 (high pressure valves) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 psi (21 MPa, 210 bar)
Flow Meter Fluid Flow Rate Range

G3000 and G3000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-3800 cc/min. (0.02-1.0 gal./min.)
G3000HR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-1900 cc/min. (0.01-0.50 gal./min.)
Coriolis Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3800 cc/min. (0.005-1.00 gal./min.)
S3000 Solvent Meter (accessory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38-1900 cc/min. (0.01-0.50 gal./min.)
312776L 5
Accessories
Standard Features Accessories

Feature
EasyKey with LCD 2KS Accessories
Fiber Optic and Power Cables, 50 ft (15.25 m)
Accessory
Wall Mount Fluid Station, 50 cc Integrator and Static
Mixer Gun Flush Box Gun Insert Selection
B Side Dump Valve, if multiple catalyst valves 15V354 Third Purge Valve Kit
Booth Control 15V536 Solvent Flow Switch Kit
Basic Web Interface 15V213 Power Cable, 100 ft (30.5 m)
15G710 Fiber Optic Cable, 100 ft (30.5 m)
15U955 Injection Kit for Dynamic Dosing
15V034 10 cc Integrator Kit
24B618 100 cc Integrator Kit
15W034 Strobe Light Alarm Indicator Kit
15V337 Advanced Web Interface
15V256 Automatic Mode Upgrade Kit
16D329 S3000 Solvent Flow Meter Kit
15V825 Discrete I/O Integration Board Kit
2KS Acid Compatible

Accessories
Intended for use with acid catalyst materials.
Accessory
26A096 No Color /1 Catalyst Change Kit
26A097 2 Color/1 Catalyst Change Kit
NOTE: This is not a complete list of available accesso-

ries and kits. Refer to the Graco website for more infor-
mation about accessories available for use with this
product.
6 312776L
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual, refer back to these Warnings. Product-specific hazard symbols and
warnings not covered in this section may appear throughout the body of this manual where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
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 a G3000, G250, G3000HR, G250HR, G3000A, or intrinsically safe Coriolis meter
are approved for installation in a Hazardous Location - Class I, Div I, Group D, T3 or Zone I Group
IIA T3.
• Do not install equipment approved only for a non-hazardous location in a hazardous area. See the
ID label for the intrinsic safety rating of your model.
• Do not substitute or modify system components as this may impair intrinsic safety.
312776L 7
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.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
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 forms from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-
facturer’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 MSDS’s 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 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, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
• Gloves
• Hearing protection
8 312776L
Important Two-Component Material Information

Isocyanates (ISO) are catalysts used in two component Material Self-ignition
materials.
Isocyanate Conditions
Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings and
Safety Data Sheet (SDS).
Spraying or dispensing materials that contain

isocyanates creates potentially harmful mists, Keep Components A and B
vapors, and atomized particulates.
Separate
• Read and understand the fluid manufacturer’s
warnings and Safety Data Sheet (SDS) to know
specific hazards and precautions related to
isocyanates.
• Use of isocyanates involves potentially hazardous Cross-contamination can result in cured material in
procedures. Do not spray with this equipment fluid lines which could cause serious injury or
unless you are trained, qualified, and have read damage equipment. To prevent cross-contamination:
and understood the information in this manual and
• Never interchange component A and component
in the fluid manufacturer’s application instructions
B wetted parts.
and SDS.
• Never use solvent on one side if it has been
• Use of incorrectly maintained or mis-adjusted
contaminated from the other side.
equipment may result in improperly cured
material. Equipment must be carefully maintained
and adjusted according to instructions in the
manual.
• To prevent inhalation of isocyanate mists, vapors,
and atomized particulates, everyone in the work
area must wear appropriate respiratory protection.
Always wear a properly fitting respirator, which
may include a supplied-air respirator. Ventilate the
work area according to instructions in the fluid
manufacturer’s SDS.
• Avoid all skin contact with isocyanates. Everyone
in the work area must wear chemically
impermeable gloves, protective clothing and foot
coverings as recommended by the fluid
manufacturer and local regulatory authority.
Follow all fluid manufacturer recommendations,
including those regarding handling of
contaminated clothing. After spraying, wash
hands and face before eating or drinking.
312776L 9
Moisture Sensitivity of NOTE: The amount of film formation and rate of crystal-
lization varies depending on the blend of ISO, the
Isocyanates humidity, and the temperature.
Exposure to moisture (such as humidity) will cause ISO

to partially cure; forming small, hard, abrasive crystals, Changing Materials
which become suspended in the fluid. Eventually a film
will form on the surface and the ISO will begin to gel,
increasing in viscosity. NOTICE
Changing the material types used in your equipment
NOTICE requires special attention to avoid equipment damage
Partially cured ISO will reduce performance and the and downtime.
life of all wetted parts.
• When changing materials, flush the equipment
• Always use a sealed container with a desiccant multiple times to ensure it is thoroughly clean.
dryer in the vent, or a nitrogen atmosphere. • Always clean the fluid inlet strainers after
Never store ISO in an open container. flushing.
• Keep the ISO pump wet cup or reservoir (if • Check with your material manufacturer for
installed) filled with appropriate lubricant. The chemical compatibility.
lubricant creates a barrier between the ISO and
• When changing between epoxies and urethanes
the atmosphere.
or polyureas, disassemble and clean all fluid
• Use only moisture-proof hoses compatible with components and change hoses. Epoxies often
ISO. have amines on the B (hardener) side. Polyureas
• Never use reclaimed solvents, which may often have aminies on the A (resin) side.
contain moisture. Always keep solvent
containers closed when not in use.
• Always lubricate threaded parts with an
appropriate lubricant when reassembling.
10 312776L
Important Acid Catalyst Information
Important Acid Catalyst Information

The 2KS Plural Component Proportioner is designed for acid catalysts (“acid”) currently used in two-component,
wood-finishing materials. Current acids in use (with pH levels as low as 1) are more corrosive than earlier acids.
More corrosion-resistant wetted materials of construction are required, and must be used without substitution, to
withstand the increased corrosive properties of these acids.
Acid Catalyst Conditions
Acid is flammable, and spraying or dispensing acid creates potentially harmful mists, vapors, and atomized
particulates. To help prevent fire and explosion and serious injury:
• Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific
hazards and precautions related to the acid.
• Use only genuine, manufacturer’s recommended acid-compatible parts in the catalyst system (hoses,
fittings, etc). A reaction may occur between any substituted parts and the acid.
• To prevent inhalation of acid mists, vapors, and atomized particulates, everyone in the work area must
wear appropriate respiratory protection. Always wear a properly fitting respirator, which may include a
supplied-air respirator. Ventilate the work area according to instructions in the acid manufacturer’s SDS.
• Avoid all skin contact with acid. Everyone in the work area must wear chemically impermeable gloves,
protective clothing, foot coverings, aprons, and face shields as recommended by the acid manufacturer
and local regulatory authority. Follow all fluid manufacturer recommendations, including those regarding
handling of contaminated clothing. Wash hands and face before eating or drinking.
• Regularly inspect equipment for potential leaks and remove spills promptly and completely to avoid direct
contact or inhalation of the acid and its vapors.
• Keep acid away from heat, sparks, and open flames. Do not smoke in the work area. Eliminate all ignition
sources.
• Store acid in the original container in a cool, dry, and well-ventilated area away from direct sunlight and
away from other chemicals in accordance with acid manufacturer’s recommendations. To avoid corrosion
of containers, do not store acid in substitute containers. Reseal the original container to prevent vapors
from contaminating the storage space and surrounding facility.
Moisture Sensitivity of Acid NOTICE

Catalysts Acid build-up will damage the valve seals and reduce
the performance and life of the catalyst pump. To pre-
Acid catalysts can be sensitive to atmospheric moisture
vent exposing acid to moisture:
and other contaminants. It is recommended the catalyst
pump and valve seal areas exposed to atmosphere are • Always use a sealed container with a desiccant
flooded with ISO oil, TSL, or other compatible material dryer in the vent, or a nitrogen atmosphere.
to prevent acid build-up and premature seal damage Never store acids in an open container.
and failure. • Keep the catalyst pump and the valve seals filled
with the appropriate lubricant. The lubricant
creates a barrier between the acid and the
atmosphere.
• Use only moisture-proof hoses compatible with
acids.
• Always lubricate threaded parts with an
appropriate lubricant when reassembling.
312776L 11
Glossary of Terms
Glossary of Terms
Advanced Web Interface (AWI) - This allows remote Coriolis Meter - a non-intrusive flow meter often used in
ProMix backup and restore, configuration, logging, and low flow applications or with light viscosity, shear sensi-
software update options. tive, or acid catalyzed materials. This meter uses vibra-
tion to measure flow.
Air Chop - the process of mixing air and solvent
together during the flush cycle to help clean the lines Custom Language - A method to load a translation file
and reduce solvent usage. into the ProMix to display languages other than those
built into the system. Only Unicode characters through
Air Chop Time- duration of each activation of the air codespace 0x00FF are supported.
purge valve during a chop sequence. User settable from
0.0-99.9 seconds. Digital Input and Output - a description of data which
is transmitted as a sequence of discrete symbols, most
Analog - relating to, or being a device in which data are commonly this means binary data represented using
represented by continuously variable, measurable, electronic or electromagnetic signals.
physical quantities, such as length, width, voltage, or
pressure. Discrete I/O - refers to data that constitutes a separate
entity and has direct communication to another control.
B Purge After Chop - Optional 2-second B solvent
valve activation after the Chop sequence. This is used Dose Size - the amount of resin (A) and catalyst (B) that
to separate the chop material and the Final Purge mate- is dispensed into an integrator.
rial to prevent unwanted mixing.
Dose Time Alarm - the amount of time that is allowed
Basic Web Interface (BWI) - This allows remote Pro- for a dose to occur before an alarm occurs. More than
Mix backup and restore, logging, and software update 30 pulses from the flow meter of the active dose valve
options. are needed while the Gun Trigger is on to prevent the
alarm.
Bootloader - The utility program that handles initial sys-
tem startup re-programming of the main ProMix applica- Dynamic Dosing - Component A dispenses constantly.
tion. Component B dispenses intermittently in the necessary
volume to attain the mix ratio.
Chop Time- refers to the total length of the chop
sequence during a purge. User settable from 0-999 sec- Ethernet - a method for directly connecting a computer
onds. to a network or equipment in the same physical location.
Closed Loop Flow Control - refers to the process ExtSP - External Set Point selection for PLC input of the
when the flow rate is adjusted automatically to maintain flow rate set point while operating in Flow Control Over-
a constant flow. ride mode.
Color/Catalyst Purge - refers to the time required to Fiber Optic Communication - the use of light to trans-
flush the lines from the color or catalyst change module mit communication signals. Blue is the transmitter, and
to the mix manifold during a color or catalyst change. black is the receiver. This must be cross-connected
between the EasyKey and the Fluid Panel for communi-
Color/Catalyst Fill - refers to the time required to fill the cation to work. The Fiber Optic cable has a blue band to
lines from the color or catalyst change module to the mix indicate the proper connection.
manifold.
Final Purge Source- source of the media used in the
Command Holdoff - The amount of time that flow rate final purge cycle. User settable to air purge valve, sol-
learning is not allowed after the set point is changed to vent purge valve, or 3rd purge valve.
allow the flow rate to stabilize.
Final Purge Time- duration of the final purge cycle.
User settable from 0-999 seconds.
12 312776L
Glossary of Terms
First Purge Source- source of the media used in the K-factor - a value that refers to the amount of material
first purge cycle. User settable to air purge valve, sol- that passes through a meter. The assigned value refers
vent purge valve, or 3rd purge valve to an amount of material per pulse.
First Purge Time- duration of the first purge cycle. User Kd - refers to the amount the fluid flow system attempts
settable from 0-999 seconds. to not overshoot the target set point.
Flow Control Resolution - a settable value that allows Ki - refers to the degree fluid flow over shoots its set
the flow control system to maximize its performance. point.
The value is based on maximum desired flow rates.
Kp - refers to the speed in which the fluid flow reaches
Flow Rate Analog Signal - the type of communication its set point.
signal that can be used on the ProControl module.
Learn Strength - How much and how quickly to apply
Flow Rate Tolerance - the settable percent of accept- the difference in the flow rate set point compared to the
able variance that the system will allow before a flow measured flow rate when updating the flow control data
rate warning occurs. table.
Flow Set Point - a predefined flow rate target. Manual Mode - when the proportioning or flow control
system is controlling the inputs without any input from
Flush Volume Check - system monitors flush volume. an outside control.
E-11 Alarm occurs if minimum volume is not achieved.
Minimum flush volume is user settable (0-999 cc). Minimum Material Fill Volume - system monitors
material fill volume. E-21 Alarm occurs if minimum vol-
Global - indicates that values on the screen apply to all ume is not achieved. Minimum material fill volume is
recipes, 1 through 60. user settable (0-9999 cc).
Grand Total - a non-resettable value that shows the Mix - when cross-linking of the resin (A) and catalyst (B)
total amount of material dispensed through the system. occurs.
GT-Off Drive Time - The amount of time to regulate the Mix Fill Push - An option for the Autodump selection to
fluid pressure based on the flow rate set point after the automatically clear the Potlife alarm if the gun is in the
gun trigger is closed. Gun Flush Box by running new mixed material through
the gun.
GT-Off Target Rise - The additional time to regulate the
fluid pressure based on the flow rate set point after the Mix Input Signal- refers to system mode status where
gun trigger is closed. system begins a dose sequence each time the mix sig-
nal is made “High”.
Gun Trigger Holdoff - The amount of time that flow rate
learning is not allowed after the gun trigger is opened to Mixed Material Fill Time - the amount of time that is
allow the flow rate to stabilize. required to load mixed material from the dose valves to
the applicator/gun.
Gun Trigger Input Signal - used to manage ratio
assurance dose times and flow control processes. Modbus/TCP - a type of communication protocol used
to communicate Digital I/O signals over an ethernet.
Intrinsically Safe (IS) - refers to the ability to locate cer-
tain components in a hazardous location. Network Station - a means to identify a particular indi-
vidual proportioning or flow control system.
Idle - if the gun is not triggered for 2 minutes the system
enters Idle mode. Trigger the gun to resume operation. One-Point Learning - Flow Control table calibration
method using learned points above a specified flow rate
Job Total - a resettable value that shows the amount of to interpolate the table at low flow rates with short gun
material dispensed through the system for one job. A job trigger times.
is complete when a color change or complete system
flush occurs.
312776L 13
Glossary of Terms
Overdose (A, B, C) Alarm - when either the resin (A), Third Purge Valve - refers to the use of three purge
or catalyst (B), or reducer (C) component dispenses too valves used to flush some waterborne materials. The
much material and the system cannot compensate for valves are used to flush with water, air and solvent.
the additional material.
V/P - refers to the voltage to pressure device in the flow
Potlife Time - the amount of time before a material control module.
becomes unsprayable.
Valve Holdoff Maximum - The maximum amount of
Potlife Volume - the amount of material that is required time that flow rate learning is not allowed after a dose
to move through the mix manifold, hose and applicator valve cycles. The system may internally use a time less
before the potlife timer is reset. than is based on the stability of the fluid meter pulse
stream.
Purge - when all mixed material is flushed from the sys-
tem.
Purge Drive - The voltage drive during the Purge

sequence, maximum of 3300 mV. The response curve
of the V/P regulator is not linear, so it may be necessary
to test the response using Manual Override mode.
Purge Time - the amount of time required to flush all

mixed material from the system.
Purge Volume Alarm - E-11 Alarm occurs if minimum

flush volume is not achieved.
Ratio Tolerance - the settable percent of acceptable

variance that the system will allow before a ratio alarm
occurs.
Sequential Color Change - the process when a color

change is initiated and the system automatically flushes
the old color and loads a new color.
Sequential Dosing - Components A and B dispense

sequentially in the necessary volumes to attain the mix
ratio.
Solvent/3rd Purge Valve Chop Time- duration of each

activation of the solvent or 3rd purge valve during a
chop sequence. User settable from 0.0-99.9 seconds.
Solvent Fill - the time required to fill the mixed material

line with solvent.
Solvent Push - enables the user to save some mixed

material by pushing it out to the gun with solvent.
Requires an accessory solvent meter.
Standby - refers to the status of the system.
System Idle - This warning occurs if the ProMix is set to

Mix, and 2 minutes have elapsed since the system
received a flow meter pulse.
14 312776L
Overview
Overview
Usage
The Graco ProMix 2KS is an electronic two-component paint proportioner. It can blend most two-component solvent
and waterborne epoxy, polyurethane, and acid-catalyzed paints. It is not for use with “quick-setting” paints (those
with a potlife of less than 15 minutes).
• Can proportion at ratios from 0.1:1 to 50:1 in 0.1 • Color change options are available for low pressure
increments with the wall mount fluid station. (300 psi [2.1 MPa, 21 bar]) air spray and high pres-
• Has user selectable ratio assurance and can main- sure (3000 psi [21 MPa, 210 bar]) systems with up
tain up to +/-1% accuracy, depending on materials to 30 color change valves and up to 4 catalyst
and operating conditions. change valves.
• Models are available to operate air spray or
air-assisted systems with a capacity of up to 3800 NOTE: Optional accessories are available for in
cc/min. field installation to achieve 30 colors.
Component Identification and Definition

See Table 1, FIG. 2, and FIG. 3 for the system components.
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.
Booth Control (BC) Used by the operator for daily painting functions including: choosing recipes, initiating job
complete, reading/clearing alarms, and placing the system in Standby, Mix, or Purge
mode. It is typically mounted inside the booth or near the painter.
Fluid Station (ST) Includes air control solenoids, flow switches, and mountings for the fluid flow meters and
the fluid manifold assembly. Its control board manages all proportioning functions.
Fluid Manifold (FM) • 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 mani-
fold, to allow for accurate calibration and ratio checks
• Mix Manifold, which includes the fluid integrator and static mixer.
 Fluid Integrator is the chamber where component A and B align at the
selected ratio and begin to mix.
 Static Mixer has 24 elements to uniformly blend the materials downstream
of the fluid integrator.
312776L 15
Overview
Table 1: Component Descriptions
Component Description
Flow Meters (MA, Three optional flow meters are available from Graco:
MB, MS) • 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 viscosi-
ties of 20–3000 centipoise. The K-factor is approximately 0.119 cc/pulse.
• G3000A is a gear meter for use with acid catalyst fluids. It is 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. It is typically used in flow
ranges of 38–1900 cc/min. (0.01–0.5 gal/min.), pressures up to 4000 psi (28 MPa,
276 bar). and viscosities of 20–3000 centipoise. The K-factor is approximately 0.061
cc/pulse.
• S3000 is a gear meter used for solvents in flow ranges of 38-1900 cc/min. (0.01–0.50
gal/min.), pressures up to 3000 psi (21 MPa, 210 bar), and viscosities of 20–50 centi-
poise. The K-factor is approximately 0.021 cc/pulse. Required to use the Solvent
Push feature.
• Coriolis is a specialty meter capable of a wide range of flow rates and viscosities.
This meter is available with 1/8 in. or 3/8 in. diameter fluid passages. For detailed
information on the Coriolis meter, see manual 313599.
The K-factor is user-settable; at lower flow rates use a lower K-factor.
 1/8 in. fluid passages: set K-factor to .020 or .061.
 3/8 in. fluid passages: set K-factor to .061 or 0.119.
Color Change An optional component. It is available as a color change valve stack for either low or high
Valves (ACV) and pressure with up to 30 color change valves. Each stack includes one additional valve for
Color Change solvent to clean the fluid line between color changes.
Module (CCM)
Catalyst Change An optional component. It is available as a catalyst change valve stack for either low or
Valves (BCV) high pressure with up to 4 catalyst change valves. Each stack includes one additional
valve for solvent to clean the fluid line between catalyst changes.
A different catalyst change valve is used on acid catalyst systems.

Dual Fiber Optic Used to communicate between the EasyKey and Wall Mount Fluid Station.
Cable (FO)
Fluid Station Power Used to provide power to the Wall Mount Fluid Station.
Supply Cable (PS)
Applicator Air Flow Switch: The air flow switch detects air flow to the gun and signals the ProMix
Handling: use Air controller when the gun is being triggered. The switch functions with the flow meters to
Flow Switch (AFS) ensure that the system components are functioning correctly. See page 54 for further
or Gun Flush Box information.
(GFB)
Gun Flush Box: The gun flush box kit provides an automated flushing system for manual
spray guns, and includes an air flow switch.
16 312776L
Overview
EK CCM
PS
BC
BCV
FO
ACV GFB
MS
ST
MB
MA
FM
BCV - acid models
TI29655a
FIG. 2. Manual System, shown with G3000 Meters, Color/Catalyst Change, One Gun Flush Box, and
Accessory Solvent Flow Meter
312776L 17
Overview
DVA FI DVB
MB
MS
MA
RVB
AT
APV
RVA SVA SM SVB SPV

TI12556b
FIG. 3. Wall Mount Fluid Station
Key:
MA Component A Meter
DVA Component A Dose Valve
RVA Component A Sampling Valve
SVA Component A Shutoff Valve
MB Component B Meter
DVB Component B Dose Valve
RVB Component B Sampling Valve
SVB Component B Shutoff Valve
MS Solvent Meter (accessory)
SPV Solvent Purge Valve
APV Air Purge Valve
SM Static Mixer
FI Fluid Integrator
AT Air Purge Valve Air Supply Tube
18 312776L
Booth Control
Booth Control
Used by the operator for daily painting functions includ- Table 2: Booth Control Key and Indicator Functions
ing: changing recipes, signalling job complete, read- (see FIG. 4)
ing/clearing alarms, and placing the system in Standby,
Mix, or Purge mode. It is typically mounted inside the Key/Indicator Definition and Function
booth or near the painter. Up Key Scrolls recipe numbers up.
Table 2: Booth Control Key and Indicator Functions

(see FIG. 4)
Down Key Scrolls recipe numbers down.
Key/Indicator Definition and Function
Display • Displays recipe number in Run
mode. Mix Mode Key • Starts Mix mode.
• If an alarm occurs, displays the • Green LED remains lit while in Mix
alarm code (E1 to E28) and red mode or in Idle mode.
Alarm indicator blinks. • Press and hold for 5 seconds to
• Recipe number displays after turn on the Solvent Push feature.
alarm is reset.
Standby • Starts Standby mode.
• If Solvent Push is on, display alter-
Mode Key • Green LED remains lit while in
nately shows dashes and the per-
Standby mode.
centage remaining (see page 65).
Recipe • Green LED stays lit while a recipe
Indicator is in use. Purge Mode • Starts Purge mode.
Key • Green LED remains lit while in
• LED shuts off when Up or Purge mode.
Down keys are pressed or if an
alarm occurs.
• LED blinks while a new recipe is
loading and turns solid after load-
ing is complete.
• LED blinks when purging. Alarm Indicator (red) Display
• Select a new recipe by pressing
Up or Down keys, then
pressing Enter .
Alarm Reset • Red LED blinks when an alarm
Key and occurs.
Indicator • Press key to reset alarm. LED
shuts off after alarm is reset.
Job Complete • Signals that job is complete, and

Key and resets A and B totalizers.
Indicator • Green LED blinks once after key is
pressed.
Recipe Indicator (green) TI11614A

Enter Key Enters selected recipe and starts color
change sequence. FIG. 4. Booth Control (see Table 2)
312776L 19
EasyKey Display and Keypad
Keypad
LCD Display
TI11630A
Navigation Keys Alarm Reset Key
FIG. 5. EasyKey Display and Keypad
Display Table 3: EasyKey Keypad Functions (see FIG. 5)

Shows graphical and text information related to setup Key Function
and spray operations. Back light will turn off after 10
minutes without any key press. Press any key to turn Setup: press to enter or exit Setup mode.
back on.
Enter: if cursor is in menu box, press Enter
NOTE: Pressing a key to turn on the display back light
key to view menu. Press Enter to save a
will also perform the function of that key. If you are
value either keyed in from the numerical
unsure whether that key will impact your current opera-
keypad or selected from a menu.
tion, use the setup or navigation keys to turn on the dis-
play back light. Up Arrow: move to previous field or menu
item, or to previous screen within a group.
Down Arrow: move to next field or menu
Keypad item, or to next screen within a group.
Used to input numerical data, enter setup screens, scroll Left Arrow: move to previous screen group.
through screens, and select setup values.
In addition to the numbered keys on the EasyKey key- Right Arrow: move to next screen group.
pad, which are used to enter values in setup, there are
keys to navigate within a screen and between screens, Alarm Reset: resets all active alarms.
and to save entered values. See Table 3. If the display becomes unresponsive,
pressing this key 4 times in succession will
re-initialize the display.
20 312776L
AC
Fiber Optic Strain Audible Alarm Power
Relief Port
Main Power
Access Port
Ground Screw I/S Power Graco Web Discrete I/O Cable

Interface Connector Ports
TI12638a TI12657a
FIG. 6. EasyKey Connections and AC Power Switch
AC Power Switch Graco Web Interface Port

Turns system AC power on or off. Used to communicate from a PC to:
 Upgrade software
I/S Power  View software version
 Download
Power circuit to Fluid Station. • Job and alarm logs
• Material usage report
• Setup values (can also upload)
Audible Alarm  Clear job, alarm, and material usage reports
Alerts the user when an alarm occurs. Available settings  Upload a custom language to view on
for selecting which alarms will cause an audible alarm screen
are explained in Configure Screen 1, page 31.  Restore factory defaults
 Restore setup password
Clear the audible alarm by pressing the Alarm Reset
See manual 313386 for more information.
key.
Ethernet Connection
Even after the Alarm Reset key is pressed, the Potlife
Exceeded alarm message will remain displayed until a You can access data on an office or industrial network
sufficient amount of mixed material has been dispensed through the internet with the proper configuration. See
to ensure that the expired material has been ejected. manual 313386 for more information.
312776L 21
Run Mode Screens
Run Mode Screens

NOTE: See FIG. 9 for a map of the Run screens.
Detailed screen descriptions follow.
Splash Screen
At power up, the Graco logo and software revision will
display for approximately 5 seconds, followed by the
Status Screen (see page 24).
FIG. 7. Splash Screen
The Splash screen will also momentarily display “Estab-

lishing Communication.” If this display remains for more
than one minute, check that the fluid station circuit board
is powered up (LED is on) and that the fiber optic cable
is properly connected (see installation manual).
NOTE: If the software version of the fluid plate does not

match the version of the EasyKey, the EasyKey will
update the fluid plate, and the fluid plate programming
screen will appear until the update is completed.
FIG. 8. Fluid Plate Programming Screen
22 312776L
Run Mode Screens
Press the Setup key to

enter Setup mode.
TI12783a
FIG. 9. Run Screens Map
312776L 23
Run Mode Screens
Status Screen 4 Potlife Timer: shows remaining potlife time in min-

utes. Two times are shown if there are two guns.
• Use the Up or Down keys to scroll through the
Run screens. 5 Status Bar: shows current alarm or operation mode
(standby, mix, purge, recipe change, or the current
alarm).
• Press the Setup key to enter the Setup screens
from the Status screen. 6 Current Flow Rate: in cc/min.
• The other keys have no function in this Status

7 Animation: when the gun is triggered, the gun
screen.
appears to spray and the component A or B hose
lights up, showing which component dose valve is
open.
1 10
2 8 8 Current Date and Time
3 7 9 Screen Number and Scroll Arrows: displays the

9 current screen number and the total number of
4 screens in a group. The Up and Down arrows on the
6 right edge of the screen indicate the scroll feature.
The total number of screens in some groups may
vary depending on system configuration selections.
5
10 Lock Symbol: indicates that Setup screens are
FIG. 10. Status Screen password protected. See page 28.
Key to FIG. 10:
1 Active Recipe: shows the active recipe.
NOTE: At power up the system defaults to Recipe

61, which is not a valid recipe number.
2 Target Ratio: for the active recipe. The ratio can be

from 0.0:1–50.0:1, in 0.1 increments.
3 Actual Ratio: in hundredths, calculated after each

dose of A and B.
24 312776L
Run Mode Screens
Totals Screen Reset Total Screen
FIG. 11. Totals Screen FIG. 12. Reset Total Screen
This screen shows the job totals, fill totals, grand totals, If job is reset, job number will increment by one for
and job number. Use the tabs to reset job totals (Job default.
Complete), reset solvent totals (Rst Solvent), or go to
Level Control Screen, page 26.
Reset Solvent Screen
The job totals generally refer to material dispensed
while in Mix mode. This is likely atomized and sprayed
material with the gun trigger “On”.
The fill totals generally refer to material dispensed while

in Mix-fill mode after a color change or a purge opera-
tion. This is likely not sprayed or atomized, and is dis-
pensed to a purge container.
Solvent Totals and the Rst Solvent tab only appear if

“Meter” is selected under Solvent Monitor in Configure
Screen 5 on page 33.
FIG. 13. Reset Solvent Total Screen
NOTE: Grand totals are not resettable.
The screen will ask if you want to reset solvent total.

Select Yes or No.
312776L 25
Run Mode Screens
Alarms Screens occur after 25% of the remaining volume is mixed.

Refill tank volume to clear the alarm.
FIG. 14. Alarms Screen
FIG. 16. Tank Level Low Screen (Tank A Shown)
Two screens show the last 10 alarms. Use the Up or

Down keys to scroll between the two screens.
See Table 10 on page 82 for a list of alarm codes.
Level Control Screen
FIG. 15. Level Control Screen
This screen shows the current volume for each fluid.

Adjust the current volumes on this screen, or use the tab
to go to Usage (Totals Screen, page 25). The Alarm
Level values may be adjusted using the advanced web
interface.
See FIG. 16. If the tank volume reaches the low-level

threshold, the EasyKey screen will display the Tank
Level Low alarm and prompt the user to do one of the
following:
1. Refill tank volume to clear the alarm.
2. Resume mixing by selecting “Spray 25% of Remain-

der.” If this selection is chosen, a second alarm will
26 312776L
Setup Mode
Setup Mode
NOTE: See FIG. 17 for a map of the Setup screens.
Press the Setup key to enter Setup mode.
Detailed screen descriptions follow.
Press the Setup key to

enter Setup mode.
This screen appears only if a

password is activated.
To access Advanced Setup Screens, page 36

and Recipe Setup Screens, page 40.
To access System Configuration

Screens, page 30.
Press the Setup key to exit

Setup mode and return to the Status
screen.
This screen appears momentarily

if a password is activated.
TI12784a
FIG. 17. Setup Screens Map
312776L 27
Setup Mode
Password Screen Set Up Home Screen

If a password has been activated (see Configure
Screen 1, page 31), the Password screen will appear.
You must enter the password to access the Set Up
Home Screen. Entering the wrong password returns the
display to the Status Screen.
NOTE: If you forget the password, you can reset the

password (to 0), using the ProMix 2KS Web Interface
(see manual 313386).
FIG. 20. Set Up Home Screen
This screen displays when you enter Setup mode. From

it you can go to Recipe and Advanced Setup Screens
(pages 36-44) or System Configuration Screens
(pages 30-33). Press the Enter key to go to the
selected screen set.
FIG. 18. Password Screen The screen also displays software versions and internet
addresses of various components. The values shown in
FIG. 20 are only examples and may vary on your screen.
NOTE: If a password is activated, Setup Locked dis- See Table 4 for further information.
plays momentarily after exiting Setup mode and return-
ing to the Status Screen. A lock symbol appears
on the Status Screen.
FIG. 19. Setup Locked Screen
28 312776L
Setup Mode
Table 4: Component Software Versions
Display (may
vary from
Component examples shown) Description
EK (EasyKey) 3.01.001 EasyKey software version.
FP (Fluid Plate) 3.01.001 Fluid Plate software version.
BC (Booth Control) -.- Booth Control not installed, not detected, or not operational.
1.XX Booth Control software version 1.00 or 1.01.
2.XX Booth Control software version 2.XX.
C1/C2 (Color Change -.- Color Change Module 1/2 not installed, not detected, or not
Modules 1 and 2) operational.
1.XX Color Change Module software version 1.00 or 1.01.
2.XX Color Change Module software version 2.XX.
AK (Autokey) No Key No AutoKey installed or detected. System operates in 2K
Manual Mode only
2K-Auto 2K AutoKey detected. System can operate in 2K Manual,
Semi-automatic, or Automatic Mode.
3K-Auto 3K AutoKey detected. System can operate in 3K Manual,
Semi-automatic, or Automatic Mode.
XP (XPORT) V6.6.0.2 Example of XPORT network module software version. Other
versions are acceptable.
MC (Micro Controller) 1042.0198 Example of fluid plate micro controller version. Other versions
are acceptable.
Axx By Cz A30 B4 Cx Color Change board valve configuration. This shows the num-
ber of valves available for each of the components. This is set
by the configuration switches on the color change boards
connected to the system.
Code Description
- Component not available with this machine configura-
tion.
x Component not used with this machine configuration.
1 Component available but no change stack.
4-30 Component available with change stack.
Number of valves flushed with a solvent valve.
IP (Internet Address) 192.168.178.3 Example of the address EasyKey is set to for basic and
advanced web interface reporting.
MAC (MAC address) 00204AAD1810 Example of internet MAC address. Each EasyKey will have a
different value in this format.
312776L 29
Setup Mode
System Configuration Screens

NOTE: See FIG. 21 for a map of the System Configura- NOTE: Each screen displays the current screen number
tion Screens. Detailed screen descriptions follow. and the total number of screens in the group.
TI12785a
FIG. 21. System Configuration and Option Screens Map
30 312776L
Setup Mode
Configure Screen 1 Screen Timeout

Select the desired screen timeout in minutes (0-99). 5 is
the default.
Configure Screen 2
FIG. 22. Configure Screen 1
Language
Defines the language of the screen text. Select English FIG. 23. Configure Screen 2
(default), Spanish, French, German, Italian, Dutch, Jap-
anese (Kanji), Korean, Chinese (Simplified), and Cus-
tom. Month
NOTE: Refer to document 313386 for instructions on Enter current month.

using the Custom Language feature to modify the
screens to support undefined languages. Day
Enter current day.
Password
The password is only used to enter Setup mode. The Year
default is 0, which means no password is required to Enter current year (four digits).
enter Setup. If a password is desired, enter a number
from 1 to 9999. Time
NOTE: Be sure to write down the password and keep it Enter current time in hours (24 hour clock), minutes, and
in a secure location. seconds. Seconds are not adjustable.
Display Units Date Format
Select the desired display units: Select MM-DD-YYYY, DD-MM-YYYY, or

YYYY-MM-DD.
• cc/liter (default)
• cc/gallon
Buzzer Alarms
As the default, the alarm buzzer is set to “Potlife Only”
and will sound only for the Potlife Alarm (E-2).
Set to “All Alarms” to have the buzzer sound for any

alarm.
Set to “All Except Potlife” to have the buzzer sound for

any alarm except a Potlife Alarm (E2). This option is not
recommended unless another active method of handling
the Potlife Alarm is implemented.
312776L 31
Setup Mode
Configure Screen 3 Configure Screen 4
FIG. 24. Configure Screen 3 FIG. 25. Configure Screen 4
1K/2K/3K Dose Time Alarm

Set this value to indicate the system performance level Enter the dose time (1 to 99 seconds). This is the
designation. Selecting a value other than the installed amount of time allowed for a dose to occur before a
system level will result in restricted functionality. dose time alarm occurs.
Run Mode Dose Size

NOTE: If an Autokey is installed, additional selections of Select the total dose size (cc) from the pulldown menu:
Semi-Automatic and Automatic are available. 100, 50, 25, 10, or select DD to turn on dynamic dosing
(see page 50).
Indicates that this is a Manual system.
Example:
Dump Valve A For a total dose size of 50 cc and a ratio of 4.0:1, the
This field only appears if the color change option is component A dose size is 40 cc and component B dose
detected from the cc board. Select “On” if an optional size is 10 cc.
Dump Valve A is installed and desired to be used.
NOTE: Increase the dose size in applications with
Dump Valve B higher flow rates or wider ratios. Decrease the dose size
for a better mix under low flow conditions.
This field only appears if the catalyst change option is
detected from the cc board, meaning that dump valve B Number of Guns
is present. On is the only setting.
Enter the number of spray guns (1 or 2).
3rd Flush Valve
Gun Flush Box
Off is default. If the system includes an optional 3rd
flush valve, set to On. Enter the number of gun flush boxes (Off, 1, or 2).
NOTE: For color change and flushing purposes, it is rec-

ommended that two GFBs are installed when using a
2-gun system.
DD Setup Mode
See Fig. 26 and Fig. 27 on page 33.
32 312776L
Setup Mode
Special Outputs
Use of Special Outputs on Manual systems requires
installation of a Discrete I/O Integration Board. Order
Graco Part No. 15V825 Discrete I/O Integration Board
Kit. See manual 406800.
NOTE: At system power up, the Special Outputs may

activate for up to 1/4 second.
Select special outputs (0-4, or 3 + GFB on #4). A selec-

tion of “0” will disable use of the Special Outputs. If the
“3 + GFB on #4” selection is chosen, the other 3 special
FIG. 26. Configure Screen 4, dynamic dosing outputs (1-3) can be used for user-defined functions and
selected
the special output #4 settings will duplicate those set-
tings established for the Gun Flush Box.
Each output has two different start times and durations

defined on the Recipe Setup screen (Flush and Fill Input
is set to “Recipe” in Option Screen 1, page 34), or on
the Advanced Setup screen (Flush and Fill Input is set
to “Global” in Option Screen 1, page 34).
Solvent Monitor
Select solvent monitor (Off, Flow Switch, or Meter).
A selection of “Meter” will cause the system to track the

FIG. 27. Configure Screen 4, dynamic dosing setup amount of solvent used. See Totals Screen, page 25
mode enabled for more information about solvent totals.
Web Browser IP
DD Setup Mode
The default web browser IP address prefix is
Selecting “DD” in the Dose Size field makes the 192.168.178.__ Assign a unique number for each
Dynamic Dosing setup mode field appear. Select On to EasyKey in your system (1-99) and enter it here.
enable DD setup mode, or Off to disable. See page 51
for further information. Control Network ID
Used for the Graco Gateway network system. See
Configure Screen 5 Graco Gateway manual 312785 for further information.
FIG. 28. Configure Screen 5
312776L 33
Setup Mode
Option Screens
NOTE: See FIG. 21 on page 30 for a map of the Option Minimum Material Fill Volume
Screens. Detailed screen descriptions follow.
Enter 0-9999 cc.
NOTE: Each screen displays the current screen number
and the total number of screens in the group. Verification Screen
Option Screen 1
FIG. 30. Verification Screen
FIG. 29. Option Screen 1 Verification

This screen appears if Flush and Fill Input or K-factor
Input are changed from “Recipe” to “Global” in Option
Flush Volume Check
Screen 1.
This field only appears if Solvent Monitor is set to
“Meter” in Configure Screen 5, page 33.
If set to “On”, Minimum Flush Volume will appear in

Recipe Setup Screen 2, page 41.
Flush and Fill Input

If set to “Global”, Color/Catalyst Purge and Color/Cata-
lyst Fill are added to Advanced Setup Screen 1, page
37. Advanced Setup Screen 2, 3, and 5 are added.
See pages 37-39.
If set to “Recipe”, Color/Catalyst Purge and Color/Cata-

lyst Fill are added to Recipe Setup Screen 2, page 41.
Recipe Setup Screen 3, 4, and 7 are added. See
pages 42-44.
K-factor Input
Global mode is useful when the material properties,
flush and fill characteristics, or K-factors are the same
for all materials used by the system.
If set to “Global,” Advanced Setup Screen 4, page 38

is added.
If set to “Recipe,” Recipe Setup Screen 5, page 43, is

added.
34 312776L
Setup Mode
Option Screen 2 B Purge After Chop

NOTE: This is used to isolate the Chop cycle from the
Final Purge cycle with solvent to prevent reaction issues
with some types of materials.
Optional 2-second burst (2 s B) operation of the B Purge

valve on the integrator after the Chop cycle.
See Color Change Sequences, page 69 for color

change charts and timing information.
FIG. 31. Option Screen 2
Auto Dump
If the auto dump feature is being used, set to “Solvent
Push” or “Mix Fill Push”. Once the auto dump is
enabled, the gun flush box is enabled and the potlife
alarm is active for 2 minutes, the system will automati-
cally flush or push out the old material based on the
selected option.
“Solvent Push” will flush out expired material using the

solvent supply. See Solvent Push Feature on page 65
for more information.
“Mix Fill Push” will push out expired material with new
mixed material. When sufficient material has been
pushed, the potlife alarm will reset. See Mix Fill Push
Feature on page 66 for more information.
Flow Rate Monitor

If set to “On,” Recipe Setup Screen 6 on page 43 is
added, enabling setting of high and low flow limits.
If set to “Off,” flow rate monitoring is disabled and Rec-

ipe Setup Screen 6 on page 43 will not appear.
Solvent Push Enable

NOTE: See Solvent Push Feature on page 65 for more
information.
To enable the Solvent Push feature, select “Solvent” or

“3rd Valve” (available if 3rd Flush Valve in Configure
Screen 3, page 32, is set to “On”).
To disable the Solvent Push feature, set to “Off.”
312776L 35
Setup Mode
Advanced Setup Screens

NOTE: See FIG. 32 for a map of the Advanced Setup
Screens. Detailed screen descriptions follow.
Advanced Setup screens 2, 3,

4, and 5 appear depending on
selections made in Option
screens 1 and 2.
TI12786a
FIG. 32. Advanced Setup Screens Map
36 312776L
Setup Mode
NOTE: Each screen displays the current screen number Color/Catalyst Fill
and the total number of screens in the group. The total
This field only appears if the system includes a color
number of screens in a group and the fields displayed
change module and Flush and Fill Input is set to
on each screen may vary depending on selections
“Global” in Option Screen 1, page 34. Enter the fill time
made in the System Configuration Screens and
(0 to 99 seconds). It refers to the time required to fill the
Option Screens.
lines from the color or catalyst module to the dose valve
or dump valve.
Advanced Setup Screen 1
FIG. 33. Advanced Setup Screen 1

Gun 1/Gun2 Potlife Volume
Enter the potlife volume (1 to 1999 cc) for each gun. This screen appears only if Flush and Fill Input is set to
This is the amount of material required to move through “Global” in Option Screen 1, page 34.
the mix manifold, hose and applicator/gun before the
potlife timer is reset. First Purge Source
Use the following information to determine approximate Select “Air,” “Solvent,” or “3rd Flush Valve” (available
pot life volume (PLV) in cc: only if 3rd Flush Valve is set to “On” in Configure
Screen 3 on page 32).
Hose ID (inches) Volume (cc/foot)* Chop Type
3/16 5.43
Select “Air/Solvent” or “Air/3rd Flush Valve” (available
1/4 9.648 only if 3rd Flush Valve is set to “On” in Configure
3/8 21.71 Screen 3 on page 32). This refers to the process of mix-
ing air and solvent (or air and 3rd flush fluid) together
Integrator manifold and mixer volume = 75 cc during the flush cycle, to help clean the lines and reduce
Spray Gun Volume = 20 cc solvent usage.
(Hose Volume* x Feet of Hose) + 75 + 20 = PLV
Final Purge Source
Color/Catalyst Purge Select “Air,” “Solvent,” or “3rd Flush Valve” (available
This field only appears if the system includes a color only if 3rd Flush Valve is set to “On” in Configure
change module and Flush and Fill Input is set to Screen 3 on page 32).
“Global” in Option Screen 1, page 34. Enter the purge
time (0 to 99 seconds). It refers to the amount of time Air Chop Time
required to flush the lines from the color or catalyst mod- Enter the air chop time (0.0 to 99.9 seconds).
ule to the dose valve or dump valve.
Solvent Chop Time/3rd Flush Valve Chop Time
Enter the solvent or 3rd flush valve chop time (0.0 to
99.9 seconds).
312776L 37
Setup Mode
Advanced Setup Screen 3 Advanced Setup Screen 4
FIG. 35. Advanced Setup Screen 3 FIG. 36. Advanced Setup Screen 4
This screen appears only if Flush and Fill Input is set to This screen appears only if K-factor Input is set to
“Global” in Option Screen 1, page 34. “Global” in Option Screen 1, page 34.
If Number of Guns is set to “2” in Configure Screen 4, K-factor A Meter
page 32, a Gun 2 column will appear in this screen.
Enter the k-factor (cc/pulse) for flow meter A. This is the
First Purge Time amount of material that passes through the flow meter
per pulse (electrical pulse signal).
Enter the first purge time (0 to 999 seconds).
K-factor B Meter
Total Chop Time
Enter the k-factor (cc/pulse) for flow meter B.
Enter the total chop time (0 to 999 seconds).
K-factor Solvent Meter
Final Purge Time
This field only appears if Solvent Monitor in Configure
Enter the final purge time (0 to 999 seconds). Screen 5, page 33, is set to “Meter.” Enter the k-factor
(cc/pulse) for the solvent flow meter.
Mixed Material Fill Time
Enter the mixed material fill time (0 to 999 seconds). It
refers to the amount of time that is required to load
mixed material from the dose valves to the applica-
tor/gun.
38 312776L
Setup Mode
This screen appears only if Flush and Fill Input is set to

“Global” in Option Screen 1, page 34 and Special Out-
puts is set to 1, 2, 3, or 4 in Configure Screen 5, page
33. The I/O board has four programmable outputs.
On-Purge
Delay time at the start of the purge cycle before the Spe-
cial Output turns on.
Length
Duration for the Special Output to be active during the
purge cycle.
On-Fill
Delay time at the start of the fill cycle before the Special
Output turns on.
Length
fill cycle.
312776L 39
Setup Mode
Recipe Setup Screens

NOTE: See FIG. 38 for a map of the Recipe screens. Detailed screen descriptions follow.
Recipe 0 Screens
Recipe screens 3, 4, 5, 6, and

7 appear depending on
selections made in Option
screens 1 and 2
TI12787a
FIG. 38: Recipe Screens Map
40 312776L
Setup Mode
NOTE: Each screen displays the current screen number Recipe Setup Screen 2
Option Screens.
Recipe Setup Screen 1
FIG. 40. Recipe Setup Screen 2
Minimum Flush Volume

This field only appears if Flush Volume Check is set to
“On” in Option Screen 1 on page 34. Enter the mini-
mum flush volume (0 to 9999 cc). Entering 0 disables
this function.
Potlife Time
Enter the potlife time (0 to 999 minutes). Entering 0 dis-
Ratio ables this function.
Enter the mix ratio of component A over component B
(0.0:1 to 50:1). Color/Catalyst Purge
Ratio Tolerance change module and Flush and Fill Input is set to “Rec-
Enter the ratio tolerance (1 to 99%). This refers to the ipe” in Option Screen 1, page 34. Enter the purge time
percent of acceptable variance that the system will allow (0 to 99 seconds). It refers to the amount of time
before a ratio alarm occurs. required to flush the lines from the color or catalyst mod-
ule to the dose valve or dump valve.
Component A (Color) Valve (if present)
Color/Catalyst Fill
change module. Enter the color valve number (1 to 30). This field only appears if the system includes a color
change module and Flush and Fill Input is set to “Rec-
Component B (Catalyst) Valve (if present) ipe” in Option Screen 1, page 34. Enter the fill time (0
to 99 seconds). It refers to the time required to fill the
This field only appears if the system includes a color lines from the color or catalyst module to the dose valve
change module. Enter the catalyst valve number (1 to or dump valve.
4).
312776L 41
Setup Mode
Recipe Setup Screen 3 Recipe Setup Screen 4
FIG. 41. Recipe Setup Screen 3 FIG. 42. Recipe Setup Screen 4
This screen appears only if Flush and Fill Input is set to This screen appears only if Flush and Fill Input is set to
“Recipe” in Option Screen 1, page 34. “Recipe” in Option Screen 1, page 34.
First Purge Source If Number of Guns is set to “2” in Configure Screen 4,

Select “Air,” “Solvent,” or “3rd Flush Valve” (available
only if 3rd Flush Valve is set to “On” in Configure First Purge Time
Chop Type
Total Chop Time
only if 3rd Flush Valve is set to “On” in Configure Enter the total chop time (0 to 999 seconds).
Screen 3 on page 32). This refers to the process of mix-
ing air and solvent (or air and 3rd flush fluid) together Final Purge Time
during the flush cycle, to help clean the lines and reduce Enter the final purge time (0 to 999 seconds).
solvent usage.
Mixed Material Fill Time
Final Purge Source
Enter the mixed material fill time (0 to 999 seconds). It
Select “Air,” “Solvent,” or “3rd Flush Valve” (available refers to the amount of time that is required to load
only if 3rd Flush Valve is set to “On” in Configure mixed material from the dose valves to the applica-
Screen 3 on page 32.) tor/gun.
Air Chop Time
Enter the air chop time (0.0 to 99.9 seconds).

Enter the solvent or 3rd flush valve chop time (0.0 to
99.9 seconds).
42 312776L
Setup Mode
Recipe Setup Screen 5 Recipe Setup Screen 6

This screen appears only if K-factor Input is set to “Rec-

This screen appears only if Flow Rate Monitor is set to
ipe” in Option Screen 1, page 34.
“On” in Option Screen 2 on page 35.
K-factor A Meter
Flow Rate Monitor
Enter the k-factor (cc/pulse) for flow meter A. This is the
Select the desired flow rate monitoring (Off, Warning, or
amount of material that passes through the flow meter
Alarm).
per pulse (electrical pulse signal).
Low Flow Limit
K-factor B Meter
Enter the low flow rate limit (1 to 3999 cc/min).
Enter the k-factor (cc/pulse) for flow meter B.
High Flow Limit
K-factor Solvent Meter
Enter the high flow rate limit (1 to 3999 cc/min).
This field only appears if Solvent Monitor in Configure
Screen 5, page 33, is set to “Meter.” Enter the k-factor
(cc/pulse) for the solvent flow meter.
312776L 43
Setup Mode
Recipe Setup Screen 7
FIG. 45. Recipe Screen 7
This screen appears only if Flush and Fill Input is set to

“Recipe” in Option Screen 1, page 34 and Special Out-
puts is set to 1, 2, 3, 4, or “3 + GFB on #4” in Configure
Screen 5, page 33. The I/O board has four programma-
ble outputs.
NOTE: If the Special Outputs is set to “3 + GFB on #4”,

the Recipe 0 Screen 4 does not display the column of
information for Special 4. That Output assumes the val-
ues assigned to GFB #1.
On-Purge
Delay time at the start of the purge cycle before the Spe-
cial Output turns on.
Length
purge cycle.
On-Fill
Output turns on.
Length
fill cycle.
44 312776L
Setup Mode
Recipe 0 Screens Air Chop Time

Enter the air chop time (0.0 to 99.9 seconds).
NOTE: See FIG. 38 on page 40 for a map of the Recipe
0 screens. Detailed screen descriptions follow.
Recipe 0 is typically used: Enter the solvent or 3rd flush valve chop time (0.0 to
• in multiple color systems to purge out material lines 99.9 seconds).
without loading a new color
• at the end of a shift to prevent hardening of cata- Recipe 0 Screen 2
lyzed material.
NOTE: Each screen displays the current screen number

Option Screens.
Recipe 0 Screen 1
FIG. 47. Recipe 0 Screen 2
If Number of Guns is set to “2” in Configure Screen 4,

Color/Catalyst Purge Time

change module. It refers to the amount of time required
to flush the lines from the color or catalyst module to the
dose valve or dump valve. Enter the purge time (0 to
FIG. 46. Recipe 0 Screen 1 999 seconds).
First Purge Time

First Purge Source
only if 3rd Flush Valve is set to “On” in Configure
Total Chop Time
Enter the total chop time (0 to 999 seconds).
Chop Type
Final Purge Time
only if 3rd Flush Valve is set to “On” in Configure Enter the final purge time (0 to 999 seconds).
Screen 3 on page 32). This refers to the process of mix-
ing air and solvent (or air and 3rd flush fluid) together
during the flush cycle, to help clean the lines and reduce
solvent usage.
Final Purge Source

only if 3rd Flush Valve is set to “On” in Configure
Screen 3 on page 32.)
312776L 45
Setup Mode
Recipe 0 Screen 3 Recipe 0 Screen 4
FIG. 48. Recipe 0 Screen 3 FIG. 49. Recipe 0 Screen 4
This screen only appears if Solvent Monitor is set to This screen appears only if Flush and Fill Input is set to
“Meter” in Configure Screen 5, page 33 and Flush Vol- “Recipe” in Option Screen 1, page 34 and Special Out-
ume Check is set to “On” in Option Screen 1, page 34 puts is set to 1, 2, 3, 4, or “3 + GFB on #4” in Configure
or 3rd Flush Valve is set to “On” in Configure Screen 3 Screen 5, page 33. The I/O board has four programma-
on page 32. ble outputs.
Minimum Flush Volume NOTE: If the Special Outputs is set to “3 + GFB on #4”,
This field only appears if Flush Volume Check is set to the Recipe 0 Screen 4 does not display the column of
“On” in Option Screen 1 on page 34. Enter the mini- information for Special 4. That Output assumes the val-
mum flush volume (0 to 9999 cc). ues assigned to GFB #1.
Exiting Fill Source On-Purge

This field only appears if 3rd Flush Valve is set to “On” in
Configure Screen 3 on page 32. Select “Off,” “Air,” Delay time at the start of the purge cycle before the Spe-
“Solvent,” or “3rd Valve.” cial Output turns on.
Length
purge cycle.
On-Fill
Output turns on.
Length
fill cycle.
46 312776L
Setup Mode
Calibration Screen
FIG. 50. Calibration Screen
Use this screen to calibrate a meter. Set to “A Meter,” “B

Meter,” or “Solvent Meter” (available if Solvent Monitor
in Configure Screen 5, page 33, is set to “Meter”).
• Start - start calibration
• Abort - stop calibration
• Purge - purge sampling valves after calibration
See Meter Calibration, page 67, for when and how to

calibrate a meter.
312776L 47
System Operation
System Operation
Operation Modes General Operating Cycle,

Sequential Dosing
Mix 1. The spray gun operator enters and loads the
System mixes and dispenses material. desired recipe. The color change LED blinks while
recipe is loading, then turns solid when complete.
Standby 2. The operator presses the Mix key to begin

operation.
Stops the system.
3. The ProMix 2KS controller sends signals to activate
the solenoid valves. The solenoid valves activate
Dose Valves A and B. Fluid flow begins when the
Purge gun is triggered.
Purges the system, using air and solvent. 4. Components A and B are introduced into the fluid
integrator (FI) one at a time as follows.
Sequential Dosing a. Dose Valve A (DVA) opens, and fluid flows into
the integrator.
Components A and B dispense sequentially in the nec-
essary volumes to attain the mix ratio.
b. Flow Meter A (MA) monitors the fluid volume
dispensed and sends electrical pulses to the
Dynamic Dosing ProMix 2KS controller. The controller monitors
these pulses and signals.
In typical operation (ratios 1:1 and above), component A
dispenses constantly. Component B dispenses intermit- c. When the target volume dispenses, Dose Valve
tently in the necessary volume to attain the mix ratio. A closes.
NOTE: The dispense volume of component A and B

Recipe (Color) Change is based on the mix ratio and dose size set by the
user and calculated by the ProMix 2KS controller.
The process when the system automatically flushes out
the old color and loads a new color. d. Dose Valve B (DVB) opens, and fluid flows into
the integrator and is aligned proportionately with
component A.
Solvent Push
e. Flow Meter B (MB) monitors the fluid volume
The Solvent Push feature enables the user to save
dispensed and sends electrical pulses to the
some mixed material by pushing it out to the gun with
ProMix 2KS controller.
solvent. The feature requires an accessory solvent
meter. See page 65 for complete information.
f. When the target volume is dispensed, Dose
Valve B closes.
Mix Fill Push
The Mix Fill Push feature enables the user to prevent
potlife expiration of material by mixing and flowing new
material through the Gun Flush Box. See page 66 for
complete information.
48 312776L
System Operation
5. The components are pre-mixed in the integrator, 7. If the gun is not triggered for two minutes, the sys-
then uniformly blended in the static mixer (SM). tem switches to Idle mode, which closes off the mix
manifold dose valves.
NOTE: To control output from the static mixer to the
gun, install an optional fluid pressure regulator. 8. When the gun is triggered again, the ProMix 2KS
continues the process where it left off.
6. Components A and B are alternately fed into the
integrator as long as the gun is triggered. NOTE: Operation can be stopped at any time by
pressing the Standby key or shutting off the
main power switch.
Table 5: Sequential Dosing Operation

Ratio = 2.0:1 Dose 1 Dose 2 Dose 3
A=2
B=1
DVA FI DVB
MB
MS
MA
RVB
AT
APV
TI12556b
RVA SVA SM SVB SPV
Key:
MA Component A Meter SVB Component B Shutoff Valve
DVA Component A Dose Valve MS Solvent Meter (accessory)
RVA Component A Sampling Valve SPV Solvent Purge Valve
SVA Component A Shutoff Valve APV Air Purge Valve
MB Component B Meter SM Static Mixer
DVB Component B Dose Valve FI Fluid Integrator
RVB Component B Sampling Valve AT Air Purge Valve Air Supply Tube
FIG. 51. Wall Mount Fluid Station, Sequential Dosing
312776L 49
System Operation
General Operating Cycle, Dynamic Dosing

Overview Dynamic Dosing System Parameters
Dynamic Dosing provides on-demand proportioning, The following parameters affect dynamic dosing perfor-
eliminating the need for an integrator and therefore min- mance:
imizing undesired material contact. This feature is espe-
cially useful with shear-sensitive and waterborne • Component A Flow: Ensure that the supply pump is
materials. sized to provide sufficient and uninterrupted flow.
Note that component A provides majority of system
A restrictor injects component B into a continuous flow at higher mix ratios.
stream of component A. The software controls the dura-
tion and frequency of each injection. See FIG. 52 for a • Component B Flow: Ensure that the supply pump is
schematic diagram of the process. sized to provide sufficient and uninterrupted flow.
• 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: 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.
To Static
Component A (continuous flow) Proportioned Material Mixer
Component B (pulsed injection)
FIG. 52. Schematic Diagram of Dynamic Dosing Operation
50 312776L
System Operation
Select a Component B Restrictor Size 3. Selecting “DD” in System Configure Screen 4

makes the DD Setup mode available. See FIG. 55.
Install the 15U955 Injection Kit in the fluid manifold as To enable DD setup mode, select On in the DD
explained in the ProMix 2KS Installation manual. Use setup mode drop down menu. This disables Off
the charts provided in that manual to select an appropri- Ratio alarms E-3 and E-4, allowing uninterrupted
ate restrictor size based on the desired flow and mix setup and tuning.
ratio.
NOTE: Do not use the material mixed when in DD setup
Turn On Dynamic Dosing mode, as it may not be on ratio due to the disabled
alarms.
1. On the EasyKey press the Setup key to access
NOTE: If DD setup mode is not turned Off at the end of
the Set Up Home screen. Select “System Configu- setup, it will automatically turn off 3 minutes after initia-
ration” to access the configuration screens. FIG. 53. tion of a Mix command.
FIG. 53. Set Up Home Screen

FIG. 55. Configure Screen 4, dynamic dosing setup
mode enabled
2. Navigate to System Configure Screen 4. Select
“DD” option from the “Dose Size” drop down menu.
FIG. 54.
FIG. 54. Configure Screen 4, dynamic dosing

selected
312776L 51
System Operation
Balancing A/B Pressure

nge
If component B pressure is too high, it will push the com- l Ra B Pressure
ponent A stream aside during B injection. The valve will n tr o
Co Too Low
not open long enough, causing a High Ratio alarm.
If component B pressure is too low, it will not be injected B Pressure

in sufficient volume. The valve will stay open too long, Too High
causing a Low Ratio alarm.
Selecting the correct component B restrictor size and

balancing the A/B pressures will keep the system in the A Pressure B Pressure
proper pressure range, resulting in a consistent mix
ratio. FIG. 57. A/B Control Range with Properly Sized
Restrictor
FIG. 57 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
nge
pressure to keep the system in the control range, hold t ro l Ra )
l
the proper mix ratio, and obtain properly mixed material. Con o smal
If pressures are not balanced (“B Pressure Too High” or (to B Pressure
Too Low
“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. B Pressure
Too High
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.
A Pressure B Pressure
In dynamic dosing, component A dose valve is con- NOTE: If the restrictor is too small, it may be
stantly on. Component B dose valve will cycle on and necessary to supply more differential pressure
off; one cycle every 0.5 – 1.0 seconds indicates proper than is available in your system.
balance.
FIG. 58. A/B Control Range with Too Large a
Monitor system performance by watching the EasyKey Restrictor
display for warning messages which provide information
on system performance, and adjust pressures accord-
ingly. See Table 6 on page 53.
FIG. 56. B Pressure Too Low, displayed on EasyKey
52 312776L
System Operation
Table 6: Dynamic Dosing Troubleshooting Guide

(for complete system troubleshooting, see Table 11 beginning on page 83)
Warning/Alarm Message Solution

B Pressure Too Low (see FIG. 56) • Increase B pressure.
• Clean restrictor or use a larger size.
• Verify B valve is opening properly.
B Pressure Too High • Increase A pressure or decrease B pressure.
• Use a smaller restrictor.
Off Ratio Low • Increase A pressure or decrease B pressure.
• Use a smaller restrictor.
Off Ratio High • Increase B pressure.
• Clean restrictor or use a larger size.
• Verify B valve is opening properly.
Mix Manifold Valve Settings

To open dose or purge valves, turn hex nut (E) counter-
clockwise. To close, turn clockwise. See Table 7 and E
FIG. 59.
TI11581a
FIG. 59. Valve Adjustment
Table 7: Mix Manifold Valve Settings
Valve Setting Function

Dose Hex nut (E) 1-1/4 turns out Limits maximum fluid flow rate into integrator
(FIG. 59) from fully closed and minimizes valve response time.
Purge Hex nut (E) 1-1/4 turns out Limits maximum fluid flow rate into integrator
(FIG. 59) from fully closed and minimizes valve response time.
Shutoff Fully open during Run/Mix Closes component A and B ports to integrator
(SVA and operation during ratio check or meter calibration. Open
SVB, FIG. 67) ports during Run/Mix operation.
Sampling Fully closed during Run/Mix Open to dispense component A and B while
(RVA and operation calibrating meters. Do not open sampling
RVB, FIG. valves unless fluid shutoff valves are closed.
67)
312776L 53
System Operation
Air Flow Switch (AFS) Function Operating Without Air Flow Switch
It is not recommended to run without an air flow switch.

Air or Air-assisted Guns If a switch fails, replace it as soon as possible.
The air flow switch (AFS) detects air flow to the gun and
signals the ProMix controller when the gun is triggered. Airless Gun
The AFS functions with the flow meters to ensure that
It is not recommended to use an airless gun with the
system components are functioning correctly.
ProMix 2KS. Two issues can arise from operating with-
out an air flow switch:
For example, if a flow meter fails or clogs, pure resin or
catalyst could spray indefinitely if the ProMix does not
• Without a gun trigger/air flow switch input the Pro-
detect the condition and intervene, which is why the
Mix 2KS does not know it is spraying and will not
AFS is so important.
generate a Dose Time Alarm (E-7 or E-8). This
means there is no way to detect a failed meter. You
If the ProMix detects through the AFS signal that the
could spray pure resin or catalyst for 2 minutes with-
gun is triggered, yet there is no fluid flow through the
out knowing.
meter, a Dose Time Alarm (E-7 or E-8) occurs after 40
seconds and the system shuts down.
• Since the ProMix 2KS does not know it is spraying
because there is no gun trigger/air flow switch input,
it will go into System Idle (E-15) every 2 minutes
when in Mix mode.
System Idle Warning (E-15)
AFS This warning occurs if the ProMix is set to Mix ,

and 2 minutes have elapsed since the system received
a flow meter pulse.
TI13350a
FIG. 60: Air Flow Switches 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 Standby
, then Mix , then trigger the gun.
54 312776L
System Operation
Start Up
1. Go through the Pre-Operation Checklist in Table 8.  Graco logo, software revision, and “Establishing
Communication” will display, followed by Status
Table 8: Pre-Operation Checklist screen. See page 22.
 At power up the system defaults to Recipe 61,
 Checklist
which is not a valid recipe number. Initiate a
System grounded color change to Recipe 0 or a valid recipe num-
ber (1-60).
Verify all grounding connections were made. See
 In bottom left corner, the system status dis-
the Installation manual.
plays, which can be Standby, Mix, Purge, or an
All connections tight and correct alarm notification
Verify all electrical, fluid, air, and system connec-
tions are tight and installed according to the
Installation manual.
Check air purge valve tubing
Check the air purge valve supply tube daily for
any visible solvent accumulation. Notify your
supervisor if solvent is present.
Fluid supply containers filled
Check component A and B and solvent supply
containers.
Mix manifold valves set
Check that mix manifold valves are set correctly. FIG. 62. Status Screen
Start with the settings recommended in Mix Mani-
fold Valve Settings, page 53, then adjust as
needed. 3. Make sure that the Booth Control is working. The
Fluid supply valves open and pressure set active recipe number should display and the
Component A and B fluid supply pressures should Standby LED should be lit.
be equal unless one component is more viscous
and requires a higher pressure setting.
4. If this is the first time starting up the system, purge it
Solenoid pressure set as instructed in Purging Fluid Supply System,
75-100 psi inlet air supply (0.5-0.7 MPa, 5.2-7 page 62. The equipment was tested with lightweight
bar) oil, which should be flushed out to avoid contaminat-
ing your material.
2. Turn the AC Power Switch ON (I = ON, 0 = OFF).
5. Make sure that the Booth Control is in Standby
mode.
I = ON
TI12656a
FIG. 61. Power Switch
312776L 55
System Operation
6. Adjust component A and B fluid supplies Watch the fluid flow rate displayed on the Status
as needed for your application. Use low- screen while the gun is fully open. Verify that the
est pressure possible. flow rate of components A and B are within 10% of
each other.
7. Do not exceed the maximum rated work-
ing pressure shown on the system identification If the fluid flow rate is too low: increase air pres-
label or the lowest rated component in the system. sure to component A and B fluid supplies or
increase the regulated fluid pressure.
8. Open the fluid supply valves to the
system. If the fluid flow rate is too high: reduce the air
pressure, close the fluid manifold dose valves fur-
9. Adjust the air pressure. Most appli-
ther, or adjust the fluid pressure regulator.
cations require about 80 psi (552
kPa, 5.5 bar) air pressure to operate properly. Do
NOTE: Pressure adjustments of each component will
not use less than 75 psi (517 kPa, 5.2 bar).
vary with fluid viscosity. Start with the same fluid pres-
10. If using a gun flush box, place the gun into the box sure for component A and B, then adjust as needed.
NOTE: Do not use the first 4-5 oz. (120-150 cc) of mate-
rial as it may not be thoroughly mixed due to alarms
and close the lid. Press the Purge key on the
while priming the system.
Booth Control. The purge sequence automatically
starts. 12. Turn on atomizing air to the gun. Check the spray
pattern as instructed in your spray gun manual.
If the gun flush box is not used, trig-
ger the gun into a grounded metal NOTE: Do not allow a fluid supply tank to run empty. It
pail until the purge sequence is com- is possible for air flow in the supply line to turn gear
plete. meters in the same manner as fluid. This can lead to the
proportioning of fluid and air that meets the ratio and tol-
When done purging, the Booth Control automati- erance settings of the equipment. This can further result
cally switches to Standby mode. in spraying uncatalyzed or poorly catalyzed material.
11. Adjust the flow rate.
The fluid flow rate shown on the EasyKey Status

screen is for either component A or B, depending on
which dose valve is open. The fluid supply lines on
the screen highlight to show which dose valve is
open.
FIG. 63. Status Screen Flow Rate Display
56 312776L
System Operation
Shutdown Pressure Relief Procedure

NOTE: The following procedures relieve all fluid and air
Overnight Shutdown
pressure in the ProMix 2KS system. Use the procedure
1. Leave the power on. appropriate for your system configuration.
2. Run Recipe 0 to purge solvent through meters and

gun.
Service Shutdown Relieve pressure when you stop spraying, before

changing spray tips, and before cleaning, checking, or
1. Follow Pressure Relief Procedure on page 57.
servicing equipment.
2. Close main air shutoff valve on air supply line and
on ProMix.
Single Color Systems
3. Shut off ProMix 2KS power (0 position). FIG. 64.
1. While in Mix mode (gun triggered), shut off the A
4. If servicing EasyKey, also shut off power at main cir- and B fluid supply pumps/pressure pots. Close all
cuit breaker. fluid shutoff valves at the pump outlets.
2. With the gun triggered, push the manual override on

the A and B dose valve solenoids to relieve pres-
sure. See FIG. 65.
0 = OFF NOTE: If a Dose Time alarm (E-7, E-8) occurs,

clear the alarm.
3. Do a complete system purge, following the instruc-

tions under Purging Using Recipe 0, page 62.
4. Shut off the fluid supply to the solvent purge valve

(SPV) and the air supply to the air purge valve
TI12657a
(APV), FIG. 67.
FIG. 64. Power Switch 5. With the gun triggered, push the manual override on
the A and B purge valve solenoids to relieve air and
solvent pressure. See FIG. 65. Verify that solvent
pressure is reduced to 0.
NOTE: If a Purge Volume alarm (E-11) occurs, clear

the alarm.
312776L 57
System Operation
Systems with Color Change and without Systems with Color/Catalyst Change and
Dump Valves Dump Valves
NOTE: This procedure relieves pressure through the NOTE: This procedure relieves pressure through the
sampling valve. dump valves.
1. Complete all steps under Single Color Systems, 1. Complete all steps under Single Color Systems,
page 57. page 57.
2. Close the A side shutoff valve (SVA), FIG. 67. Open 2. Shut off all color and catalyst supplies to the valve
the A side sampling valve (RVA). stacks.
3. Direct the A side sampling tube into a waste con- 3. Press and hold the dump valve A solenoid override,
tainer. FIG. 65.
4. See FIG. 66. Open the color change module. Using 4. See FIG. 66. Open the color change module. Using
the solenoid identification labels as a guide, press the solenoid identification labels as a guide, press
and hold the override button on each color solenoid and hold the override button on each color solenoid
until flow from the sampling valve stops. until flow from dump valve A stops.
5. Press and hold the solvent solenoid override until 5. Press and hold the dump valve B solenoid override,
clean solvent comes from the sampling valve, then FIG. 65.
release.
6. See FIG. 66. Using the solenoid identification labels
6. Shutoff the solvent supply to the color change stack as a guide, press and hold the override button on
solvent valve. each catalyst solenoid until flow from dump valve B
stops.
7. Press and hold the solvent solenoid override until
solvent flow from the sampling valve stops. 7. Press and hold the dump valve A solenoid override,
FIG. 65.
8. Open the A side shutoff valve (SVA), FIG. 67. Close
the A side sampling valve (RVA). 8. Press and hold the A side (color) solvent solenoid
override until clean solvent comes from the dump
valve, then release.
9. Press and hold the dump valve B solenoid override,

FIG. 65.
10. Press and hold the B side (catalyst) solvent solenoid

override until clean solvent comes from the dump
valve, then release.
11. Shutoff the solvent supply to the color/catalyst

change stack solvent valves.
12. Press and hold the A and B solvent solenoid over-

rides and dump valve overrides until solvent flow
from the dump valves stops.
58 312776L
System Operation
F1 F2 Power
J1 Fiber
Optic
CAN
J13
CAN
J12
J3
Valve Dose A 1
3rd Purge
Purge A
Purge B
Dump A
Dump B
Dose B
GFB 2
GFB 1
J9
1 J14 1 J15 1 J8
Dump Valve A
Dump Valve B
Optional Solenoid
GFB 1 Locations
GFB 2
Dose Valve A 3rd Purge Valve

Solenoid Solenoid
Dose Valve B Purge Valve A Purge Valve B

Solenoid Solenoid Solenoid TI12652b
FIG. 65. Fluid Solenoids
312776L 59
System Operation
Color
Solenoid Solenoid
Identification Identification
Label Label
Color
Catalyst
TI12826a
Solvent Solenoid
Overrides
FIG. 66: Color Change Solenoids
Key:
DVA FI DVB MA Component A Meter
MB DVA Component A
Dose Valve
RVA Component A
MS Sampling Valve
MA SVA Component A
Shutoff Valve
MB Component B Meter
RVB DVB Component B
Dose Valve
RVB Component B
Sampling Valve
SVB Component B
Shutoff Valve
AT MS Solvent Meter
APV Air Purge Valve
SM Static Mixer
TI12556b FI Fluid Integrator
APV AT Air Purge Valve Air
Supply Tube
RVA SVA SM SVB SPV
FIG. 67. Wall Mount Fluid Station
60 312776L
System Operation
Purging
If using an electrostatic gun shut off the electrostatics

Read Warnings, page 7. Follow the Grounding before flushing the gun.
instructions in your system Installation manual.
To avoid splashing fluid in the eyes, wear eye protec- 2. Set the solvent supply pressure regulator at a pres-
tion. 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
There are 4 purging procedures in this manual: setting of 100 psi (0.7 MPa, 7 bar) is sufficient.
• Purging Mixed Material (below) 3. If using a gun flush box, place the gun into the box
• Purging Using Recipe 0 (page 62)
• Purging Fluid Supply System (page 62)
• Purging Sampling Valves and Tubes (page 64)
and close the lid. Press the Purge key on the
Use the criteria listed in each procedure to determine Booth Control. The purge sequence automatically
which procedure to use. starts.
If the gun flush box is not used, trig-

Purging Mixed Material ger the gun into a grounded metal
There are times when you only want to purge the fluid pail until the purge sequence is com-
manifold, such as: plete.
• end of potlife When done purging, the Booth Control automati-

• breaks in spraying that exceed the potlife cally switches to Standby mode.
• overnight shutdown
• before servicing the fluid manifold assembly, hose 4. If the system is not completely clean, repeat step 3.
or gun.
NOTE: If necessary, adjust purge sequence so only
Solvent purges the component B (catalyst, right) side of one cycle is required.
the mix manifold and the inner tube of the integrator. Air
purges the component A (resin, left) side and the outer
tube of the integrator.
Trigger the gun to relieve pressure. Engage trigger

1. Press the Standby key on the Booth Control. lock.
5. If spray tip was removed, reinstall it.
6. Adjust the solvent supply regulator back to its nor-

Trigger the gun to relieve pressure. mal operating pressure.
If you are using a high pressure gun, engage the trig-
ger lock. Remove spray tip and clean tip separately.
312776L 61
System Operation
Purging Using Recipe 0 Purging Fluid Supply System

Recipe 0 is typically used: Follow this procedure before:
• in multiple color systems to purge out material lines • the first time material is loaded into equipment*
without loading a new color • servicing
• at the end of a shift to prevent hardening of cata- • shutting down equipment for an extended period of
lyzed material. time
• putting equipment into storage
To setup Recipe 0, go to Advanced Setup. Select the
Recipe tab and change the Recipe to 0. The Recipe 0 * Some steps are not necessary for initial flushing,
Setup Screen appears. Set the chop times from 0-999 as no material has been loaded into the system
seconds in increments of 1 second. yet.
1. Press the Standby key on the Booth Control. 1. Press the Standby key on the Booth Control.
Trigger the gun to relieve pressure. Trigger the gun to relieve pressure.
If you are using a high pressure gun, engage the trig- If you are using a high pressure gun, engage the trig-
ger lock. Remove spray tip and clean tip separately. ger lock. Remove spray tip and clean tip separately.
If using an electrostatic gun, shut off the electrostatics

If using an electrostatic gun shut off the electrostatics
before flushing the gun.
before flushing the gun.
2. Attach solvent supply lines as follows:

2. If using a gun flush box, place the gun into the box
and close the lid. • Single color/single catalyst systems: discon-
nect the component A and B fluid supplies at
3. Select Recipe 0 and press Enter . the flow meter inlets, and connect regulated sol-
vent supply lines.
4. If a gun flush box is not used, trigger
the gun into a grounded metal pail • Multiple color/single catalyst systems: dis-
until the purge sequence is com- connect only the component B fluid supply at
plete. the flow meter inlet and connect a regulated sol-
vent supply line.
5. The color change LED blinks while Recipe 0 runs
and turns solid after purge sequence is complete. • Multiple color/multiple catalyst systems:
connect the solvent supply lines to the desig-
6. If the system is not completely clean, you can nated solvent valve on the color and catalyst
repeat Recipe 0 by pressing Enter . valve stacks. Do not connect a solvent supply to
either flow meter.
62 312776L
System Operation
3. Adjust the solvent fluid supply pressure. Use the

lowest possible pressure to avoid splashing.
4. Remove the Fluid Station cover to access the sole-

noid valves. See FIG. 65.
5. Purge as follows:
• Single color/single catalyst systems: Purge

component A side. Press the manual override
on the Dose Valve A solenoid valve and trigger
the gun into a grounded metal pail.
Purge component B side. Press the manual

override on the Dose Valve B solenoid valve
and trigger the gun into a grounded metal pail
until clean solvent flows from the gun.
Repeat to thoroughly clean the fluid integrator.
• Multiple color/single catalyst systems:

Select Recipe 0 and press Enter to purge
the component A side. The color change LED
blinks while Recipe 0 runs and turns solid after
purge sequence is complete.
Purge component B side. Press the manual

override on the Dose Valve B solenoid valve
and trigger the gun into a grounded metal pail
until clean solvent flows from the gun.
• Multiple color/multiple catalyst systems:

Select Recipe 0 and press Enter to purge
the component A side and the component B
side. The color change LED blinks while Recipe
0 runs and turns solid after purge sequence is
complete.
6. Reinstall the Fluid Station cover.
7. Shut off the solvent fluid supply.
8. Disconnect the solvent supply lines and reconnect

the component A and B fluid supplies.
9. See page 55 for Start Up procedure.
312776L 63
System Operation
Purging Sampling Valves and Tubes 8. Close sampling valves.
Follow this procedure after meter calibration. NOTE: Select Abort on Calibration screen to cancel
current calibration and close dose or purge valves.
1. Press the Standby key on the Booth Control.
9. Fully open both fluid shutoff valves.
2. See FIG. 67. Close both fluid shutoff valves and 10. On a single color system, reconnect component A
sampling valves. fluid supply line to flow meter A.
3. Route the sampling tubes into a grounded waste NOTE: After calibration it is necessary to clean out con-
container. taminated mix material. Do a manual purge and resume
the recipe just tested, or do Recipe 0 then go on to the
4. On a single color system, attach a solvent supply
next recipe.
line to Flow Meter A inlet.
5. On the EasyKey, press the Setup key and

access the Advanced Setup screens.
6. Press the Right Arrow key to select the Calibra-
tion screen. Press the Down Arrow key and

select Purge from the menu. Press the Enter
key.
Dose A, solvent purge valve (B side), and color

change solvent valves (if used) will open.
FIG. 68. Calibration Screen
7. To avoid splashing, slowly open the sampling

valves and dispense solvent until the valves and
tubes are clean.
NOTE: When performing a calibration purge, the

solvent valve(s) close automatically after 2 minutes
or when Abort is selected on the screen.
64 312776L
System Operation
Solvent Push Feature

The Solvent Push feature enables the user to save close the Dose Valves (DVA, DVB) and open the
some mixed material by pushing it out to the gun with Solvent Purge Valve (SPV).
solvent. The quantity saved is 50% of the potlife volume
entered in Advanced Setup Screen 1 on page 37. If 4. The system will dispense solvent to push the mixed
there are 2 guns, the smaller potlife volume is used. material out to the gun. The Booth Control display
alternately shows dashes and the percent remaining
Solvent Push requires an accessory solvent meter (MS). (0-99%) of the 50% of the potlife volume.
Order Graco Part No. 16D329 S3000 Solvent Meter Kit.
See manual 308778. NOTE: To manually interrupt Solvent Push, press the
1. See FIG. 69. Install the solvent meter (MS) on the Standby key. The Solvent Purge Valve (SPV) or
side of the fluid station, as explained in the ProMix
3rd purge valve will close. To re-enter Solvent Push,
2KS Installation Manual.
press the Mix key.
2. To enable Solvent Push, select “Solvent” or “3rd
Valve,” as desired. See Option Screen 2, page 35.
5. When the total solvent dispensed exceeds 50% of
NOTE: If you are using a 3rd purge valve instead of the the potlife volume, the system will go into Standby
solvent purge valve to run the Solvent Push feature,
connect the solvent supply line from the solvent meter to mode.
the inlet of the 3rd purge valve.
6. Perform a manual purge or recipe change to purge
NOTE: The system must be in Mix to initiate Solvent the remaining mixed material. This will clear the sys-
Push. tem out of Solvent Push, allowing you to resume
Mix mode.
3. Press and hold the Mix key for 5 seconds NOTE: Once the system senses that solvent exceeds
to turn on Solvent Push. The green Mix LED will 50% of potlife volume, attempts to re-enter Solvent
light and the Recipe LED will blink. The system will Push will cause an Overdose A/B Alarm (E-5, E-6).
DVA is closed DVB is closed

Key:
DVA Component A Dose Valve
DVB Component B Dose Valve
MS Solvent Meter (required) MS
APV Air Purge Valve
SMC Solvent Meter Cable
SS Solvent Supply Line
SMC
TI12556b
SS SPV is open
FIG. 69. Solvent Push Setup
312776L 65
System Operation
Mix Fill Push Feature

The Mix Fill Push feature enables the user to prevent 1. The system gets a Potlife alarm.
potlife expiration of material by mixing and flowing new
material through the Gun Flush Box. 2. The buzzer will do a double "chirp" every 4 seconds
to indicate an impending Mix Fill Push.
Mix Fill Push requires an accessory Gun Flush Box for
each gun that will use this feature. Order Graco Part No. 3. After waiting for the 2-minute Auto Dump time the
15V826 Fun Flush Box Kit. See manual 312784. system will run the Mix Fill Push.
NOTE: On a one-gun system the gun must be in the

NOTE: If the gun is not in the box the Mix Fill Push fea-
GFB. On a 2-gun system both guns must be in the
ture will not operate.
GFBs.
NOTE: The Mix Fill Push operation will run every time
4. If one of the guns in not in the GFB, the system will
the Potlife alarm occurs with the gun in the box. Unat-
not perform any of the Mix Fill Push or Auto Dump
tended systems can therefore repeatedly perform this
operations. The system will retry every 30 seconds
operation as the potlife keeps happening.
in case the gun is then installed in the GFB.
Mix Fill Push requires a Gun Flush Box for the gun. If 5. With the guns in the GFBs, the system will propor-
two guns are used, each requires a Fun Flush Box for tion mixed material through the guns in order to
this feature to operate. The second Gun Flush Box must reset the potlife volume.
be configured as a Special Output. See Configure
Screen 5 on page 33. 6. The alarm is cleared.
To enable Mix Fill Push, select “Mix Fill Push” in the 7. The event is logged in the Alarm Log as two alarms:
Auto Dump field. See Option Screen 2, page 35. E-5 Overdose A and E-6 Overdose B.
FIG. 70. Mix Fill Push Timing Chart
66 312776L
Meter Calibration
Meter Calibration
4. Place the beakers (minimum size - 250 cc) in hold-
ers. Put the sampling tubes into the beakers.
NOTE: If tubes need replacing, use 5/32 in. or 4 mm

OD tubing.
To avoid splashing fluid in the eyes, wear eye protec-
tion. The fluid shutoff valves and ratio check valves are
retained by mechanical stops that prevent accidental 5. On the EasyKey, press the Setup key to access
removal of the valve stem while the manifold is pres- setup screens.
surized. If you cannot turn the valve stems manually,
relieve the system pressure, then disassemble and 6. Select Recipe & Advanced Setup and press the
clean the valve to remove the resistance.
Enter key to select.
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.
• At least once per month as part of regular mainte-

nance.
• Whenever a flow meter is serviced or replaced.
NOTE:
• K-factors on the Calibration Screen are
updated automatically after the calibration pro- 7. Press the Right Arrow key to select the Calibra-
cedure is completed.
tion Screen. Press the Enter key to select
• K-factor values on the screen are viewable only. either A Meter, B Meter, or Solvent. Press the Down
If needed, you can manually edit the K-factors Arrow key and select Start from the menu. Start
in Advanced Setup Screen 4 (page 38) or only one at a time.
Recipe Setup Screen 5 (page 43).
• All values on this screen are in cc, independent

of the units set in Configure Screen 1.
• The controller will use the active recipe

K-factors for meter calibration. The active
recipe must be recipe 1 to recipe 60. Recipes
0 and 61 do not have K-factor values.
1. Before calibrating meter A or B, prime the system

with material. For a color/catalyst change system,
make sure the color/catalyst valve is open.
2. Shut off all spray or dispense devices connected to

the ProMix.
3. Close both fluid shutoff valves and sampling valves.
312776L 67
Meter Calibration
8. Dispense component A, B, or Solvent into beaker. 12. After the volume for A, B, or Solvent is entered, the
ProMix 2KS controller calculates the new flow meter
K-factor and shows it on the Calibration Screen.
NOTE: K-factor values on the screen are viewable

only. If needed, you can manually edit the K-factors
in Advanced Setup Screen 4 (page 38) or Recipe
a. To avoid splashing, slowly open sampling Setup Screen 5 (page 43).
valves.
13. Always purge sampling valves after calibrating
b. For more accurate calibration, adjust the valve meters. Use one of the following methods.
to dispense at a flow rate similar to your produc-
tion spray flow rate. • Follow the Purging Sampling Valves and
Tubes procedure, page 64.
c. Dispense a minimum of 250 cc; make sure
enough material is dispensed to accurately read • Place the sampling valve fluid tubes into a com-
the volume with your beaker. The A and B vol- patible cleaning fluid (TSL or solvent) or cap
umes do not have to be equal or at any particu- them.
lar ratio.
NOTE: If fluid hardens in sampling tubes, replace
d. Close sampling valve tightly. them with 5/32 in. or 4 mm OD tubing.
9. The volume that the ProMix measured displays on 14. Make sure both sampling valves are closed and
the EasyKey. both fluid shutoff valves are fully open.
10. Compare the amounts on the EasyKey to the 15. Before you begin production, clear the system of
amount in the beakers. solvent and prime it with material.
NOTE: For maximum accuracy, use a gravimetric a. Go to Mix mode.

(mass) method to determine the actual volumes dis-
pensed. b. Trigger the gun into a grounded metal pail until
mixed material flows from the gun nozzle.
11. If the screen and actual volumes are different, enter
the actual dispensed volume in cc for A, B, or Sol- c. To begin operation, see Start Up, page 55.
vent Volume field, and press the Enter key.
If the value was substantially different, repeat the

calibration process.
NOTE: If the screen and actual volume is the same

or if for any reason you want to cancel the calibra-
tion procedure, scroll to Abort on the Calibration
Screen menu and press the Enter key.
68 312776L
Color Change
Color Change
Color Change Procedures Color Change Sequences

FIG. 71 through FIG. 80 illustrate various color change
Multiple Color Systems sequences. See Table 9 to determine which figure to
1. Shut off air to the gun. reference, based on the recipe change and system con-
figuration. The time sequences are detailed in the fol-
2. Place the gun in the gun flush box if used, and close lowing paragraphs.
the lid.
NOTE: For software version 2.04.xxx and older, the sys-
tem uses the color/catalyst purge and fill times from the
3. Switch to Standby mode at the Booth Control. new recipe.
NOTE: See Setup Mode on page 27 to select purge

4. Use the scroll keys, or , to select the new sources and set desired purge, chop, and fill times.
color. Press Enter to begin the color change NOTES:
sequence.
• The system uses old recipe data for the purge cycle.
5. If a gun flush box is not used, trigger However, it opens the new color/catalyst valve
the gun into a grounded metal pail based on the new recipe data.
until the color change sequence is
complete. • The system uses the new recipe data for the fill
cycle.
6. When the color change indicator light stops flashing
on the Booth Control, the color change sequence is • For the one gun flush box (GFB) option, the spray
complete. gun must be inserted in the GFB during the entire
color change cycle (purge and fill). The GFB trigger
NOTE: The color change timer does not start until output will be on during the recipe change cycle.
the gun is triggered and fluid flow is detected. If no
flow is detected within 2 minutes, the color change • For the two gun flush box (GFB) option, both spray
operation aborts. The Booth Control enters Standby guns must be inserted in the GFBs during the entire
color change cycle (purge and fill). The system will
mode at the previous color. turn each GFB trigger output on and off based on
the preset time for each gun.
7. When you are ready to spray, remove the gun from
the gun flush box if used, and close its door. • For Special Outputs options, the system will turn
each output on and off based on the preset times.
NOTE: The gun flush box door must be closed for Each Special Output has two different start times
the atomizing air valve to open. and durations.
• For systems without dump valves, the First Purge

8. Press the Mix key to start spraying. begins after the Color/Catalyst Change steps are
completed.
Single Color Systems
• Dump Valve B is required for a Catalyst Change
1. Follow procedure for Purging Fluid Supply Sys- system.
tem, page 62.
• When going from Recipe X to Recipe 0, only the
2. Load the new color. See Start Up, page 55. purge cycle data from Recipe 0 is used.
3. Press the Mix key to start spraying. • When going from Recipe 0 to Recipe Y, only the fill
cycle data from Recipe Y is used.
312776L 69
Color Change
Color Purge/Dump First Purge

• This sequence flushes out the color with solvent, Select the First Purge Source (air, solvent, or 3rd valve)
from the color valve to the Dump A valve. and First Purge Time. For most applications, air is
selected.
• The color change solvent valve and the Dump A
valve open during the Purge Time. The system purges the old material from the dose
valves to the gun, using only the selected purge media
• The color change solvent valve closes when the (usually air). The selected purge valve opens during the
Purge Time expires. First Purge Time and closes when the time expires.
Color Fill Chop Cycle

• This sequence fills the line with the new color all the Select the Chop Type (air/solvent or air/3rd valve) and
way to the Dump A valve. Chop Times.
• The new color valve and the Dump A valve open The air purge valve opens only during the air chop
during the Fill Time. cycle, and the solvent (or 3rd valve) opens only during
the solvent chop cycle. The number of chop cycles is
• The new color valve and the Dump A valve close determined by dividing the Total Chop Time by the sum
when the Fill Time expires. of the Air and Solvent Chop Times.
Catalyst Purge/Dump Final Purge

• This sequence flushes out the catalyst with solvent, Select the Final Purge Source (air, solvent, or 3rd valve)
from the catalyst valve to the Dump B valve. and Final Purge Time. For most applications, solvent is
selected.
• The catalyst change solvent valve and the Dump B
valve open during the Purge Time. The system fills the line with solvent from the dose
valves to the gun, using only the selected purge media
• The catalyst change solvent valve closes when the (usually solvent). The selected purge valve opens
Purge Time expires. during the Final Purge Time and closes when the time
expires.
Catalyst Fill
Fill
• This sequence fills the line with the new catalyst all
the way to the Dump B valve. This sequence fills the line from the dose valves to the
gun, and is also referred to as the mixed material fill.
• The new catalyst valve and the Dump B valve open The system begins mixing components A and B until the
during the Fill Time. Fill Time expires.
• The new catalyst valve and the Dump B valve close

when the Fill Time expires.
70 312776L
Color Change
Table 9: Color Change Chart Reference
Starting Ending Change

Recipe Recipe Type Dump A Exiting Fill Refer to Fig.
X Y Change Yes NA FIG. 71
X Y Change No NA FIG. 72
0 Y Fill Yes Yes FIG. 73
0 Y Fill Yes No FIG. 74
0 Y Fill No Yes FIG. 75
0 Y Fill No No FIG. 76
X 0 Purge Yes NA FIG. 77
X 0 Purge No NA FIG. 78
0 0 Purge Yes NA FIG. 79
0 0 Purge No NA FIG. 80
NOTE: For manual systems, the Digital I/O signals iden-

tified in the color charts on the following pages represent
internal states.
312776L 71
72
Color Change
ProMix 2KS Recipe Change Chart #1 X to Y
Stack Valves A1 to A2, B1 to B2
Dump A Enabled, 3rd Flush Valve Enabled
Color/Catalyst/(Reducer) Color Change Stack Purge and Fill Operations by Time

Purge from X, Fill from Y --> A Purge A Fill B Purge B Fill Waiting
Stack Valves Color Change Stack Flush Sequence Color Change Stack Components
Solvent A If a component is not changing, that time segment is skipped
Dump A Flush out old color and fill with new color
Component A
Solvent B
Dump B Flush out old catalyst and fill with new catalyst
Component B
Separate Gun 1 and Gun 2 Dose Valve and Integrator Flush Purge and Chop Operations by Time
Purge from X --> First Purge Total Chop 2sB Final Purge
Purge Valves Dose Valve and Integrator Flush Sequence Purge Operation Details
First Purge Selection Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Purge A (Air) Fixed for Purge A (Air)
Purge B (Solvent) If Chop Type is "Air/Solvent"
3rd Purge Valve on A If Chop Type is "Air/3rd Purge"
2 s B Purge after Chop Fixed Purge B. Enabled in Options Screen 2
Final Purge Selection Select Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Separate Gun 1 and Gun 2 Dose Valve and Integrator Mix Fill Operations by Time
Fill from Y -->
Dose Valves Mixed Fill Time using Sequential Dosing
Dose A
Dose B
Mixed Fill Time using Dynamic Dosing
GFB Outputs Gun and Hose Flush Operations by Time Gun and Hose Mix Material Fill Operations by Time
If No Gun Flush Boxes
Gun Trigger(s) by Operator
1 Gun This happens on the same time scale as the Dose Valve and Integrator Flush Sequence
Gun Flush Box Output 1
2 Guns Each Integrator Flush Purge, Chop, and Mix Material Fill operation runs sequentially for Gun 1 then for Gun 2
Digital I/O Discrete I/O Signals by Time

Color Change Input <- Start of Color Change
Purge Active Output
Fill Active Output End of Color Change ->
Mix Ready Output
Special Outputs <- Start of On-Purge <- Start of On-Fill
Special Output #1 <- Length -> <- Length ->
3 + GFB on #4
312776L
2KS X to Y K15
FIG. 71: ProMix 2KS Recipe Change Chart #1 X to Y

312776L
ProMix 2KS Recipe Change Chart #2 X to Y

Stack Valves A1 to A2, B1 to B2
No Dump A, 3rd Flush Valve Enabled

Purge from X, Fill from Y --> A Purge A Fill B Purge B Fill Waiting
Solvent A If a component is not changing, that time segment is skipped
Dump A No Dump A Flush out old color and fill with new color
Component A
Solvent B
Dump B Flush out old catalyst and fill with new catalyst
Component B
Purge from X --> Waiting First Purge Total Chop 2 s B Final Purge
Fill from Y -->
Dose A <- A Purge and A Fill through Dose A with no Dump A
Dose B
Gun Flush Box Output 1 GFB 1 Only

Purge Active Output
Mix Ready Output
Color Change
3 + GFB on #4
2KS X to Y K13
FIG. 72: ProMix 2KS Recipe Change Chart #2 X to Y

73
74
Color Change
ProMix 2KS Recipe Fill Chart #3 0 to Y
Stack Valves A1, B1
Exiting Fill Enabled

No Purge, Fill from Y --> Waiting A Fill B Fill
Stack Valves Color Change Stack Fill Sequence Color Change Stack Components
Solvent A Only active components are filled
Dump A Push out solvent and fill with new color
Component A
Solvent B
Dump B Push out solvent and fill with new catalyst
Component B
No Purge --> Exit. Fill Waiting
Exiting Fill Selection From Recipe 0 Recipe 0: Purge A (Air), Purge B (Solvent), or 3rd Valve on A
Fill from Y -->
Dose A
Dose B

Purge Active Output
Mix Ready Output
312776L
3 + GFB on #4
2KS 0 to Y K15
FIG. 73: ProMix 2KS Recipe Fill Chart #3 0 to Y

312776L

Stack Valves A1, B1
No Exiting Fill

No Purge, Fill from Y --> A Fill B Fill
Dump A Push out solvent and fill with new color
Component A
Solvent B
Component B
No Purge --> Waiting
Fill from Y -->
Dose A
Dose B

Purge Active Output
Mix Ready Output
Color Change
3 + GFB on #4
2KS 0 to Y K14
75
76
Color Change
Stack Valves A1, B1

No Purge, Fill from Y --> Waiting A Fill B Fill
Stack Valves Color Change Stack Fill Sequence Color Change Stack Components
Dump A No Dump A Push out solvent and fill with new color
Component A
Solvent B
Component B
No Purge --> Exit. Fill Waiting
Fill from Y -->
Dose A <- A Fill through Dose A with no Dump A
Dose B

Purge Active Output
Mix Ready Output
3 + GFB on #4
2KS 0 to Y K13
312776L

312776L

Stack Valves A1, B1
No Exiting Fill

No Purge, Fill from Y --> A Fill B Fill
Dump A No Dump A Push out solvent and fill with new color
Component A
Solvent B
Component B
No Purge --> Waiting
Fill from Y -->
Dose A <- A Fill through Dose A with no Dump A
Dose B

Purge Active Output
Mix Ready Output
Color Change
3 + GFB on #4
2KS 0 to X K12

77
78
Color Change
ProMix 2KS Recipe Purge Chart #7 X to 0
Stack Valves Off

Purge from 0, No Fill --> A Purge B Purge
Solvent A Every recipe 0 entry will flush all components
Dump A Flush out old color
Component A
Solvent B
Dump B Flush out old catalyst
Component B
Purge from 0 --> First Purge Total Chop 2sB Final Purge
No Fill -->
Dose A
Dose B

Purge Active Output End of Color Change ->
Fill Active Output
Mix Ready Output
Special Outputs <- Start of On-Purge
Special Output #1 <- Length ->
3 + GFB on #4 This activates for Autodump operations only
312776L
2KS X to 0 K15
FIG. 77: ProMix 2KS Recipe Purge Chart #7 X to 0

312776L
ProMix 2KS Recipe Purge Chart #8 X to 0

Stack Valves Off

Purge from X, Fill from Y --> A Purge B Purge Waiting
Dump A No Dump A Flush out old color
Component A
Solvent B
Component B
Purge from 0 --> Waiting First Purge Total Chop 2 s B Final Purge
No Fill -->
Dose A <- A Purge through Dose A with no Dump A
Dose B

Fill Active Output
Mix Ready Output
Color Change
3 + GFB on #4 This activates for Autodump operations only
2KS X to 0 K13
FIG. 78: ProMix 2KS Recipe Purge Chart #8 X to 0

79
80
Color Change
ProMix 2KS Recipe Purge Chart #9 0 to 0
Stack Valves Off
Color/Catalyst/(Reducer) Color Change Stack Purge and Fill Operations by Time - From Recipe 0
Purge from 0, No Fill --> Waiting A Purge B Purge Waiting
Dump A Flush out old color
Component A
Solvent B
Component B
Separate Gun 1 and Gun 2 Dose Valve and Integrator Flush Purge and Chop Operations by Time - From Recipe 0
Purge from 0 --> Exit. Fill First Purge Total Chop 2sB Final Purge
No Fill -->
Dose A
Dose B

Fill Active Output
Mix Ready Output
312776L
3 + GFB on #4
2KS 0 to 0 K3
FIG. 79: ProMix 2KS Recipe Purge Chart #9 0 to 0

312776L
ProMix 2KS Recipe Purge Chart #10 0 to 0

Stack Valves Off
Color/Catalyst/(Reducer) Color Change Stack Purge and Fill Operations by Time - From Recipe 0
Purge from 0, No Fill --> Waiting A Purge B Purge Waiting
Dump A No Dump A Flush out old color
Component A
Solvent B
Component B
Separate Gun 1 and Gun 2 Dose Valve and Integrator Flush Purge and Chop Operations by Time - From Recipe 0
Purge from 0 --> Exit. Fill Waiting First Purge Total Chop 2sB Final Purge
No Fill -->
Dose A <- A Purge through Dose A with no Dump A
Dose B

Fill Active Output
Mix Ready Output
Color Change
3 + GFB on #4
2KS 0 to 0 K1
FIG. 80: ProMix 2KS Recipe Purge Chart #10 0 to 0

81
Alarms and Warnings
Alarms and Warnings

NOTE: Do not use the fluid in the line that was dis- To Reset Alarm and Restart
pensed off ratio as it may not cure properly.
NOTE: When an alarm occurs be sure to determine the
E-Code before resetting it. See Table 10. If you forget
System Alarms which E-Code occurred, use the Alarms Screens (page
26) to view the last 10 alarms, with date and time
System alarms alert you of a problem and help prevent stamps.
off-ratio spraying. If an alarm occurs, operation stops
and the following occurs: To reset alarms, see Table 11. Many alarms can be
• A red LED illuminates steadily or blinks on the

cleared by simply pressing the Alarm Reset key.
Booth Control.
• Booth Control displays an alarm E-Code, E-1 to
E-28. See FIG. 81. Table 10: System Alarm/Warning Codes
• Buzzer sounds (for E-2 only; see page 31 to set for
Code Description Details
all alarms).
• Status bar on the EasyKey Display shows the alarm E-1 Communication Error Alarm Page 83
E-Code with a description (see Table 10). E-2 Potlife Alarm Page 83
E-3 Ratio High Alarm Page 84
Alarm Indicator (red) Display E-4 Ratio Low Alarm Page 85
E-5 Overdose A/B Dose Too Short Alarm Page 86
E-6 Overdose B/A Dose Too Short Alarm Page 86
E-7 Dose Time A Alarm Page 87
E-8 Dose Time B Alarm Page 87
E-9 Not used NA
E-10 Remote Stop Alarm Page 88
E-11 Purge Volume Alarm Page 88
E-12 CAN Network Communication Error Page 89
Alarm
E-13 High Flow Alarm Page 90
E-14 Low Flow Alarm Page 90
E-15 System Idle Warning Page 90
E-16 Setup Change Warning Page 90
Recipe Indicator (green) TI11614A
E-17 Power On Warning Page 90
FIG. 81. Booth Control E-18 Defaults Loaded Warning Page 90
E-19 I/O Alarm Page 91
E-20 Purge Initiate Alarm Page 92
System Warnings
E-21 Material Fill Alarm Page 92
Table 10 lists the System Warning Codes. Warnings do E-22 Tank A Low Alarm Page 92
not stop operation or sound an alarm. They are saved in
E-23 Tank B Low Alarm Page 92
the date/time stamped log, which can be viewed on a
PC, using the ProMix 2KS Web Interface (see manual E-24 Tank S Low Alarm Page 92
313386). E-25 Auto Dump Complete Alarm Page 93
E-26 Color/Catalyst Purge Alarm Page 93
E-27 Color/Catalyst Fill Alarm Page 93
E-28 Mix Fill Push Complete Page 93
82 312776L
Alarm Troubleshooting
Table 11. Alarm Troubleshooting
E-1: COMM ERROR
Cause Solution
No power to the EasyKey. Connect power to EasyKey.

No power to Fluid Station. The intrinsically safe power Verify that the cable is correctly connected. See Installa-
cable between the EasyKey and Fluid Station is not con- tion manual.
nected.
No power to Fluid Station. The fluid control board fuse is Verify condition of fuse and replace if necessary. See
blown. Repair-Parts manual.
The fiber optic cable between the EasyKey and Fluid Verify that the cable is correctly connected. See Installa-
Station is not connected. tion manual.
The fiber optic 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).
Dirty fiber optic cable ends. Disconnect fiber optic cable ends and clean with a
lint-free cloth.
A communication cable or connector failed. Replace cable.
E-2: POTLIFE ALARM
Cause Solution
The potlife time has been exceeded for the mixed mate-
rial. Press the Alarm Reset key to stop the audible
alarm. Purge the system with solvent, fresh mixed mate-
NOTICE rial, or a new color:
To prevent mixed material from curing in the equip-
ment, do not shut off power. Follow one of the solu- • Solvent Purge - See Purging Mixed Material on
tions at right. page 61. The system purges until the preset purge
time is complete.
• New Mixed Material Purge - Go to Mix mode and

spray the required volume to restart the timer.
• Color Change - Perform a color change, page 69.
312776L 83
E-3: RATIO HIGH ALARM

Sequential Dosing System
The mix ratio is higher than the set tolerance on the previous dose cycle.
Dynamic Dosing System

The mix ratio is higher than the set tolerance for an A to B component volume comparison.
Cause Solution
There is too little restriction in the system. • Check that the system is fully loaded with material.
• Check that the supply pump’s cycle rate is set prop-

erly.
• 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 Restrict gun needle travel to slow down the initial fluid
rate was probably too high. delivery rate until fluid hoses are loaded with material.
If the alarm occurred after you were spraying for some Adjust component A and B fluid supply regulator pres-
time, the pressures from the fluid supplies could be sures until they are about equal. If the pressures are
unbalanced. already about equal, verify that component A and B dose
valves are operating properly.
Slow actuation of the component A or B valves. This can Manually operate the Dispense A and B solenoid valves
be caused by: as instructed in the ProMix 2KS Repair-Parts manual 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 • There may be dirt or moisture in the air supply. Filter
interrupting valve actuation air. appropriately.
• A dose valve is turned in too far. • Refer to Table 7: Mix Manifold Valve Settings,
page 55, for adjustment guidelines.
• Fluid pressure is high and air pressure is low. • Adjust air and fluid pressure. See recommended air
pressure above.
84 312776L
E-4: RATIO LOW ALARM

Sequential Dosing System
The mix ratio is lower than the set tolerance on the previous dose cycle.
Dynamic Dosing System

The mix ratio is lower than the set tolerance for an A to B component volume comparison.
Cause Solution
There is too much restriction in the system. • Check that the system is fully loaded with material.
• Check that the supply pump’s cycle rate is set prop-

erly.
• 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 Restrict gun needle travel to slow down the initial fluid
rate was probably too high. delivery rate until fluid hoses are loaded with material.
If the alarm occurred after you were spraying for some Adjust component A and B fluid supply regulator pres-
time, the pressures from the fluid supplies could be sures until they are about equal. If the pressures are
unbalanced. already about equal, verify that component A and B dose
valves are operating properly.
Slow actuation of the component A or B valves. This can Manually operate the Dispense A and B solenoid valves
be caused by: as instructed in the ProMix 2KS Repair-Parts manual 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 • There may be dirt or moisture in the air supply. Filter
interrupting valve actuation air. appropriately.
• A dose valve is turned in too far. • Refer to Table 7: Mix Manifold Valve Settings,
page 55, for adjustment guidelines.
• Fluid pressure is high and air pressure is low. • Adjust air and fluid pressure. See recommended air
pressure above.
312776L 85
E-5: OVERDOSE A/B DOSE TOO SHORT ALARM and

E-6: OVERDOSE B/A DOSE TOO SHORT ALARM
E-5: the A dose overshoots and, when combined with B, is too large for the mix chamber capacity.
E-6: the B dose overshoots and forces an A side dose that, when combined with B, is too large for the mix chamber
capacity.
Cause Solution
Valve seal or needle/seat are leaking. Check FIG. 11 Repair the valve (see valve manual 312782).
Totals Screen on page 25. If A and B are dosing simul-
taneously (sequential dosing only), there is a leak.
Sampling valve is leaking. Tighten or replace valve.
Flow meter fluctuations caused by pressure pulsations. Check for pressure 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 2KS is reading any fluid flow.
4. If the ProMix 2KS shows there is fluid flow and there

are no leaks from the gun or any other seals or fit-
tings, the flow meters are probably being affected by
pressure pulsations.
5. Close the fluid shutoff valve between the fluid supply

system and the flow meter. The flow indication
should stop.
6. If necessary, install pressure regulators or a surge

tank on the fluid inlets to the ProMix 2KS to reduce
the fluid supply pressure. Contact your Graco distrib-
utor for information.
Slow actuation of component A or B valves. See E-3: RATIO HIGH ALARM and E-4: RATIO LOW
ALARM, pages 84-85.
Running a high mix ratio and a high flow rate. It may be necessary to restrict the flow rate through the
component B dose valve by adjusting its hex nut (E).
See page 53.
86 312776L
E-7: DOSE TIME A ALARM and E-8: DOSE TIME B ALARM

E-7: gun trigger input is active (AFS or Integration) and fewer than 31 A meter pulses were detected during the
dose time selected.
E-8: gun trigger input is active (AFS or Integration) and fewer than 31 B meter pulses were detected during the
dose time selected.
Cause Solution
Fully trigger the gun.

System is in Mix mode and gun is only partially
triggered, allowing air but no fluid to pass through gun.
Fluid flow rate is too low. Increase flow rate.
Dose time setting is too short for the current flow rate. Increase the dose time setting.
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 dif-

ference between the amount of fluid dispensed and the
flow meter volume displayed by the EasyKey. Clean or
repair meter as necessary. Also see meter manual
308778.
Follow Meter Calibration procedure, page 67.

Slow actuation of component A or B valves. See E-3: RATIO HIGH ALARM and E-4: RATIO LOW
ALARM, pages 84-85.
The supply pump is not turned on. Turn on the supply pump.
There is an air leak downstream from the air flow switch. Check the air lines for leaks and repair.
The air flow switch is stuck open. Clean or replace air flow switch.
System is in Mix mode with 0 volume entered for Min Verify condition of fuse and replace if necessary. See
Material Fill Volume (see Option Screen 1, page 34), Repair-Parts manual.
and Fuse F1 is blown.
312776L 87
E-9: Not used

E-10: REMOTE STOP ALARM
Cause Solution
Automation has requested that the system abort all oper- Abort operations. Troubleshoot automation system.
ations.
E-11: PURGE VOLUME ALARM
Cause Solution
ProMix 2KS solvent flow switch is not activated while Verify that the gun is not shut off and that the solvent
purging. flow switch is activated while purge is taking place.
Minimum flush volume is not achieved. Increase solvent supply or decrease minimum volume
setting.
No meter pulses during Color/Catalyst Dump. Color change solvent supply not set up or functional.
Check Color Change setup.
88 312776L
E-12: CAN COMM ERROR ALARM
Cause Solution
Communication between the Color Change Module and • Verify that all cables are connected securely and that
the Fluid Station is interrupted. the Color Change and Booth Control power LEDs
turn on. If the power LED does not turn on, the prob-
lem is probably caused by a bad connection. The nut
on the connector must make at least 5 complete
turns to ensure a good connection. If the power LED
still does not light, the cable or board is bad.
• Check the color change board DIP switch settings.
See the Installation manual.
• Check the fluid plate board DIP switch setting. An
incorrect setting will not cause E-12 alarms, but a
correct setting will help prevent E-12 caused by elec-
trical noise. See the Installation manual.
• Check EasyKey software version (displayed at
power up for all versions and when the lock key is
pressed for version 2.02.000 and above). If older
than 1.06.002, upgrade. Be sure to save settings
through BWI or AWI before upgrading, as they will
be erased.
• The sticker on the color change board shows the
software part number and version, for example
15T270 1.01. If the version is older than 1.01,
replace the board.
• If all software versions and DIP switch settings are
correct and you still have E-12 alarms, then the sys-
tem has a bad connection, bad cable, or bad circuit
board. Use a multimeter on the CAN connectors to
test whether there is a good connection between
systems. If there is, you have a bad circuit board. If
there is not, you have a bad connector, connection,
or cable.
• Appears on the EasyKey display if the unit is pro-
grammed for Manual Mode, and a booth control is
not connected.
• The dip switch settings on the Color Change Module
were changed (see manual 312787) while the power
was on. Cycle the power to clear the alarm.
• The dip switch configuration on the Color Change
Control Module (see manual 312787) is setup incor-
rectly.
Communication between the Color Change Module and Verify condition of fuse and replace if necessary. See
the Fluid Station is interrupted. The fluid control board Repair-Parts manual.
fuse is blown.
Communication between the Booth Control and the Fluid Verify that the cable is correctly connected.
Station is interrupted.
312776L 89
E-13: HIGH FLOW ALARM or E-14: LOW FLOW ALARM (may also be set as Warnings)
Cause Solution
Fluid system is producing too much or too little flow. Troubleshoot fluid system for restrictions, leaks,
exhausted fluid supply, incorrect settings, etc. Increase
or decrease flow rate, as required.
E-15: SYSTEM IDLE WARNING
Cause Solution
Mix input is high, but the gun has not been triggered for 2 If not painting, clear alarm and resume operation.
minutes.
If painting, shut down and inspect fluid meter and air flow
switch.
E-16: SETUP CHANGE WARNING
Cause Solution
The system setup parameters have been changed. No action required. See Event Log available through
advanced web interface.
E-17: POWER ON/POWER OFF WARNING
Cause Solution
The power to the system has been cycled. No action required. See Event Log available through
Voltage becoming too low due to weak power supply. Replace power supply. See Repair-Parts manual.
Power wires are disconnected or making intermittent Check that all wires are securely connected. Ensure that
contact. wires are not stretched too tightly.
Reset button has been pushed (S1 on EasyKey display No action required. See Event Log available through
board, S3 on Autokey). advanced web interface.
Software update is initiated on EasyKey. No action required. See Event Log available through
E-18: DEFAULTS LOADED WARNING
Cause Solution
The factory defaults have been installed on the system. No action required. See Event Log available through
90 312776L
E-19: I/O ALARM
Cause Solution
The Mix and Purge digital inputs are on at the same time. Ensure that only one input is on at a time. At least 1 sec
delay is required when switching from Mix to Purge or
vice versa.
NOTE: The I/O alarm incorporates several sub-alarms relating to internal data issues, as detailed below. These
alarms are only seen in the Alarm log or through BWI or AWI, and may not apply to all software versions.
Fluid Plate Reboot (FP Reboot): Occurs if the system Flush the system or perform a color change. If possible,
detects a fluid plate control board reboot or power cycle identify the origin of the reboot or power cycle.
not triggered from the EasyKey. The system reverts to
Recipe 61, and mixed material may be in the lines.
Autokey Lost: Occurs if the Autokey is lost or changed Reinstall the Autokey, or verify that the Autokey is set
after having been detected. (A short term loss of the properly.
Autokey will not be registered.) Some system functions
may become unavailable. For example, an automatic
system will not respond to PLC or robot control.
Illegal Source: Occurs if a recipe outside of the range Verify that the source data is from a valid recipe (1-60).
1-60 is detected as the source data for global recipe data
copies. This is possible if an invalid configuration file is
sent to the EasyKey.
2K/3K Error: Occurs if the recipe data is incompatible Verify that the Autokey is set properly or that the configu-
with the current Autokey setting (2K or 3K). This is possi- ration file is valid.
ble if the Autokey is changed or an invalid configuration
file is sent to the EasyKey.
Init Error: Occurs if the recipe data codes specifying the Verify that the configuration file is valid.
type of machine they were made on are not what is
expected. For example, a 3KS machine receives a con-
figuration file originally made on a 2KS machine.
Config Error: Occurs if a configuration file sent to the Verify that the configuration file specifications and the
EasyKey specifies a different hardware setup than what hardware conform.
exists. For example, the configuration file specifies 2
color change boards but only 1 is present.
Range Error: Occurs if a valve used in a recipe is not Verify that the recipe specifications and the hardware
present in the current hardware setup. For example, a conform.
recipe calls for valve 30 but the system has only 12
valves.
Level Control (LC) Error: Occurs if level control data is Verify that the Autokey is set properly.
received by the EasyKey, and the current Autokey set-
ting (2K or 3K) has changed since the level control data
was originally initialized.
Level Control (LC) Range Error: Occurs if level control Set level control data correctly.
data includes a valve range exceeding the capability of
the machine.
Modbus (MB) Overflow: Occurs if the Modbus connec- Verify the Modbus protocol to the EasyKey.
tion to a PLC experiences data overflow.
312776L 91
E-20: PURGE INITIATE ALARM
Cause Solution
System detects atomizing air to the gun when purge is Shut off gun air.
selected.
For systems with a gun flush box, gun is not in the box Place gun in gun flush box. Verify that gun flush box is
when purge is selected. operating properly.
For systems with auto dump on, gun is not in the box Place gun in gun flush box. Verify that gun flush box is
when auto dump is initiated. operating properly.
For systems with a gun flush box, Fuse F2 is blown. Verify condition of fuse and replace if necessary. See
Repair-Parts manual.
E-21: MATERIAL FILL ALARM
Cause Solution
For systems with minimum mixed material fill volume Check for restrictions or leaks in the fluid supply system.
entered, the system detects that fill volume is not
achieved during mixed material fill time. Check if the fill volume is properly configured:
• Adjust fill volume.

• Adjust fill time.
For systems without color change and with minimum Verify condition of fuse and replace if necessary. See
mixed material fill volume entered, Fuse F1 is blown. Repair-Parts manual.
E-22: TANK A LOW ALARM, E-23: TANK B LOW ALARM, or E-24: TANK S LOW ALARM
Cause Solution
The tank volume reaches the low-level threshold. The EasyKey screen will display the alarm and prompt
the user to do one of the following:
• Refill tank volume to clear the alarm.

• Resume mixing by selecting “Spray 25% of remain-
ing volume.” If this selection is chosen, a second
alarm will occur after 25% of the remaining volume is
mixed. Refill tank volume to clear the alarm.
92 312776L
E-25: AUTO DUMP COMPLETE ALARM
Cause Solution
A potlife alarm is active for more than 2 minutes, the gun Be sure to spray all mixed material before potlife expires.
flush box is enabled and gun is in the gun flush box, and
an auto dump flush sequence is complete.
E-26: COLOR/CATALYST PURGE ALARM
Cause Solution
System detects no meter pulses, or a disruption in meter Check that meter cable is connected.
pulses lasting longer than 1 second throughout the
Color/Catalyst purge time duration. Clean or repair meter.
E-27: COLOR/CATALYST FILL ALARM
Cause Solution
System detects no meter pulses, or system must detect Check that meter cable is connected.
at least 10cc of material from each side throughout the
Color/Catalyst fill time duration. Clean or repair meter.
Gun, dump valve, or correct color/catalyst valve not Open the valve.
open.
Exhausted fluid supply. Check fluid level and refill if necessary.
Switch settings (S3-S6) on color change board do not Verify that color change board switches are set correctly.
match hardware configuration. See installation manual.
Fuse F1, F2, or both are blown. Verify condition of fuses and replace if necessary. See
Repair-Parts manual.
E-28: MIX FILL PUSH COMPLETE
Cause Solution
Mix fill push has been completed. Potlife expired material has been purged.
312776L 93
Schematic Diagrams
Schematic Diagrams
System Pneumatic Schematic
COLOR COLOR
CHANGE VALVE
CONTROL STACKS
AIR EXHAUST MUFFLER
MANIFOLD COLOR 1
COLOR 2
1/4 TUBE
1/4 TUBE
12 VDC COLOR 3
SE BE DOSE A COLOR 4
4-WAY SOLENOID CLO 2 TU VALVE COLOR 5
A B 5/3 N COLOR 6
E
OP COLOR 7
COLOR 8
12 VDC
TO MANIFOLD
COLOR SOLVENT
SE BE
FLUSH AIR TO FLUID INLET

DOSE B COLOR 9
4-WAY SOLENOID CLO 2 TU VALVE
COLOR 10
A B 5/3 N
E COLOR 11
OP
COLOR 12
CATALYST 1
12 VDC
CATALYST 2
SE BE PURGE A
CLO 2 TU
05 VALVE CATALYST 3
4-WAY SOLENOID
A B 5/3 N CATALYST 4
E
3/8 AIR FILTER OP CATALYST SOLVENT
MANUAL DRAIN
CONTROL AIR
5 MICRON
12 VDC
WALL MOUNT ONLY
SE BE PURGE B COLOR 13
4-WAY SOLENOID CLO 2 TU VALVE
A B 5/3 EN COLOR 14
OP COLOR 15
COLOR 16
AIR INPUT COLOR 17
12 VDC
COLOR 18
SE BE PURGE C
CLO 2 TU VALVE COLOR 19
(OPTIONAL)
4-WAY SOLENOID
A B 5/3 N COLOR 20
E
OP COLOR 21
AIR EXHAUST MUFFLER COLOR 22
PURGE AIR
COLOR 23
12 VDC COLOR 24
E DUMP A COLOR 25
UB VALVE
3-WAY SOLENOID 2T (OPTIONAL) COLOR 26
A 5/3 N COLOR 27
E
OP COLOR 28
AIR INPUT COLOR 29
12 VDC COLOR 30
E DUMP B
UB VALVE
3-WAY SOLENOID 2T (OPTIONAL)
A 5/3 N
E
OP
MAC
36 SERIES SOLENOID VALVES
12 VDC
E GFB 1
UB VALVE
A 5/3 N
E
OP
12 VDC
E GFB 2
UB VALVE
A 5/3 N
E
MANIFOLD OP
94 312776L
Schematic Diagrams
System Electrical Schematic

NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS system. Some compo-
nents shown are not included with all systems.
Non-Hazardous Area
NON-HAZARDOUS AREA
OPERATOR INTERFACE LINE L1
L1 N
DC OK N FILTER
+ POWER 1 L1 85-250 VAC GND
+24 VDC + 2 N L1 TERMINAL L1
SUPPLY N BLOCK N
COMMON -
COMMON - GND GND
1 GND LUG
2
3 GND N L1
85-250
1 POWER VAC
2 ROCKER
1A SWITCH
POWER HARNESS 1 UNUSED OPEN 1B
2 UNUSED 2A
J1 3 UNUSED OPEN 2B
4 UNUSED HARNESS
5 UNUSED
1 +12VDC I/S (RED)
J5 2 COM (BLACK)
BARRIER 3 SHIELD
BOARD CABLE
1 +24VDC (50' STD.)/
J4 2 OPEN
3 COMMON (100' OPTION)
ALARM
J4 DISPLAY
MEMBRANE 1 BOARD 1 +
SWITCH 2 J9 2 -
WITH 3 3 +
4 4 - 1 MIX INPUT
RIBBON
5 RJ45
2 PURGE INPUT
CABLE 6 RJ45 3 JOB COMPLETE INPUT
3' 4 EXTERNAL CLR CHG READY
7 J6 J2
8 5 RESET ALARM INPUT
POWER DIST. RJ45 RJ45 6 DIGITAL INPUT COMMON
9
10 TERMINAL 1 DIGITAL INPUT COMMON
11 BLOCKS 2 RECIPE BIT 0 INPUT
3 RECIPE BIT 1 INPUT
- + 4 RECIPE BIT 2 INPUT
J3 5 RECIPE BIT 3 INPUT
J2 - + 6 RECIPE BIT 4 INPUT
REMOTE 7 RECIPE BIT 5 INPUT
1 I/O 8 RECIPE CHANGE INPUT
DISPLAY 2 - +
INTEGRATION
3 - + BOARD 1 DIGITAL OUTPUT COMMON/POWER
4 2 PURGE/RECIPE CHG ACTIVE OUTPUT
5 3 MIX ACTIVE OUTPUT
SHIELD
6 4 MIX READY OUTPUT

J4 5 FILL ACTIVE
7 6 FLOW CAL. ACTIVE
8 7 FLOW RATE ALARM OUTPUT
9 FLOW CONTROL CAL. (BLK) 1 8 DIGITAL OUTPUT COMMON/POWER
10 1
11 2 GUN TRIGGER (WHT) 2 1 DIGITAL OUTPUT COMMON/POWER
12 3 DIGITAL IN COMMON (RED) 3 2 SPECIAL OUTPUT #1
4 REMOTE STOP (GRN) 4 3 SPECIAL OUTPUT #2
13 J5 4 SPECIAL OUTPUT #3
14 J5 5 ALARM RESET (BRN) 5 5
ALARM OUTPUT (BLU) 6 SPECIAL OUTPUT #4
15 6 6 DIGITAL OUTPUT COMMON/POWER
16 7 DIGITAL OUTPUT COMMON (ORG) 7
17 8 POT LIFE (YEL) 8
18 9 FLOW RATE ANALOG IN (PUR) 9
19 10 FLOW RATE ANALOG COMMON (GRAY) 10
20
I/O HARNESSES (+24) YEL
(COM) GRAY BEACON
ORG
TERMINAL BRN
1 RS485 INTEGRATION A (WHT/BLU) 1 BLOCKS RED
2 RS485 INTEGRATION B (BLU/WHT) 2
J10 3 RS485 INTEGRATION GROUND (SHIELD) 3
4 RS485 NETWORK A (WHT/ORG) 4
5 RS485 NETWORK B (ORG/WHT) 5
6 RS485 NETWORK GROUND (SHIELD) 6
CABLE
J7 FO IN (BLK)
J8 FO OUT (BLU)
RJ45 RJ45
3'
P1
RJ45
BULKHEAD
3'
(25'-200' OPTIONS)
RJ45
WEB SERVER
RJ45
MODULE
312776L 95
Schematic Diagrams
System Electrical Schematic

NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix 2KS system. Some compo-
nents shown are not included with all systems.
Hazardous Area
FLUID PANEL CONTROL BOX HAZARDOUS AREA

3X CABLE
FLUID 1 PWR (RED)
PANEL 2 COM (BLACK) FLOW METER A
3 SIG (WHITE)
CONTROL J3
4 SHIELD/GRN
BOARD 5 PWR (RED)
6 COM (BLACK) FLOW METER B I.S. METERS
SIG (WHITE)
SHIELD/GRN
1 PWR (RED)
2 COM (BLACK) FLOW METER SOLVENT
3 SIG (WHITE)
J12 4 SHIELD/GRN J2
SIG (RED) TECNO
5 J1 1
6 2 COM (BLK) V/P
GROUND V/P ANALOG OUT (WHT) 1 FLOW
TERMINAL PRESS. (GRN) 2 CONTROL
+12 V (RED) 3 BOARD
1 UNUSED GND (BLK) 4 J4
2 UNUSED CHASSIS (BARE) 5 1 + PRESSURE (GRN) FLUID
J10 J13 3 UNUSED 2 COM (RED) PRESS.
4 UNUSED (10')/
(40') 3 EX+ (WHT) SENS.
1 +12VDC I/S 5 UNUSED 4
2 COM 6 UNUSED - PRESSURE (BLK)
5 SHIELD (BARE)
3 SHIELD 1
2
J5 3
4
5
6
MH2
J7/J11
1 4 5 2 3
COLOR
BOARD 1
6' STD. (COLORS
(3'-100' OPTIONS)
3 1 THRU 12,
GRD (BLK)
2 +12VDC (RED) CATALYST
J11 5 SHIELD (BARE) 1 THRU 4)
4 CAN H (WHT) MANIFOLD MANIFOLD
1 CAN L (BLU) +12VDC 1 6 COM CLR 9
CLR 8 2 5 +12VDC
COM
+12VDC 3 4 COM CLR 10
CLR 7
50' STD. COM 4 J8 J9 3
2
+12VDC
+12VDC 5 COM CLR 11
BOOTH CLR 6 1 +12VDC
COM 6
3 GRD (BLK) 3
2 +12VDC (RED) 2 CONTROL
+12VDC 1
J7 5 SHIELD (BARE) 5 BOARD CLR 5
COM 2
6
5
COM
+12VDC
CLR 12
4 CAN H (WHT) 4 CLR 4 +12VDC 3
J15 J16 4 COM
1 1 4 CAT 4
CAN L (BLU) COM 3 +12VDC
+12VDC 5 2 COM
CLR 3 6 CAT 3
COM 1 +12VDC
+12VDC 1 6 COM CAT 2

CLR 2 COM 2 5 +12VDC
3 4 COM
MANIFOLD CLR 1 +12VDC
COM 4 J14 J10 3 +12VDC
CAT 1
6 BLACK DUMP B +12VDC 5 2 COM SOL CAT
RED SOL CLR 6 1 +12VDC
5 COM
4 BLACK GFB #1 1 4 5 2 3
J8 RED
3-WAY SOLENOID
3 J7/J11
2 BLACK GFB #2 6' STD.
1 RED
J7/J11
12 VDC
6 BLACK DUMP A 1 4 5 2 3
5 RED COLOR
4 BLACK NOT USED BOARD 2
J15 3 RED MANIFOLD (COLORS
2 BLACK PURGE C
13 THRU 30)
1 RED
6 BLACK PURGE B MANIFOLD MANIFOLD
RED +12VDC 1 6
5 CLR 21 COM CLR 22
4-WAY SOLENOID
COM 2 5 +12VDC
4 BLACK PURGE A 3
J14 3 RED CLR 20 +12VDC
COM 4 J8 J9 4
3
COM
+12VDC
CLR 23
2 BLACK CLR 19 +12VDC 5 2 COM CLR 24
NOT USED
12 VDC
COM 6 1 +12VDC
1 RED
+12VDC 1
6 BLACK CLR 18 2 6 COM
NOT USED COM CLR 25
5 RED 3 5 +12VDC
CLR 17 +12VDC
COM 4 J15 J16 4 COM CLR 26
J9 4 BLACK 5 3 +12VDC
3 RED DOSE B CLR 16 +12VDC
6 2 COM
COM CLR 27
2 BLACK 1 +12VDC
1 RED DOSE A +12VDC 1
CLR 15 6 COM CLR 28
COM 2 5 +12VDC
+12VDC 3
1 SIG AIR FLOW SWITCH 1
CLR 14
COM 4 J14 J10 4
3
COM
+12VDC
CLR 29
2 COM CLR 13 +12VDC 5 2 COM CLR 30
3 SIG COM 6 1 +12VDC
4 COM AIR FLOW SWITCH 2
5 SIG
FO OUT 6 COM SOLVENT FLOW SWITCH
J4 J1
(BLU) 7 SIG GFB 1 PRESSURE SWITCH
8 COM
FO IN 9 SIG GFB 2 PRESSURE SWITCH
J6 10 COM
(BLK)
96 312776L
312776L
DISPLAY BOARD
GREEN/BLACK/WHITE 22 AWG
4
-
RED/BLACK/WHITE 22 AWG ALARM
3 +
J9 BLACK 18 AWG
2 BLACK 18 AWG
- COMMON L
RED 18 AWG
1 - L
24 VDC+ HIGH
RED 18 AWG OUTPUT VOLTAGE
+ 24 VDC+ IN N
DC OK N
+
EasyKey Electrical Schematic
-
POWER SUPPLY
- +
- +
GRN/YEL 16 AWG
- +
BLACK 18 AWG
J4-3
J4
24 VDC+ J4-2
IN GND LUG
RED 18 AWG
J4-1
GND GND
RED 16 AWG RED 16 AWG L1 RED 16 AWG L1
UNUSED 1A 1 L1
J1-5
BROWN 16 AWG BROWN 16 AWG N BROWN 16 AWG N
2A 2 N
J1-4 UNUSED
BARRIER BOARD J1-3 UNUSED
J1 POWER LINE FILTER
ROCKER SWITCH TERMINAL BLOCKS
J1-2 UNUSED
J1-1 UNUSED
+12 VDC I/S (WHITE)

J5-3
COMMON (BLACK)
J5 J5-2
J5-1 SHIELD/GRND
IS POWER
12 VDC
RJ45 RJ45
DISPLAY BOARD P1
RJ45 RJ45 BULKHEAD
Schematic Diagrams
97
98
NOTE: Maximum system flow is 3800 cc/min.
3800
3500
3000
25cc Dose
2500
Meter Performance Data (G3000 on A and B)
10cc Dose 50cc Dose

2000
1500
Flow Rate (cc/min)

1000
500
0
1:1 2:1 3:1 4:1 5:1 6:1 7:1 8:1 9:1 10:1 11:1 12:1 13:1 14:1 15:1 16:1 17:1 18:1 19:1 20:1 21:1 22:1 23:1 24:1 25:1 26:1 27:1 28:1 29:1 30:1
Ratio
Meter Performance Data (G3000 on A and B)
Test Conditions
Fluid: Hydraulic Oil
Viscosity: 65.7 centipoise
Ratio Tolerance: 5%
Valve Setting: 1.25 Turns Open (standard setting)
A and B Feed Pressure: 300 psig
312776L
312776L
NOTE: Maximum system flow is 3800 cc/min.
3800
3500
3000
50cc Dose
2500
25cc Dose
2000
1500
10cc Dose 25cc Dose
Flow Rate (cc/min)

1000
50cc Dose
500
0
1:1 2:1 3:1 4:1 5:1 6:1 7:1 8:1 9:1 10:1 11:1 12:1 13:1 14:1 15:1 16:1 17:1 18:1 19:1 20:1 21:1 22:1 23:1 24:1 25:1 26:1 27:1 28:1 29:1 30:1
Ratio
Test Conditions
Fluid: Hydraulic Oil
Viscosity: 65.7 centipoise
Ratio Tolerance: 5%
Valve Setting: 1.25 Turns Open (standard setting)
Meter Performance Data (G3000 on A, Coriolis on B)
A and B Feed Pressure: 300 psig

99
100 312776L
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, 5.2 - 7 bar)
Air filter inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8 npt(f)
Air filtration for air logic and purge air (Graco-supplied) . . 5 micron (minimum) filtration required; clean and dry air
Air filtration for atomizing air (user-supplied) . . . . . . . . . . 30 micron (minimum) filtration required; clean and dry air
Mixing ratio range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1:1- 50:1*
On-ratio accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . up to + 1%, user selectable
Fluids handled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . one or two component:
• solvent and waterborne paints
• polyurethanes
• epoxies
• acid catalyzed varnishes
• moisture sensitive isocyanates
Viscosity range of fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 20- 5000 cps*
Fluid filtration (user-supplied) . . . . . . . . . . . . . . . . . . . . . . 100 mesh minimum
Fluid flow rate range*
G3000, G250, G3000A Meter . . . . . . . . . . . . . . . . . . 75 - 3800 cc/min. (0.02-1.00 gal./min.)
G3000HR, G250HR Meter. . . . . . . . . . . . . . . . . . . . . 38 - 1900 cc/min. (0.01-0.50 gal./min.)
Coriolis Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 - 3800 cc/min. (0.005-1.00 gal./min.)
S3000 Solvent Meter (accessory) . . . . . . . . . . . . . . . 38 - 1900 cc/min. (0.01-0.50 gal./min.)
Fluid inlet sizes
Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 npt(f)
Dose Valve/Color Valve Adapters . . . . . . . . . . . . . . . 1/4 npt(f)
Fluid outlet size (static mixer) . . . . . . . . . . . . . . . . . . . . . . 1/4 npt(f)
External Power Supply Requirements . . . . . . . . . . . . . . . 85 - 250 Vac, 50/60 Hz, 2 amps maximum draw
15 amp maximum circuit breaker required
8 to 14 AWG power supply wire gauge
Operating temperature range . . . . . . . . . . . . . . . . . . . . . . 41- 122° F (5-50° C)
Environmental Conditions Rating . . . . . . . . . . . . . . . . . . . indoor use, pollution degree (2), installation category II
Noise Level
Sound pressure level . . . . . . . . . . . . . . . . . . . . . . . . . below 70 dBA
Sound power level . . . . . . . . . . . . . . . . . . . . . . . . . . . below 85 dBA
Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303, 304 SST, Tungsten carbide (with nickel binder),
perfluoroelastomer; PTFE
Wetted materials on acid models 316, 17-4 SST; PEEK,
(ME1001 - ME1004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . perfluoroelastomer; PTFE
* Dependent on programmed K-factor and application. The maximum allowable flow meter pulse frequency is 425
Hz (pulses/sec). For more detailed information on viscosities, flow rates, or mixing ratios, consult your Graco dis-
tributor.
See individual component manuals for additional technical data.
312776L 101
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
For the latest information about Graco products, visit www.graco.com.
For patent information, see www.graco.com/patents.
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.
Original instructions. This manual contains English. MM 312776
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2008, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
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Operation

ProMix ® 2KS 312776L

Manual system for proportional mixing of plural component coatings.

Approved for use in explosive atmospheres (except the EasyKey).

Related Manuals Equipment Approvals

ProMix® 2KS FLUID PANEL

ATEX Certificate is listed here

ProMix® 2KS POWER REQUIREMENTS

AMPS 2 AMPS MAX

ATEX Certificate is listed here

System Configuration and Part Numbers

FIG. 1: Identification Label

Hazardous Location Approval

ProMix Fluid Components Maximum Working Pressure

Flow Meter Fluid Flow Rate Range

Standard Features Accessories

2KS Acid Compatible

NOTE: This is not a complete list of available accesso-

ELECTRIC SHOCK HAZARD

EQUIPMENT MISUSE HAZARD

TOXIC FLUID OR FUMES HAZARD

PERSONAL PROTECTIVE EQUIPMENT

Important Two-Component Material Information

Spraying or dispensing materials that contain

Exposure to moisture (such as humidity) will cause ISO

Important Acid Catalyst Information

Acid Catalyst Conditions

Moisture Sensitivity of Acid NOTICE

Purge Drive - The voltage drive during the Purge

Purge Time - the amount of time required to flush all

Purge Volume Alarm - E-11 Alarm occurs if minimum

Ratio Tolerance - the settable percent of acceptable

Sequential Color Change - the process when a color

Sequential Dosing - Components A and B dispense

Solvent/3rd Purge Valve Chop Time- duration of each

Solvent Fill - the time required to fill the mixed material

Solvent Push - enables the user to save some mixed

Standby - refers to the status of the system.

System Idle - This warning occurs if the ProMix is set to

Component Identification and Definition

Table 1: Component Descriptions

Table 1: Component Descriptions

A different catalyst change valve is used on acid catalyst systems.

RVA SVA SM SVB SPV

FIG. 3. Wall Mount Fluid Station

Table 2: Booth Control Key and Indicator Functions

Job Complete • Signals that job is complete, and

Recipe Indicator (green) TI11614A

EasyKey Display and Keypad

Navigation Keys Alarm Reset Key

FIG. 5. EasyKey Display and Keypad

Display Table 3: EasyKey Keypad Functions (see FIG. 5)

Ground Screw I/S Power Graco Web Discrete I/O Cable

FIG. 6. EasyKey Connections and AC Power Switch

AC Power Switch Graco Web Interface Port

Run Mode Screens

FIG. 7. Splash Screen

The Splash screen will also momentarily display “Estab-

NOTE: If the software version of the fluid plate does not

FIG. 8. Fluid Plate Programming Screen