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Graco 312775G manual

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Table of contents for the manual

  • Page 1

    Installation ProMix ® 2KS Plural Compon ent Proportioner 312775G EN Manual system for proportiona l mixing of plural component coatings. For professional use only. For us e in ex plosi ve at mosph eres (e xcep t the Ea syKey ). TI1250 4a See page 4 for model in format ion, in cluding maxi mum working p ressure. Equip ment appr oval lab els are on [...]

  • Page 2

    2 312775G Contents Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Equipment Approvals . . . . . . . . . . . . . . . . . . . . . . . 3 System Configuration and Pa rt Numbers . . . . . . . 4 Configur ator Key . . . . . . . . . . . . . . . . . . . . . . . . . 4 Standard Features . . . . . . . . . . . . . . . . . . . . . . . 5 [...]

  • Page 3

    Relate d Manual s 312775G 3 Related Ma nuals Component Manuals in English Equipment Approv als Equipm ent app rovals appear o n the fol lowin g labels which a re att ached to th e Fluid Statio n and Eas yKey ™ . See F IG . 1 on page 4 for label lo cation s. Manual D escript ion 312776 ProMi x 2KS Manu al Syste m Opera tion 312777 ProMix 2KS Manua[...]

  • Page 4

    System Configu ration a nd Part Numbers 4 312775G System Configura tion and Part Numbers Conf igura tor Ke y The configured part nu mber for your equipme nt is printed on th e equipment identification labels. See F IG . 1 for location of the identification labels. The part number includes one digit from each of the following six categories, dependi[...]

  • Page 5

    System Con figurat ion and Part Numbers 312775G 5 Standard Featu res Hazardous Lo cation Approval Models u sing a G 3000, G3 000HR, or i ntrinsi cally safe Co riolis me ter for b oth A a nd B meter s are a pproved for installati on in a Hazardo us Location - Class I, D iv I, Group D, T3 or Zone I Group IIA T3. Maximum Working Pressure Maximum worki[...]

  • Page 6

    Acce ssori es 6 312775G Accessories Accessor y Gun Flus h Box Gun Inse rt Se lecti on 15V354 T hird Pu rge Val ve Kit 15V536 S olven t Flow Sw itch Kit 15V213 P ower Cable , 100 ft (30.5 m) 15G710 Fi ber Optic Cable, 100 ft (30. 5 m) 15U955 Injection Kit for Dynamic Dosing 15V034 10 cc In tegrator Kit 15V033 25 cc In tegrator Kit 15V021 50 cc In te[...]

  • Page 7

    Warn ings 312775G 7 Warnings The foll owing war nings are for the setup, us e, ground ing, ma intena nce, and r epair o f this equ ipment . The ex clama- tion poin t sym bol alerts you to a general warning and the hazard sy mbols refer to p rocedur e-specif ic ris ks. Whe n these sy mbols a ppear in the bod y of th is ma nual, re fer back to thes e[...]

  • Page 8

    Warnings 8 312775G SKIN INJEC TION HAZARD High-pres sure flui d from gun, hose leaks, or ruptured com ponent s will pierce sk in. This may look like just a cut, bu t it is a s erious i njury th at can resu lt in a mputation . Get immediate surgical treatment. • Tighte n all flui d connec tions be fore operati ng the equipm ent. • Do not point g[...]

  • Page 9

    Importa nt Two-Compon ent Ma terial Info rmatio n 312775G 9 Important Two-Compon ent Material In formation Isocyanate Conditions Material Self-ignition Keep Compo nents A and B Separate Moisture Sensitivity o f Isocyanates Isocy anates ( ISO) are catalys ts used i n two c omponent coatin gs. ISO wi ll reac t with moist ure (such a s humidi ty) to f[...]

  • Page 10

    Compone n t Iden tification and Def inition 10 312775G Compon ent I denti fica tion an d Defi nitio n F IG . 2. Manual System, shown with G3000 Meters, Color/Ca talyst Change, One Gun Flush Box, and Accessor y Solvent F low Met er TI12 504a EK BC* ST ACV CCM* MS MA MB FM GFB BCV FO* PS* Air Cont rols/ Filter * See the Pr oMix 2K S Repair- Parts man[...]

  • Page 11

    Compone nt Identification and De finition 312775G 11 Fluid Manifold (FM) • Pneum atically O perated Dose Va lves for com ponent A and B • Purge V alves fo r solvent a nd air p urge • Samplin g Valve s for calib rating the flow meters and perfor ming ratio c hecks • Shutoff Valves for com ponent A and B to cl ose their flu id passa ges to t [...]

  • Page 12

    Locat ion 12 312775G Location Location Req uirements • Mount E asyKey a nd Fluid Station w ithin 5 0 ft (15.2 m) of eac h other, using 15U533 ca ble. NOTE: An optio nal 15 V213 100 ft (30.5 m) cable i s also av ailab le. • EasyKey : Instal l in the n on-ha zardous area at a conveni ent lo cation for the oper ator to v iew and operate. • Fluid[...]

  • Page 13

    Loc ation 312775G 13 F IG . 3. Intrinsically Safe In stallatio n NON-HAZARDOUS LOCATION ONLY HAZARDOUS (CLASS IFIED) LOCATION CLASS I, DIV I, GROUP D, T3 (US AND CANADA) CLASS I, ZONE I GROUP II A T3 (ATEX ONLY) TAUB = -20°C TO 50°C ProMix 2K S EasyKey I nterface Safety Barrier ProMix 2KS Sm art Fluid Plate (Wall Panel or RoboMix Flow Meter A Flo[...]

  • Page 14

    General In formation 14 312775G General Information • Re feren ce numbers and letter s in pa ren these s in the text refe r to numbe rs and lette rs in the illustra- tions. •F IG . 2, pa ge 10, s hows t he basic c ompone nts of a manual s ystem. Contac t your Graco distr ibutor for actual s ystem de signs. • Be sure all acc essories are ade q[...]

  • Page 15

    Air Supply 312775G 15 Air Connection s See the S ystem Pneu matic Sc hematic on page 29. 1. Tighten all P roMix s ystem a ir and fl uid line conne c- tions as they may have loosened during shipm ent. 2. Install a bl eed-typ e air sh utoff v alve into the co ntrol air filt er inle t on Wa ll Mount F luid S tation. F IG . 4 . 3. Connect a cl ean, dry[...]

  • Page 16

    Fluid Su pply 16 312775G Fluid Supply Requirements ProMix models are avai lable to opera te air spr ay or air-assis ted sys tems with a capaci ty of up to 3800 cc/m in. • Fl uid su ppl y pres sure tanks, feed pump s, or circu - latin g system s ca n be used. • Material s can be transfe rred from their or igina l con- tainers or from a c entral [...]

  • Page 17

    Flui d Su pply 312775G 17 F IG . 6. Wall Mount Fluid Station, Sequential Dosing TI12 556b Key: MA Comp onent A Meter DVA Compone nt A Dos e Valve RVA Compone nt A Sampling Val ve SVA Component A Shutoff Valve MB Comp onent B Meter DVB Compone nt B Dos e Valve RVB Compone nt B Sampling Val ve SVB Component B Shutoff Valve MS Solvent Mete r (accessor[...]

  • Page 18

    Fluid Su pply 18 312775G Setup the Fl uid Ma nifold for Dy namic Dosing If you wil l be oper ating us ing dynam ic do sing, the fluid manifold must b e setup pr operly for you r applicat ion. Orde r the 1 5U95 5 Injec tion Kit (a ccessory). 1. Remove the s crews (A) a nd static mixer bracke t assembl y (B). S ee F IG . 8. 2. Loosen the stati c mixe[...]

  • Page 19

    Flui d Su pply 312775G 19 10. Instal l the t wo setsc rews and o-ring s (L3 *). Insta ll the long set screw (S) at the front of th e housing, for ease of access. 11. Scr ew the stat ic mi xer (SM) into the i njectio n cap (M*). Install th e retained fi tting (F) on the static mixer t ube and secure with the nu t (N1). 12. Foll ow instruc tions unde[...]

  • Page 20

    Fluid Su pply 20 312775G Solvent Meter Accesso ry The P roMix 2K S Solvent P ush featur e requir es insta lla- tion of the acce ssor y solv ent met er (MS ). Orde r Grac o Part No. 2 80555 S 3000 Sol vent Meter Kit. Se e manu al 308778. NOTE: You must as semble the mete r sensor to the meter bod y befo re co nnect ing the ca ble to the sen sor for [...]

  • Page 21

    Elec tr ical 312775G 21 Electrical Requirements NOTE: All opt ions ord ered on t he ProMi x sy stem are electric ally test ed at the fa ctory. The P roMix operates with 85- 250 VAC, 5 0/60 Hz inp ut powe r, wi th a maxi mum of 2 amp cu rrent dr aw. The power su pply circuit m ust be protected wi th a 15 amp maxim um c ircui t breake r. Not in clude[...]

  • Page 22

    Electric al 22 312775G Connect EasyKey to Fluid Station Con trol There are two 50 ft (15.2 m ) cables to route be tween the EasyKe y and Fluid S tation Control: the Flui d Station Powe r Ca ble a nd th e Fib e r Opt ic C able. 1. Connec t the ap propriate Fl uid Stati on Pow er Cable end to t he Eas yKey conn ector . Se e F IG . 13 . 2. Connec t th[...]

  • Page 23

    Elec tr ical 312775G 23 Fluid Station Control Board Switch Settings On the 2K S fluid s tatio n control bo ard, set switch S 1 to ON ( down) or OFF (up) , as shown in F IG . 15. F IG . 15. Fluid Station Board Connections VDC J10 (Power In put) J11 (Color Ch ange Modu le) J7 (Booth Control) J4 (Fiber Optic O utput - b lue) J6 (Fib er Opti c Inp ut -[...]

  • Page 24

    Electric al 24 312775G Connect Co lor Change Modu le To inst all the c olor ch ange mo dule(s ), see ma nual 312787. Connect a 5-pin el ectric al ca ble from the labele d con- nection p ort (J11) on the flu id statio n cont rol board to the color c hange b oard. Se e F IG . 16. If you ar e using t wo color change m odules to add c olors, connect a [...]

  • Page 25

    Elec tr ical 312775G 25 F IG . 16. Color Change Board Switches S 3-S6 S3 S4 S5 S6 OFF ON OFF ON Switch S3 -S6 Positions J7 J11 TI13661 a[...]

  • Page 26

    Electric al 26 312775G F IG . 17. Color Change Module Electrical Schematic WIRING DIA GRAM COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC COM +12VDC J8 J15 J14 J9 J16 J10 COL OR 8 (21) COL OR 7 (20) COL OR 6 (19) COL OR 5 (18) COL OR 4 (17) COL OR 3 (16) COL OR 2 (15) COL OR 1 (14) COL OR FLUSH (13) COL OR 9[...]

  • Page 27

    Elec tr ical 312775G 27 Grou ndi ng Ground the ProMi x syst em as ins tructed here and in the indivi dual comp onent m anuals. A ground w ire and clamp, p art no . 223547, is avail able from Graco. NOTE: Differen t ground p oints (uneq ual po tential) may cause c urrent to fl ow through comp onent cabl es, caus- ing inco rre ct signa ls. EasyK ey C[...]

  • Page 28

    Electric al 28 312775G F IG . 18: Grounding Key: EasyKey gr ound screw EasyKey gr ound wire Fluid Station ground screw Fluid Station ground wire True Earth Ground - chec k your local code for requirements Gun Flush Box ground wire connection point Gun Flush Box ground wire Power Cable, B ooth Control/Fluid Station Color Control Module ground screw [...]

  • Page 29

    Schema tic Dia grams 312775G 29 Schematic Diagrams System Pneumat ic Schematic 3/8 AIR FIL TER MANU AL DRAIN 5 MICRON W ALL MOUNT ONLY FLUSH AIR TO FL UID INLET 1/4 TUBE TO MANIFOLD 1/4 TUBE 4-W A Y SOLENOID 12 VDC PURGE A VA LV E DUMP A VA LV E (OPTIONAL) 4-W A Y SOLENOID 12 VDC 3-W A Y SOLENOID 12 VDC 3-W A Y SOLENOID 12 VDC MANIFOLD AIR EXHAUST [...]

  • Page 30

    Schema tic Diag rams 30 312775G System Electrical Schema tic NOTE: The el ectrica l schem atic illus trate s all pos sible w iring expa nsion s in a P roMix 2 KS sys tem. So me co mpo- nents sh own ar e not in cluded wi th all s ystems. Non-Hazardous Area BARRIER BOARD OPERA TOR INTERF ACE 1 2 L1 N 85-250 VAC GND N L1 85-250 V AC 1 2 3 J5 +12VDC I/[...]

  • Page 31

    Schema tic Dia grams 312775G 31 System Electrical Schem atic NOTE: The el ectrica l schem atic illus trate s all pos sible w iring expa nsion s in a P roMix 2 KS sys tem. So me co mpo- nents sh own are no t incl uded with all s ystems. Hazardous Area HAZARDOUS AREA +12VDC I/S COM SHIELD J10 1 2 3 1 2 3 4 5 6 J3 PWR (RED) COM (BLACK) SIG (WHITE) SHI[...]

  • Page 32

    Dime nsions a nd Mounting H ole Layou ts 32 312775G Dimensions and Mount ing Hole Layouts Module A Overall Widt h in. (mm) Overall Depth in. (mm) B Overall Height in. (mm) Mounting Dime nsions, Width (C) x Hei ght (D) in. (mm) E Mounting Hole Size in. (mm) Weight lb (kg) EasyKey 14.0 (355.6) 6.6 (167 .6) 13.5 (342.9) 12.0 x 12. 75 (304.8 x 323.9 ) [...]

  • Page 33

    Dimensio ns and Mountin g Hole L ayouts 312775G 33 TI11892 a Booth Control Module TI12 909a Booth Control Bracket EasyK ey TI1189 1a E A B C D E A B D C[...]

  • Page 34

    Dynamic Dosin g Restri ctor Sel ection G raphs 34 312775G Dynamic Dosing Re strict or Selection Gra phs Use the graph s on pages 35- 39 as a guide to determin e the corr ect res trictor si ze for your des ired flo w and mate - rial vis cosity . Table 3 list s the ava ilable r estric tor sizes . Example: Applic ation: air spray syst em with a 5:1 mi[...]

  • Page 35

    Dynamic Dos ing Restricto r Selection G raphs 312775G 35 F IG . 19. Dynamic Dosing Performance (1 :1 Ratio, 90 centipoise fluid, 100 psi A side pressure) 0 500 1000 15 00 2000 3000 2500 3500 0 Flow Rate (cc/min) Differentia l Press ure betwee n A and B psi (bar, MPa) 4000 (276 , 27.6) 3500 (241 , 24.1) 3000 (207 , 20.7) 2500 (172 , 17.2) 2000 (138 [...]

  • Page 36

    Dynamic Dosin g Restri ctor Sel ection G raphs 36 312775G F IG . 20. Dynamic Dosing Performance (5 :1 Ratio, 90 centipoise fluid, 100 psi A side pressure) 0 500 1000 15 00 2000 3000 2500 3500 0 Flow Rate (cc/min) Diffe rential Pr essure bet ween A an d B psi (bar, MPa) 1400 (97, 9.7) 1200 (83, 8.3) 1000 (69, 6.9) 800 (55, 5.5) 600 (41, 4.1) 400 (28[...]

  • Page 37

    Dynamic Dos ing Restricto r Selection G raphs 312775G 37 F IG . 21. Dynamic Dosing Performance (1 0:1 Ratio, 90 centipoise fluid, 100 psi A side pressure) 0 500 1000 15 00 2000 3000 2500 3500 0 Flow Rate (cc/min) Differen tial Pressu re betw een A and B psi (bar, MPa) 800 (55, 5.5) 700 (48, 4.8) 600 (41, 4.1) 500 (34, 3.4) 400 (28, 2.8) 300 (21, 2.[...]

  • Page 38

    Dynamic Dosin g Restri ctor Sel ection G raphs 38 312775G F IG . 22. Dynamic Dosing Performance (2 0:1 Ratio, 90 centipoise fluid, 100 psi A side pressure) 0 500 1000 1 500 200 0 3000 2500 3500 0 Flow Rate (cc/min) Diffe rential Pr essure bet ween A an d B psi (bar, MPa) 300 (21, 2.1) 250 (17.2, 1.7 2) 200 (14, 1.4) 150 10.3, 1.0 3) 100 (7.0, 0.7) [...]

  • Page 39

    Dynamic Dos ing Restricto r Selection G raphs 312775G 39 F IG . 23. Dynamic Dosing Performance (3 0:1 Ratio, 90 centipoise fluid, 100 psi A side pressure) 0 500 1000 15 00 2000 3000 2500 3500 0 Flow Rate (cc/min) Differen tial Pressu re between A and B psi (bar, MPa) 160 (11, 1.1) 140 9.7, 0. 9) 120 8.3, 0. 8) 100 (7, 0.7) 80 (5.5, 0.55) 60 (4.1, 0[...]

  • Page 40

    Dynamic Dosin g Restri ctor Sel ection G raphs 40 312775G[...]

  • Page 41

    Technica l Data 312775G 41 Technical Da ta * Dep endent on programm ed K-facto r and app licatio n. The ma ximum all owable flow me ter pulse frequency is 425 Hz (pulses /sec) . For more detailed i nformati on on vis cosities, flow r ates, or m ixing rati os, cons ult your Graco di s- tributor. See indi vidua l compon ent man uals for additi onal t[...]

  • Page 42

    All written and visual data contained in this document reflects the latest product information available at the time of publica tion. Graco rese rves the right t o make changes at any time without notice. Graco H eadquarte rs: Minneapolis International O ffices: Bel gium, China, Jap an, Korea GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEA[...]