Graco 333282B User's Manual
Contents
1. 24M485 12345 12345 24N913 ug m GFBIN2. DUMP CATALYST 1 CATALYST2 CATALYST3 CATALYST 4 DUMP COLOR 25 COLOR 26 COLOR 27 COLOR 28 COLOR 29 COLOR 30 39 Electrical Schematics FLUSH CATALYST CATALYST 4 FLUSH CATALYST 1 CATALYST 2
3. NON HAZARDOUS LOCATION HAZARDOUS LOCATION 12345 COLOR CHANGE MANIFOLD prd MANIFOLD COLOR FLUSH Z mE l mru 6 lt CATALYSTFLUSH 3 4 COLOR 1 lt CE mmsy CATALYST1 COLOR 2 7 2L CATALYST 2 1 6 COLOR 3 E12 5 CATALYST3 COLOR 4 2 4 15 16 3 oo l CATALYST 4 caos SAX 2 com J exe 1 6 com COLOR 6 H2 PL caon7 2 COM 4J 14 J103 doc N ljcaon COLOR 8 6 J AADC M COLOR 12 mm 12345 DES lt 12345 COLOR CHANGE MANFOLD MODULE 8 MANFOLD a COLORS 6 1 cow COLOR 13 2 COM 2 41 48 5 COLOR 22 3 4 COLOR 14 VC 4J8 19 191 COLOR 15 H 2 lt CO
4. Uses P JS EE Jas e D34 d 5 m D33 zls Fis 31802 7 d u29 0247 B20 gi ay D31 E zi Mc _ m RO 029 E m 1 nee E ran J9 1 J15 1 m 8 zm D39 D41 __ age l pma D32 ED P Ji E 035 E D38 D27 2 E 16 1 pe yi 14 1 m E 037 i 37 030 Jd 045 028 Hi grs u20 u25 046 24 25 Es e sm malam um e Vo 52 56 Ls 5 u2 e eee m 244 mU D8 RIS Bia GL Mam D10 Rit R5 R3 e EN 72 gt mm EM EN EM run F1 e ojd Tje e e Ls e NEL e ti22013a J J11 Figure 14 Color Change Board 34 333282B Troubleshooting Color Change Board Diagnostics lps LED green Blinks heartbeat during normal operation EI LED green Turns on when power is supplied to the board D10 LED yellow Turns on when board is communicating with electronic control 027 039 LED green Turn on when a signal is sent to actuate the 041 043 046 related solenoid valve 333282B 35 Electrical Schematics Electrical Schematics NOT
5. ON ON ON 56 55 54 OFF OFF OFF 0 0 1 1 2 1 2 3 4 i 4 gt mie 7 7 8 8 NEN DEM Vl L J7 J11 ti23754a Figure 2 IS Control Module 16 333282B Setup the Modules CIBC 333282B 17 Installation Installation To avoid electric shock turn off power at the main circuit breaker before opening the enclosure All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations Do not substitute or modify system components as this may impair intrinsic safety Do not install equipment approved only for non hazardous location in a hazardous location See the identification label for the intrinsic safety rating for your model This equipment stays pressurized until pressure is manually relieved To help prevent serious injury from pressurized fluid such as skin injection splashing fluid and moving parts follow the Pressure Relief Procedure in the PD2K Operation Manual before installing the kit Mounting the Control Modules 1 See Dimensions page 71 2 Ensure that the wall and mounting hardware are strong enough to support the weight of the equipment fluid hoses and stress cause during operation 18 3 Using the equipment as a template mark the mounting holes on the
6. 12345 COLOR CHANGE MODULE 1 MANFOLD NA 1 Cours a MANIFOLD FLUSH 1709 SEI DUMP mA 4 8 J9 3 COLOR 1 2 H 24 4 COLOR2 i 1 6 COLOR 3 ADM 42 Coe E COLOR3 3 pap 9ME 2 15 16 30 IN caon4 Ee cde COLORS MY He THO Mx COLORS 11 6 COM caos 4 COM 2 5 En L lcoon6 COLOR 7 M al J103 __ cao7 COLORS Ae H 17345 12345 COLOR CATALYST CHANGE CHANGE MODULE 2 31 MODULE 5 r MANIFOLD MANIFOLD m aac 01 COLORS er axc pii 6 FLUSH 2 9THRU19 5 S DUMP FLUSH 2 1THRU4 8 am 3 ar 92 4 8 J9 H Sic COLOR 9 CATALYST 1 AM 4J8 935 Proc axbc 2 GM L 2L COLOR 10 H A 2 Ri cavalyst2 MX 1 6 1 6 COLOR 11 cow 2 5 Ax LN COLOR IL CATALYST3 2 5 ore COORD __ COM 2115 1165 COLOR 12 CATAYST4 _ m HB 1163 Havoc 5 2 COM UNUSED 5 2 UNUSED CXORB 16 101 aoc UNUSED 16 1 UNUSED H2VDC 1 6 COM UNUSED 1 6 UNUSED 2 dem NE m COLOR 15 COM 2 4 J10 3 COLOR 15
7. 25 THRU 32 Figure 19 Electrical Schematic Sheet 3 Alternate Configuration for Catalyst Change Control CONTINUED ON THE NEXT PAGE 40 CATALYST CHANGE MANIFOLD OG MANIFOLD AADC 1 AIAYST gr a e L k COM 4 J8 J9 i VDC L axo com COM 6 AN 1 Havoc UNUSED 1 6 UNUSED UNUSED 2 5 UNUSED UNUSED 3 15 J 16 4 UNusED UNUSED 4 3 UNUSED UNUSED 5 2 UNUSED UNUSED L16 1 UNUSED UNUSED 01 6 UNUSED NES H CUNEO 14 J10 3 UNUSED UNUSED 5 2 UNUSED UNUSED 16 1 UNUSED cs 54321 CATALYST CHANGE MODULE 5 MANIFOLD ue i CATALYST ns MANIFOLD Hs SPI ape TEL Sot a TE T se m NN COM 6 1 aoc d UNUSED i 6 UNUSED NES 3 H ED 440725 1163 UNUSED 5 2 UNUSED UNUSED L16 1 UNUSED ee H SHINEE UNUSED 3 14 4 UNUSED UNUSED 14 J 10 3 UNUSED UNUSED 15 2 UNUSED UNUSED 06 1 UNUSED DUMP CATALYST 3 CATALYST 4 DUMP CATALYST 1 CATALYST 2 333282B FROM CANIS BOARD 24M485 ON PAGE 2 Electrical Schematics
8. NOTE There can be only one solvent valve and one dump valve per pump Inlet Manifold Outlet Manifold 0 0 m TA Q 2 11 Jt N a M p TT e O CH J7 J11 ti22010a Figure 1 Non IS Control Module 14 333282B Setup the Modules Outlet Manifold Outlet Manifold Dump Du 37 712 _ fe 655 s s forz Non IS Control Module 2 Non IS Control Module 5 Inlet Manifold Outlet Manifold Outlet Manifold Solenoid Valve Solenoid Valve 1 Soven 1 1 Solvents 1 Dump e oats esas a feats s 5 oats Non IS Control Module 3 Non IS Control Module 6 Inlet Manifold Outlet Manifold Inlet Manifold Outlet Manifold Solvent Dump Dump Catalyst 3 Catalyst 4 Not Used Not Used 6 Coe2t 6 e Notusea 6 Notused 8 ____ 23 8 69023 8 Notusea Notus
9. 30 Troubleshooting 32 2 Color Change Solenoid Valves 32 Color Change Board 34 Electrical Schematics 36 Optional Cables and Modules 42 ete u eh ese eqs 43 Replace a Color Valve 43 Replace a Solenoid 44 Replace the Color Change Board Fuse 44 Replace the Color Change Board 45 46 Non IS Color Change Kits 46 IS Color Change 50 Valve Manifold Kits 53 Color Change Control Module Kits 64 Expansion Kits 69 Dimensions eee lr erui de 71 Technical Data 75 Graco Standard Warranty 76 333282B Related Manuals Current manuals are available at www graco com Deo 332458 332564 332565 333282B PD2K Proportioner Installation Manual Systems for Automatic Spray Applications PD2K Proportioner Operation Manual Systems for Automatic Spray Applications PD2K Proportioner Repair Parts Manual Systems for Automatic
10. o o o mam s e e r s v v s 2 2 s e v 1 s a e o o m u y s so as fo 2 2 amos o z zm o o a a o o o memor wu 22 22 o 2 v s as 22 15 o ramos 2 1 ra 1 s ar ar fre fo 1 2 qw n m o as s ao 2 o o o pm 1 18 o o Eae wm z s as s ss 7 o 2 reme __ o f s 5 o o o Fames e s o s e y s er o we s 1 2 v r r 22 o 2 12 333282B 57 Parts High Pressure Valve Manifold Kits Non Circulating Valve Manifold Kits Circulating Valve Manifold Kits wmm ame 3 amem ure ur wmes sve vanes urs 10 vehes A meer vas ume wes ves wma iras ure 24T665 20 valves 24T695 21 valves 24T696 24T667 22 valves 24T697 24 668 24 698 24 669 24T699 24T670 24T700 24T671 241701 247672 241702 247673 241703 247674 241704 247675 241705 247676 241706 24T845 acid catalyzed
11. eU rase J2 J1 IS ti21938a Figure 5 Detail of Isolation Board Cable Connections 19 Installation Install the Valve Manifolds NOTE Always label the color connections to prevent cross connections Label the inlet manifold outlet manifold and each color valve with its assigned color The solvent and dump valves should be furthest from the manifold stack primary inlet or outlet 1 20 Install a mounting bracket 101 on the PD2K with four screws 103 High pressure systems For stability be sure to fasten the bottom screws 103 to the pump bracket Ie ti22858a 103 N Te 3 101 VA Install the inlet and outlet valve manifolds 102 on the mounting bracket 101 with four screws 104 washers 105 and nuts 106 NOTE On low pressure systems the supplied bracket 101 will accommodate a manifold 524 Figure 6 Install the Valve Manifolds with 16 valve positions 14 colors On high pressure systems the supplied bracket 101 will accommodate a manifold with 14 valve positions 12 colors A larger valve stack will require a customer supplied sourced bracket Repeat for the opposite side of the PD2K Connect the air lines from the solenoids to the
12. 70 300 psi 2068 MPa 20 68 a _______ 100 psi 0 7 MPa 7 0bar 900 psi 2068 MPa 20 68 bar A Goo _______ 100 psi 0 7 MPa 7 0bar ___ 300 psi 2 068 MPa 20 68 bar mms sco ______ 100 psi 0 7 MPa 300 psi 2068 MPa 2068 4 333282B Models Control Module Pressure Valves High Pressure Non Circulating Color Change Kits 24R959 1500 psi 10 34 MPa 103 4 bar 24R960 1500 psi 10 34 MPa 103 4 bar 24R961 1500 psi 10 34 MPa 103 4 bar 24R962 1500 psi 10 34 MPa 103 4 bar High Pressure Acid Compatible Non Circulating Catalyst Change Kits 24T579 A 2 catalyst acid 100 psi 0 7 MPa 7 0 bar 1500 psi 10 34 MPa 103 4 bar compatible 24T580 A 4 catalyst acid 100 psi 0 7 MPa 7 0 bar 1500 psi 10 34 MPa 103 4 bar compatible High Pressure Circulating Color Change Kits 24R963 1500 psi 10 34 MPa 103 4 bar 24R964 1500 psi 10 34 MPa 103 4 bar 24R965 1500 psi 10 34 MPa 103 4 bar 24R966 1500 psi 10 34 MPa 103 4 bar NOTE Systems can use 1 to 30 colors and up to 4 catalysts To add colors catalysts If current control module is full If all solenoid ports are in use in your control module s an additional control module is needed Order another complete color change change kit shown above If current control module is not full If empty solenoid ports remain in your control module see Expansion Kits page 69 33
13. 24T846 acid A catalyzed 2 5 20 valves 21 valves 22 valves 23 valves 23 valves 24 valves 24 valves 25 valves 25 valves 26 valves 26 valves 27 valves 27 valves 28 valves 28 valves 29 valves 29 valves 30 valves 30 valves 31 valves 31 valves 3 valves 5 valves 58 333282B Valve Manifold Kit Parts ti21642a 333282B q Ec 9 ll 9 PER 9 ers 9 5 9 x 9 SEZ ee 9 Parts 59 Parts a No N z 247582 VALVE for circulating kits includes item 2 24T583 VALVE for non circulating acid compatible kits includes item 2 111820 SCREW cap socket head 10 24 x 0 75 in 19 mm 241728 connecting 1 645 in 42 mm 557716 PLUG 7 16 20 1 104644 PLUG screw 10 32 x 0 156 in 4 mm See the following tables to determine the quantity of each part in your valve manifold kit 24 729 connecting 3 290 in 84 mm 14 15 16 18 9 16N271 MANIFOLD for circulating 13 24T523 FITTING fluid 7 16 20 x kits 1 4 npt m 111450 O RING chemically 111328 CONNECTOR tube resistant 10 32 m x 5 32 in 4 mm OD tube 24T581 VALVE for non circulating kits includes item 2 12 104893 O RING
14. LT TETELETTTI xis ds Cr EHE PUMP ENCODER AND MOTOR m PUMP ENCODER AND MOTOR pom 16037 Enn 16039 Figure 16 Electrical Schematic Sheet 2 Part 1 CONTINUED ON THE NEXT PAGE 333282B 37 Electrical Schematics GUN TRIGGER INPUTS IJ Boo imu p wy I 1 I L 7 o PRESSURE SWITCH 121323 gt SOLVENT FLOWSWITCH 1 120278 GCAMODULE EFCM FI RBS nnn 3L FLOWRATE ANALOG IN 2 4 ANALOG 2 13 2439 7 H FLOWRATE 19 A o SOLVENT FLOWSWTCH 2 12
15. NOTE For ease of maintenance install a ball Color 2 Tung valve at all fluid line tees 12 Connect a supply line from the outlet valve of the remote catalyst valve stack to inlet B on the remote mix manifold 333282B 27 Installation Connect Circulating Fluid Lines Circulation valves enable constant circulation of a color when that color is not being sprayed When a color valve is closed the system bypasses the dosing pump by directing that color from the inlet color valve to the outlet color valve to the remote color valve through a circulation line then back to the color supply When a color valve is open the circulation line is shut off The color is directed through the material A dosing pump and out to the remote color valve stack and mix manifold as in normal operation NOTE On circulating systems install a cap T on any unused valve fittings NOTE There can be only one solvent valve S and one dump valve D per pump NOTE On high pressure systems see Install the Back Pressure Regulator High Pressure Systems Only page 21 1 Connect all fluid lines as described in Connect Non Circulating Fluid Lines page 26 These lines are used during normal mixing and spraying 2 Connect the circulation lines as follows a Connecta 1 4 npt f circulation line for each color from the color valve s circulation fitting R1 R2 etc on the inlet color valve stack B to the corresponding circulat
16. EX 241472 8 18 117 1 t8 pofi 1 333282B 55 Parts O 57 N lt CN I NTO O 40 CGN CN O o T E oni s X e NINE TI 2 5 2 c Kit No 333282B 56 Parts Low Pressure Circulating Valve Manifold Kit Part Quantities T s Je 7 s o e o a 5 De 2 9 mme 2 o 2 le p pr fs p fo D P e 2 2 fo s s o mme s p s P 2 mme o s s o lt r s o 8 s o o mme r r 5 1 r s Pr 2 2 mme s s s fo Pe o o s p ole s s 2 5 s o o s 2 o s o o mme s p r 22 v o Pr 2 12 s fo o y 1 s 25 2 o mnes 7 u o s 7 s 2 mme r u 4 o s a fo s o o s o rele h s o n 5 lo 2 s o rele s as
17. are not available separately Find your module kit no in the left column and the desired reference number in the top row to find the part quantity used in your control module kit Kit 6 Position Description Connector Solenoid Plug 313 Tie Strap 321 Ferrule Connector 322 Fitting 324 36 333282B 65 Parts IS Color Change Control Modules 304 335 ti23755a 333282B 66 Ref Part Description Qty No 301 PANEL 1 302 24T566 BOARD circuit 302a 123690 FUSE 125 mA 303 112324 SCREW machine pan head 4 40 x 0 25 in 6 mm 304 240567 COVER 305 119162 CONNECTOR 6 position 6 307 116343 SCREW ground M5 x 0 8 308 123691 HOLDER fuse 309 157636 MANIFOLD 310 121324 SOLENOID 311 16 00 SCREW machine serrated 4 7 head 10 32 x 0 5 in 13 mm 312 103833 SCREW machine head 4 10 32 x 0 375 in 10 mm 313 121628 SCREW self sealing 4 40 x x 0 25 in 6 mm 315 100139 PLUG pipe 1 8 316 co6061 MUFFLER 317 115671 FITTING connector 1 8 1 npt m x 1 4 in 6 mm OD tube IS Control Module Part Quantities i o Ref Part Description Qty No No 318 112698 ELBOW 1 8 npt m x 1 4 in 2 6 mm OD tube 319 590332 TUBE polyethylene 1 4 in 6 1 mm OD 320 598095 TUBE nylon 5 32 in 4 mm 1 OD 321 22 STRAP tie mu 3 324 109193 E
18. 3 mm 4 0 28 7 2x0 41 in 10 mm mm 333282B 73 Dimensions 1 F G ti23761a K gt Figure 28 Remote Mix Manifold Bracket qu cog Ch e EH F 3 00 in 76 mm 1 45 in 37 mm 2 00 in 51 mm 1 05 in 27 mm 2 50 in 64 mm 0 50 in 13 mm xC o C H __ 1 25 in 32 mm 0 11 3 mm 4 x 0 22 in 6 2 x 0 41 10 mm mm 74 333282B Technical Data Technical Data Color Change Kits Maximum fluid working pressure Low pressure kits 300 psi 2 1 MPa 21 bar High pressure kits 1500 psi 10 5 MPa 105 bar Maximum working air 100 psi 0 7 MPa 7 0 bar pressure Air supply 85 100 psi 0 6 0 7 MPa 6 0 7 0 bar Viscosity range of fud Fluid inlet size Wetted parts ee LENNON ERN 333282B 75 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and pearing 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
19. ptfe High Pressure Non Circulating Valve Manifold Kit Part Quantities Reference Numbers 5 mes s ume fe mew s mre fo k X N wo N wo NIL OO B QI T O gt N B O OI N 0 N gt i 5 amp B B iS a af oa e s _ _ 60 333282B Parts T lt lt gt gt LO O O N NE NEN O tO 10 oI INJ CN CGN O O cO c 40 N ICNICNICGN O TO y y gt q N 5 2 24163 9 18 247667 247668 247669 247670 247671 247672 247673 247674 247675 247676 247845 247846 Kit
20. 333282B Dimensions Dimensions _ N 0 0 n in in D B o 9 418 P J en E UL C ti22017a Figure 24 Non IS Control Module x A B c D E F Bin F 11 30 in 1478 7 67 in 195 9 8in 249 mm 5 70 in 145 0 31 in 8 mm 5 80 in 147 mm mm mm mm A x eeu 0 6 D B H B 0 UH w ti22018a Figure 25 IS Control Module LR B c pn E r 16 57 in 421 8 22 209 15 07 in 383 6 70 in 170 0 31 in 8 mm 4 52 in 115 mm mm mm mm mm 333282B 71 Dimensions T V D U O ti22181a Figure 26 Manifold Mounting Bracket Non IS 3 84 in 98 11 44 in 291 0 312 in 8 mm mm mm diameter 72 333282B Dimensions Lo A B M Y e _ EE P RAR o N G yi p am mix D E ti23760a N Figure 27 IS Valve Manifold Bracket i 5 63 in 168 1 92 in 49 mm 3 35 in 85 mm 1 80 in 46 mm 1 32 in 84 mm mm K 0 65 in 17 mm L w 0 24 in 6 mm 1 00 in 25 mm 0 88 in 22 mm 0 40 in 10 mm 0 40 in 10 mm 0 11 in
21. If all solenoid ports in use in your IS control module an additional IS control module is needed Order a Control Module Expansion Kit shown above If current control module is not full If empty solenoid ports remain in your control module see Expansion Kits page 69 8 333282B Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure specific risks When these symbols appear in the body of this manual or on warning labels 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 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 Do not u
22. No 61 333282B Parts High Pressure Circulating Valve Manifold Kit Part Quantities pee Te Te meer p gt _ s s s me s s Gems s s o s mea s m s r ees s 10 o v Gees n T 7 eme s e 2 fo ez ewe ps u 1 ree pu fo T T mee Je pu s r 3 ee pe s o r P i Ree Te e 1 s pu e fo su e C 2 or rs fe fao a n 2 2 2 r 2 oo ber w z z 2 pe r F Ce eee 2 qa 2 u r C n 2 fo 12 2 mee pu pa 2 o Ja r r 3 ao s fo o ro u s os r C gt as 5 2 Rer pe pas 26 o 25 r gt 5 r em w or r s s zr r o s ers w o 2 is rC or s o 2 ps 30 s o a0 ss r gt or o 7 o s s ae T T e e o 12 8 9 3 e 8 rss 1 1 2 3 29 3 12 13 13 13 s 62 333282B Notes Parts 333282B 63 64 Parts Color Change Control Module Kits Non IS Color Change Contr
23. Pressure 16W563 High Pressure Le conten T5 109 SCREW cap hex 104429 Low Pressure 113469 High Pressure 50 110 TOOL repair color change valve not shown 24U236 Low Pressure 24R124 High Pressure 111 TOOL installation color change valve not shown 24U239 Low Pressure 24U240 High Pressure 223547 WIRE assembly 25 ft 2 100046 WASHER lock 4 114 16V429 CABLE CAN 50 ft 15 2 m 1 not shown See the following tables for the part number used your color change 333282B Parts Low Pressure IS Kits Kit Description Standard Valve Man Control Module ifold Kits 101 see Kit 106 see Low Pressure Valve IS Color Change Control Manifold Kits page 53 for Modules page 66 for all available kits parts Low Pressure Non Circulating Color Change Kits 333282B 51 Parts High Pressure IS Kits Kit Description Standard Valve Man Control Module ifold Kits 101 see Kit 106 see Low Pressure Valve IS Color Change Control Manifold Kits page 53 for Modules page 66 for all available kits parts High Pressure Non Circulating Color Change Kits 52 333282B Valve Manifold Kits The low pressure and high pressure valve manifold kits listed in this section are used in both the Non IS and IS color valve stacks Low Pressure Valve Manifold Kits Non Circulating Valve Manifold Kits Kit No 24T457 24T458 24T459 24T460 24T461 247462 241463 24T464 24T46
24. Spray Applications Related Manuals Manual No Deseo 332709 Pump Repair Parts Manual 332454 Color Change Valve Repair Parts Manual 332456 3rd and 4th Pump Kits Instructions Parts Manual Models Models Non Intrinsically Safe Modules These kits are installed in the non hazardous location near the pumps See the Kit label for the product part number See the module identification label for maximum air working pressure approval information and certification ProMix PD2K COLOR CHANGE CONTROL PART NO SERIES SERIAL MAX AIR WPR 7 7 100 MPa bar PSI Serial No Series No e Non Intrinsically Safe Color Change Control Module Label Kit Identification Label Kit No Kit Description Maximum Air Working Pressure Maximum Fluid Working Control Module Pressure Valves h GRACO INC P O Box 1441 Minneapolis MN eraco 55440 U S A Artwork No 294057 Rev B Artwork No 293992 Rev C Low Pressure Non Circulating Color Change Kits 24R915 2coloror2 catalyst 100 psi 0 7 MPa 7 0 bar 300 psi 2 068 MPa 20 68 bar 24R916 4 color or 4 catalyst 100 psi 0 7 MPa 7 0 bar 300 psi 2 068 MPa 20 68 bar 24R917 6coor 100psi 0 7 MPa 7 0 bar 300 psi 2 068 MPa 20 68 bar ner A sev 1005507 MPa 7 0bar 300ps 2068 MPa 20 68 bar _ Low Pressure Circulating Color Change Kits A ze 0 7
25. rating of your model Do not substitute system components as this may impair intrinsic safety Equipment that comes in contact with the intrinsically safe terminals must be rated for Intrinsic Safety This includes DC voltage meters ohmmeters cables and connections Remove the unit from the hazardous area when troubleshooting SKIN INJECTION HAZARD High pressure fluid from dispensing device 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 Do not point dispensing device at anyone or at any part of the body Do not put your hand over the fluid outlet Do not stop or deflect leaks with your hand body glove or rag Follow the Pressure Relief Procedure when you stop dispensing and before cleaning checking or servicing equipment HET Tighten all fluid connections before operating the equipment Check hoses and couplings daily Replace worn or damaged parts immediately MOVING PARTS HAZARD Moving parts can pinch cut or amputate fingers and other body parts Keep clear of moving parts Do not operate equipment with protective guards or covers removed Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure and disconnect all power sources MPa bar PSI TOXIC FLUID OR FUMES Toxic fluids or fumes can cause serious injury
26. s in both the IS and solenoid s and air fitting s at the appropriate and Non IS areas position s in the solenoid manifold See Setup the Modules page 13 Connect one end of the tubing to the solenoid s air fitting 11 Return the unit to service 10 Install the control module covers 4 Connect the solenoid wires to the appropriate pins on the control module board See Electrical Schematics page 36 NOTE If installing a one valve kit it is not necessary to disassemble the manifold stack as shown in the figure Skip step 5 and go on to step 6 5 If your kit is adding a manifold block 1 remove the screws 10 Slide the existing manifolds off the rods 15 16 keeping the manifolds in the correct order Install the new manifold block 1 The new block must be in the bottom position to maintain correct location of the solvent and dump valves Screw the rods 16 included in the kit into the existing rods Slide the existing manifold blocks onto the rods being sure that they are in the same positions as before Ensure all o rings 6 17 are in place then install the screws 10 30 333282B ti21641a Figure 13 Install an Expansion Kit Low Pressure Valve Manifold Shown 333282B Installation 31 Troubleshooting Troubleshooting NOTE Check all possible remedies before disassembling the system Color Change S
27. systems see Install the Back Pressure Regulator High Pressure Systems Only page 21 1 Use the top valve of the inlet valve stack as the solvent valve S Connect a solvent supply line to the 1 4 npt m solvent valve inlet on the color and catalyst valve stacks Hazardous Area Non Hazardous Area 26 JJ 0 Use the top valve of the outlet valve stack as the dump valve D Connect a waste dump line to the 1 4 npt m dump valve outlet on the color and catalyst valve stacks Connect the supply line for each color to the corresponding color valve fitting C1 C2 etc on the inlet color valve stack Connect a supply line from the bottom fitting of the inlet color valve stack to the inlet manifold of the material A dosing pump Connect a supply line from the outlet manifold of the material A dosing pump to the bottom fitting of the outlet color valve stack Remote Color and Catalyst Valve Manifolds 0 T 7 uu 0 ti23757a Non IS inlet and outlet color and catalyst valve manifolds Valve Manifold Stack Schematic 333282B Installation 6 Connect a dedicated supply line for each color 13 Co
28. the air lines from the solenoids to the valves See Connectthe Valve Air Lines page 24 Connect the fluid supply lines to the valves See Connect the Fluid Lines page 26 ti23762a 23 Installation Install the Remote Mix Manifold 1 Z4 Using the equipment as a template mark the mounting holes on the wall or robot arm near the automatic dispensing device Install the remote mix manifold See Dimensions page 71 Use two bolts to attach the equipment securely Install the remote mix manifold to the bracket with four screws Connect the fluid supply lines to the remote mix valve See Connect the Fluid Lines page 26 O ti23767a Connect the Valve Air Lines Non Hazardous Area 1 2 Connect 5 32 in 4 mm OD air tubes from the inlet solenoids to the air inlets of each inlet valve using the label inside of the color control module as a guide See Setup the Modules page 13 Repeat for the outlet valves Hazardous Area Connect 5 32 in 4 mm OD air tubes from the solenoids to the air inlet of each valve using the labels inside of the remote color control module as a guide See Setup the Modules page 13 333282B Notes Installation 333282B 25 Installation Connect the Fluid Lines Connect Non Circulating Fluid Lines NOTE There can be only one solvent valve S and one dump valve D per pump NOTE On high pressure
29. valves See Connectthe Valve Air Lines page 24 NOTE On high pressure systems see Install the Back Pressure Regulator High Pressure Systems Only page 21 Connect the fluid supply lines to the valves See Connect the Fluid Lines page 26 5 ZUM 103 104 1i22079a 333282B Installation Install the Back Pressure Regulator High Pressure Systems Only NOTE The back pressure regulator is required on high pressure systems to prevent the system s feed pumps from overdriving the dosing pumps during color change pump flush and color fill operations Adjust the back pressure during the dump process to be approximately 7596 of the supply pressure from the feed pumps but never more than 300 psi 2 1 MPa 21 bar less than the supply pressure Install the back pressure regulator 120 and attaching hardware at the dump valve of the outlet manifold stack 1 Install the gauge 123 in the open port of the tee 122 2 Screw the tee 122 onto the dump valve fitting of the outlet manifold stack 3 Assemble the two nipples 121 to the back pressure regulator 120 Screw the regulator assembly into the tee 122 as shown 4 Connecta 1 4 npt f dump line to the downward facing nipple 121 333282B 5 Connect the fluid supply lines to the valves See Connect the Fluid Lines page 26 ti22620a Figure 7 Install Back Pressure Regulator at Dump Valve of Outle
30. 0278 pL 96 gt SAFETY INTERLOCK SWITCH 2 l ADVANCED j 12345678 9 10 11213 14 15 16 17 18 19 20 2122 23 2425 12 34 5 6 7 8 9 101112 13 14 15 16 17 18 19 20 21 22 23 425 2 5 eig 25 PIN D SUB CABLE q58 16T659 lt P 1 BREAKOUT MODULE PUMP 240527 1 BREAKOUT MODULE PUMP 4 24N527 2 3 4 5 6 7 8 2 3 4 5 6 7 8 l n i IUE x BE TOT x 2 galgo ENCODER MOTOR id T 5 ENCOCERMOTOR 38 SEE DETAILAOR B z gt reci SEE DETAILAOR 1 i i E FIBI 7 os E BS uw BS Puea E 96 R TWISTED PAR CABLE 16 159 id J TWISTED PAIR CABLE 10 159 Figure 17 Electrical Schematic Sheet 2 Part 2 CONTINUED ON THE NEXT PAGE 38 333282B FROM CAN IS BOARD 24485 ON PAGE 2 Electrical Schematics FROM CAN IS BOARD 24485 ON PAGE 2
31. 3282B 5 Models Intrinsically Safe Modules These kits utilize intrinsically safe control modules that are installed in the hazardous area near the dispense valve See the kit identification label for the product part number See the module identification label for maximum air working pressure approval information and certification ProMix PD2K COLOR CHANGE CONTROL PART NO _ SERIES SERIAL YR MAX AIR WPR Serial No e intrinsically safe equipment G bar PSI 2 mE r Class Divi Group D T3 m HATS GB Ww GRACO INC Series No APPIO Install P 16P577 C Artwork No 294055 Rev A C IECEx FMG 13 0011 P O Box 1441 0359 Intrinsically Safe Color Change Module Identification Label Kit Identification Label Minneapolis MN Ex 0359 2 APPROVED eraco 55440 U S A Table 1 Low Pressure Non Circulating Remote Mix Manifold Kits Maximum Fluid Working Pressure 300 psi 2 07 MPa 20 7 bar Number of Color Solvent Valves Number Catalyst Solvent Valves 24V157 2 24V158 24V331 eooo o 4 24V332 24V333 24 334 24V335 Control Module Kits Use to add a second control module includes all needed solenoids manifolds valves and a CAN cable 13 18 24V165 r j 24V164 E 1 13 30 24 16 I Artwork No 293992 Rev C 6 333282B Models Table 2 Low Pressure Circulating Remote Mix Manif
32. 4 3 Locate fuse F1 302a on the color change board Pull the fuse away from the board 4 Install the new fuse 5 Reinstall the cover Restore electrical power to the system 333282B Repair Replace the Color Change Board 2 Remove the color change module cover 304 3 Note where each cable is connected then disconnect all cables from the color change board connectors NOTICE 4 Remove the seven mounting screws 303 and the board 302 To avoid damaging the circuit boards wear Part ging 2 i 5 Install the new board Reinstall the screws No 112190 grounding strap on your wrist and ground appropriately 6 Reconnect the cables to the proper connectors as noted in step 3 See To avoid electrical component damage remove all Electrical Schematics page 36 system power before plugging any connectors 7 Reinstall the cover 304 Restore electrical 1 Remove electrical power from the system power to the system 304 311 332 n 324 Rc gt A 316 301 amp 317 315 318 319 302 315 307 312 310 321 322 sr 0 e e e 0 BH 313 314 1 0 d ott 305 309 gt gt gt 309 160 j 9 0 e e s e 0 U 303 302a ti21639a Figure 23 Control Module Repair Non IS Module Shown 333282B 45 Parts Part
33. 5 102 see Non IS Color Low Pressure Change Control Valve Manifold Modules page Kits page 53 for 64 for parts all available kits Low Pressure Non Circulating Color Change Kits 24R915 2 color or 2 247458 247557 240239 60 ft 18 3 m catalyst 24R916 4 color or 4 24T460 24T558 24U239 120 ft 36 6 m catalyst Low Pressure Circulating Color Change Kits 333282B 47 Parts High Pressure Non IS Kits Kit No Kit Description Standard Valve Control Module Tool 114 Tube Length Manifold Kits Kit 108 see 115 102 see Non IS Color High Pressure Change Control Valve Manifold Modules page Kits page 58 for 64 for parts all available kits High Pressure Non Circulating Color Change Kits 24R959 2 color or 2 24T648 24T557 24U240 60 ft 18 3 m catalyst 24R960 4 color or 4 24T650 24T558 24U240 120 ft 36 6 m catalyst 24R961 24T652 247559 240240 210 ft 64 05 m 248962 24 654 247560 240240 360 ft 109 8 m High Pressure Acid Compatible Non Circulating Catalyst Change Kits High Pressure Circulating Color Change Kits 24T579 2 catalyst 24U182 24T557 24U240 60 ft 18 3 m 48 333282B Notes Parts 333282B 49 Parts IS Color Change Kits ti23770a 101 KIT manifold valve See Valve Manifold Kits page 53 for available kits 24 351 MANIFOLD mix remote 24N346 HOSE coupled 2 5 ft 105 HOSE static mixer 16W564 Low
34. 5 241466 24T467 247468 247469 24 470 241471 24T472 24T473 24T474 24T475 24T476 24T477 24T478 24T479 24T480 247481 247482 247483 24T484 24T485 24T486 Series KtNo Series ja j 241458 JA 24148 247459 2449 247460 Ja O 2440 avast ja 24140 24742 Ja 24142 247463 24148 241464 2444 26 Ja 247495 466 Ja 24146 247467 1 24487 247468 1 24148 Ja 24148 1 2400 24101 24742 1 241502 a 24103 2414 ja 24105 1 24106 24147 24107 247478 a 24108 247479 A 24109 247480 JA 2aTs10 amasi ja 247511 Ja 24 512_ 1 241143 1 24104 1 24 515 A 24146 333282B Parts Circulating Valve Manifold Kits 247487 247488 247489 241490 241491 241492 241493 241494 247495 247496 247497 247498 247499 247500 247501 247502 247503 247504 247505 247506 247507 247508 247509 247510 241511 241512 241513 241514 241515 241516 53 Parts Valve Manifold Kit Parts ti21641a 54 333282B Parts No wes onse 13 24T523 FITTING fluid 7 16 20 x 1 4 npt m 111328 CONNECTOR tube 10 32 x 5 32 4 mm OD tube Ref Part No Descript
35. E The electrical schematic illustrates all possible wiring expansions in a ProMix PD2K system Some components shown are not included with all systems NOTE See Optional Cables and Modules page 42 for a list of cable options 2 ue eet H RELAY 065161 06550 2 POSITION POWERMODULE INTEGRATION SWITCH fo 248257 GATEWAY CABLE Jores 2N POWER 48 10A POWER SUPPLY LINE FILTER B SUPPLY 16820 6446 dex 5 8 GATEWAY 1 5 248910 A 114095 TERMINALBLOCKS WTH FUSES d 5 s POWERIN 5 5 5 5 lt g gt 25 CATALYST CHANGE MODULE 6 24N985 A y bd bs ius Eug Ros dug Eo abe abs gt n 2 eA MODULE EFCM 24N913 GUNTRIGGER INPUTS 119159 119159 N SOLENOID 121324 SJ SOLVENT CUTOFF 121324 PRESSURE SW 121323 SWITCH 120278 SOLVENT d FLOW SWITCH 120278 INPUTS SOLVEN
36. Instructions Parts GRACO Color Change and Remote Mix Manifold Kits x To add optional color change function and at the gun mixing of two component materials when used with a ProMix PD2K Proportioner for Automatic Spray Applications For professional use only Important Safety Instructions Read all warnings and instructions in this manual and in your system installation operation and repair parts manuals Save these instructions See page 3 for model part numbers and approvals information ti22961a PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 3 Models dieu cet des ed Shu aa 4 Non Intrinsically Safe Modules 4 9 Important Isocyanate ISO Information 12 Setup the Modules 13 Setup Non IS Control Modules 13 Setup IS Control Modules 16 Installati n tir a UE EM 18 Mounting the Control Modules 18 Air S pply n iu et LR nats tineis 18 GIOUNCING 18 Non Hazardous Location 19 Hazardous Location 22 Connect the Valve Air Lines 24 Connect the Fluid Lines 26 Install an Expansion
37. LBOW connector 10 32 m x 5 32 in 4 mm OD tube Ds uno 16W50 LABEL instructions 1 See the following table to determine the quantity of each part in your control module Kit Parts labeled are not available separately Find your module kit no in the left column and the desired reference number in the top row to find the part quantity used in your control module kit Kit No Kit Solenoid Plug 313 Tube 320 Ferrule 322 Connector Description 310 Fitting 324 24T571 2 color and 2 catalyst 24T572 4 color and 2 catalyst 24T573 6 color and 2 10 catalyst 24T574 8 color and 2 12 catalyst 6 0 2 2 4 24T774 12 color and 1 2 catalyst 13 24 color 4 0 16 12 16 24 775 4 color and 4 1 50 ft 15 2 m 2 catalyst 333282B 30 ft 9 1 m 40 ft 12 2 m 4 mE r 12 16 20 24 32 0 67 Parts Kit No Kit Solenoid Plug 313 Tube 320 Ferrule 322 Connector Description 310 Fitting 324 24T776 6 color and 4 12 12 60 ft 18 3 m 24 12 catalyst 24TTTT 8 color and 4 14 70 ft 21 3 m 28 14 catalyst 241778 12 color and 90 ft 27 4 m 4 catalyst 13 30 color 241779 13 18 color 6 248 30 94 68 333282B Expansion Kits Parts To add colors catalysts order the correct Non IS Expansion Kit Also order the corresponding IS Expansion Kit See IS Expansion Kits page 70 Non IS Expansion Kits The foll
38. LOR24 6 pe er COLOR 16 mE 5 SVC coonz COLOR 17 2 4 1 J16 Siac COLOR26 COLOR18 0 COLOR 27 1 6 ja 2 P _ 28 COLOR20 COM al 14 J 10 aoc COLOR 21 Z VIX TH M ES CABLE 16426 54321 BOOTH CONTROL 24 731 Figure 20 Electrical Schematic Sheet 3 Hazardous Location 333282B 41 Electrical Schematics Optional Cables and Modules NOTE The total length of all cable used in the system must not exceed 150 ft 45 m See the Electrical Schematics page 36 A M12 CAN Cables for Hazardous Locations NOTE The total length of cable used in the hazardous location must not exceed 120 ft 36 m Length ft m 2 0 0 6 3 0 1 0 6 0 2 0 10 0 3 0 15 0 5 0 25 0 8 0 50 0 16 0 100 0 32 0 16V423 6V424 6V425 6V426 6V427 6V428 6V429 6V430 h gt a 2 9 AN M12 CAN Cables for Non Hazardous Locations Only A CAN Cables for Non Hazardous Locations Only 13 0 4 0 50 0 15 0 5U531 5U532 5V205 5V206 5V207 5V208 15U533 15V213 j 125306 1428 7 42 AN 25 Pin D SUB Cables for Non Hazardous Locations Only 16T659 2 5 0 8 16V659 6 0 1 8 A Alternates for Communication Module 24
39. R910 for Non Hazardous Locations Only Module Part No Module Part No CGMDNO DeviceNet Profibus CGMEPO Ethernet IP CGMPNO Profinet You must purchase Map Token Kit 17 087 for use with these kits A Alternates for Color Change Modules by Part Number Factory Configuration for Non Hazardous Locations Only see page 61 Alternates for Color Change Modules by Part Number Factory Configuration for Hazardous Locations Only see page 62 6 24T571 2 color 2 catalyst 24T572 4 color 2 catalyst 24T573 6 color 2 catalyst 24T574 8 color 2 catalyst 13 24 color 24T778 12 color 4 catalyst 13 30 color 241779 13 18 color 333282B To avoid electric shock turn off power at the main circuit breaker before opening the control module All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations Do not substitute or modify system components as this may impair intrinsic safety NOTICE To avoid damaging the circuit boards wear Part No 112190 grounding strap on your wrist and ground appropriately To avoid electrical component damage remove all system power before plugging any connectors Replace a Color Valve Use the following procedure to replace a valve whether the valve is part of the color stacks near the pump or part of the remote color stacks MPa bar PSI 1 Flush and relieve pressure as described in your PD2K ope
40. Relief Procedure when equipment is not in use Check equipment daily Repair or replace worn or damaged parts immediately with genuine manufacturer s replacement parts only Do not alter or modify equipment Alterations or modifications may void agency approvals and create safety hazards Make sure all equipment is rated and approved for the environment in which you are using it 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 11 Important Isocyanate ISO Information Important Isocyanate ISO Information Isocyanates ISO are catalysts used in two component materials Isocyanate Conditions Spraying or dispensing materials containing isocyanates creates potentially harmful mists vapors and atomized particulates Read and understand material manufacturer s warnings and material MSDS to know specific hazards and precautions related to isocyanates Prevent inhalation of isocyanate mists vapors and atomized particulates by providing sufficient ventilation in the work area If sufficient ventilation is not available a supplied air respirator is required for everyone in the work area To prevent contact with isocyanates appropriate personal pr
41. T METER 258718 FLOWRATE ANALOG IN FLOWRATE ANALOG IN FLOWRATE ANALOG IN FLOWRATE ANALOG IN Figure 15 Electrical Schematic Sheet 1 36 A CABLE 16 429 SAFETY INTERLOCK SWTCH ADVANCED DISPLAY MODULE 24 451 248219 A 16 426 feroz CAN IS BOARD 24M485 FAN FAN 24P658 24P658 la 5 16 036 16P037 16P036 16P037 WIRE HARNESS WRE PUMP INLET PUMP INLET 8 TRANSDUCER 2 DUCER gt BARRIER 162289 16P290 a 162289 162290 SPLITTER BOARD 16 243 PUMP OUTLET uj PUMP OUTLET 248192 TRANSDUCER TRANSDUCER 16280 16290 8 162289 16290 8 PUNP VIP FOR g PUMP VP FOR FLUIDREG FLUIDREG A Kia 5 3 lo wa lo wa Big 8 848 m FLOWSENSOR m FLOWSENSOR m 120278 C 3000 METER 3000 METER 239716 258718 239716 258718 167510 16 619 16 510 16 619 CABLE 167659 CABLE 161659 CABLE 161659 CABLE 16T659 FAN FAN 24P658 24P658 ENCODERARD MOTOR 16P036 16P037 16P036 16P037 WIRE HARNESS m WIRE HARNESS st 24P 684 24265 24 684 24PGES PUMP INLET PUMP INLE
42. T e TRANSI 5 TRANSDUCER gt 16289 162290 16289 162290 a PUNPOUTLET uj PUMP OUTLET TRANSDUCER TRANSDUCER n 16289 16 290 162289 16P290 PUMP VP FOR 2 PUMP VP FOR 5 FLUDREG A FLUDREG A Cae Cae 3 gage 5 Esa x pens FLOWSENSOR FLOWSENSOR amp 120278 120278 JOR G3000 METER G3000 METER 239716 258718 239716 258718 16 10 16V519 16 510 164519 BOOTH CONTROL 24 731 HAZARDOUS LOCATION NON HAZARDOUS LOCATION 333282B Electrical Schematics __ CONTINUED ON PAGE 3 CONTINUED ON PAGE 3 UNUSED 15 UNUSED 4 3 10 UNUSED 1 CABLE 02227 CABLE 1 1 CABLE uj aP P4 3 P3 P4 3 518 1 1 2 54 p 15 5 5 4 TA 5 BW eme UU 75 GCAMODULE 12345 12345 248910 GATEWAY 2 A A NONIS EFCM 4 3 A CABLE 164429 a
43. TERFACE 4 1 85 22 0220 UNEED 8 L 6 5 um F E mE Em ELE mnnn 1 2 55 5 HH HH D Lm GROUND BAR z 5 p BLACK WIRE 065159 S E ue gals 167659 3 ron lt 167660 133553 7 3 9 3T TH ETT gt 177155725 TET ADEE BREAKOUT MODULE PUMP 1 240527 BREAKOUT MODULE PUMP 2 24N527 I n ale 2 3 4 5 6 7 8 2 3 4 5 6 7 8 B AJAX LUE HET MU LUE HELL HIE Bg 1 L4 o TO TO NL GRND g alle d E POWER SUPPLY N 3 16 820 WRE HARNESS 555 835 5 8558 VRE HARNESS 855 55 BEBE 556 1 NS 3 1 SEE 8 8 5 amp amp ME 324 SEE DETAILAORB 8 E 8 IE 324 28 LN H 2888 Hth 2888 2ROSITI 1 1 zo amp 1 NN Bs t 25 NE 8 ea ea we Skee gs ge of SIs Bg I g g m L N 1 iu b FILTER HTHHE TWISTED PAR CABLE 18 159 ud 16 446 J TWISTED PAR CABLE 16 159 L GRND N aca DETAILA LOWPRESSURE DETAIL B HIGH PRESSURE PUMPS 24 706 24 714 i PUMPS 24M707 24M715 i L N GRND BREAKOUT MODULE BREAKOUT MODULE TERMNAL 24N527 24N527 BLOCK 2 3 2 3 114095 12525 I73T GRND eus manto z L mal 858 8 88 8 88 i 188888 888 8 888 88 222 38 23 3 33 3 22222 222 2 222 22
44. UNUSED 4 14 1103 UNUSED UNUSED UNUSED 4 6 1 AC COLOR 16 UNUSED 16 1 UNUSED e 12345 LEE 12345 i 12345 12345 COLOR COLOR CHANGE CHANGE u MANFOLD S MANIFOLD MANIFOLD pon MANIFOLD L 1 00 6 CoM L 4 NDC 1 44 6 COM FLUSH A COM 2 I7THRU24 5 XDVDC DUMP FLUSH COM 2 25THRU 32 5 VDC H3 4 COM 1 13 4 COM caonz lA VE 418 19 cotor 17 COLOR 25 VE 418 19 MMC mi COLOR 18 A 1H 82 Ha A 2 1 6 EL 6 COLOR 19 or H 5 COLOR 19 COLOR 27 ADI 5 5 eM LEN COLOR 20 woe 43 15 103 ES cotor 20 COLOR 28 fae a5 16 come gt H5 2 aoc 5 2 004 4 COLOR 21 1 COLOR21 COLOR 29 HNG 2 1 ME 1 axo 1 6 cov azc O1 6 COM coon2 2 5 dc CX IcooR2 COLOR 30 2 CoM 2 5 M 23 kap 205 4 14 1103 M co on23 UNEED 2 14 10 3E UNED UNUSED Ul ED COLOR 24 COM 6 1 Havoc D COLOR 24 UNUSED 16 1 UNUSED w 54321 ww 12345 S LE DUE 15V206 Figure 18 Electrical Schematic Sheet 3 May be unused in some configurations CONTINUED ON THE NEXT PAGE 3332828
45. 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 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 r daction
46. du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es 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 333282 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2014 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revision B September 2014
47. ed gt coor24 9 Notused o NotUsed There should be only one solvent valve and one dump valve per pump 333282B 15 Setup the Modules Setup IS Control Modules NOTE Two IS color change control modules may 3 For each module set the switches to ON or OFF be installed in the hazardous area The module as shown in the following table for colors 1 12 is labeled board 7 The module for colors 13 30 is labeled board 8 An alternate label IS Control Module Switch E for Module 8 Colors 13 30 is provided with the Control 54 module kit Affix the label according to your system Module configuration Module 7 Configure each module according to its designated number as follows NOTICE Module 8 To avoid damaging the circuit boards wear Part No 112190 grounding strap on your wrist and ground appropriately 4 Use the following figure and tables to determine the solenoid valve assigned to each valve in the To avoid electrical component damage remove all valve manifold system power before plugging any connectors 1 Remove electrical power from the system 2 Open the color change module Locate switches S4 S5 and S6 on the control module board The Switches may be shipped in the OFF position
48. ion Qty No 16P259 MANIFOLD 111450 O RING chemically resistant 3 24T441 VALVE for non circulating kits includes item 2 241442 VALVE for circulating kits includes item 2 24R051 PLUG cc valve E 247525 Ron connecting 3 in 76 24 524 R connecting 1 5 in 38 111504 O RING chemically resistant s wes 9 157974 WASHER plain 19 104644 PLUG screw 10 32 0 156 in 4 mm 104092 SCREW cap socket head IQ eA See the following tables to determine the quantity 100179 NUT hex 10 24 of each part in your valve manifold Low Pressure Non Circulating Valve Manifold Kit Part Quantities Kit No 1 2 s fe Js 6 7 s ro e e 44 ss 16 17 18 19 1 2 2 o 2 2 1 s 2 fo 1 2 jo 241458 2 3 1 ja o 1 1 Ja 4 ja s 0 1 5 2 241459 2 0 4 h t 5 5 4 3 0 1 4 0 247460 3 6 5 1 6 4 1 3 Je je 5 ja 3 1 7 2 2441 3 6 6 6 4 t 1 3 7 7 3 3 241462 4 8 7 1 8 5 t t 4 8 8 0 5 1 1 9 8 6 2404 5 10 1 foje t 1 3 2445 5 O 10 6 1 1 3 2448 6 jajaj 1217 t 1 r pe n 1 T fe P am v pe ua o Pa 3 ame s pe s 1 T 9 3 amari Je pe s o s 5 3 Em 3 E EN 247467 6 12 12 o 12 7 1 1 3
49. ion fitting R1 R2 etc on the outlet color valve stack C This circulation line bypasses the material A dosing pump when the color valve is closed allowing continuous circulation of that color 28 b Connect a dedicated fluid supply line for each color to the corresponding color valve C1 C2 etc on the outlet color valve stack Connect the other end of each line to the corresponding color valve on the remote color stack c Connect a 1 4 npt f circulation line from the circulation port on each remote valve back to the fluid supply container ti21984a Figure 12 Valve Manifold Connections Circulating System KEY D Dump valve fitting S Solvent fitting C1 Color 1 fitting C2 Color 2 fitting R1 Color 1 circulation fitting R2 Color 2 circulation fitting 333282B Installation uU gt E ti23759a Fluid Flow Schematic Diagram Circulating Mode Pump Not Shown for Clarity KEY A Color supply B Inlet color stack C Outlet color stack D Remote color stack E Remote mix manifold F A Automatic spray gun G Return line to fluid supply 333282B 29 Installation Install an Expansion Kit 6 Install the valves as follows a For a one valve kit remove the plug 4 and o ring 2 In
50. ittings and tubing Manifold with two non circulating valves Includes valves solenoids fittings and tubing Manifold with two circulating valves Includes valves solenoids fittings and tubing High Pressure Acid Compatible Expansion Kits Kit No Without Manifold 24T590 With Manifold 24T591 24T592 Kit Description One non circulating acid compatible valve replaces a plug Includes valve solenoid fittings and tubing Manifold with one non circulating acid compatible valve Includes valve plug solenoid fittings and tubing Manifold with two non circulating acid compatible valves Includes valves solenoids fittings and tubing 69 Parts IS Expansion Kits The following kits are available to add color valves in an IS area Order a kit without a manifold if you have room for a valve on an existing manifold Order a kit with a manifold if all ports on your existing manifolds have valves already See Install an Expansion Kit page 30 for instructions Low Pressure Expansion Kits Without Manifold 241449 24T450 With Manifold 70 Kit Description One non circulating valve replaces a plug Includes valve IS solenoid fittings and tubing One circulating valve replaces a plug Includes valve IS solenoid fittings and tubing Manifold with one non circulating valve Includes valve plug IS solenoid fittings and tubing Manifold with one circulating valve I
51. many as six control modules may be installed in the non hazardous location 1 Mount the first non IS color control module as described in Mounting the Control Modules page 18 2 Connect the 5 pin CAN cable 109 to J7 on the color control module 108 324 ti22187a Figure 3 Cable Connector J7 at Non IS Color Control Module NOTICE To avoid damaging the circuit boards wear Part No 112190 grounding strap on your wrist and ground appropriately To avoid electrical component damage remove all system power before plugging any connectors Remove electrical power from the system Remove the cover from the PD2K electrical control box 5 Install the supplied 2 cable grommet 110 on the cable 109 and secure the grommet to the side of the electrical control box 6 Connect the cable 109 to J2 on the non IS side of the isolation board inside the electrical control box See Electrical Schematics page 36 for a list of M12 CAN cables for use in a non hazardous area 333282B Installation 7 To install additional color control modules six maximum mount the module s as described in Mounting the Control Modules page 18 Connect a 5 pin CAN cable from J11 of the previous color control module to J7 of the next control module Replace the cover of the PD2K electrical control box before turning on power to the system 110 ti22183a Figure 4 Cable Connection at PD2K Electrical Control Box NON IS
52. mp 1 Module 5 Pump 2 Module 5 2 Pump 1 3 Not Not Applicable _ Pump 3 Pump 2 Pump 4 Module 5 Pump 2 Pump Not Applicable _ Color Change Control Modules Colors and Catalysts Module 2 Colors 9 16 Module 3 Colors 17 24 Module 4 Catalyst Catalyst Colors 1 2 3 4 25 30 Not Not Not Applicable 13 Setup the Modules Configure each module according to its designated Non IS Control Module Switch Settings number as follows Control S6 S5 S4 Module Module 1 i 1 OF OF OF Module 2 1 Remove electrical power from the system Module 3 2 Open the color change module Locate switches 54 S5 and S6 on the control module board The switches are shipped in the OFF position Module 4 ON ON ON S6 S5 S4 Module 5 OFF OFF OFF 3 For each module set the switches to ON or OFF as shown in the following table Module 6 4 Use the following figure and tables to determine the solenoid valve assigned to each valve in the valve manifold NOTICE To avoid damaging the circuit boards wear Part No 112190 grounding strap on your wrist and ground appropriately To avoid electrical component damage remove all system power before plugging any connectors
53. ncludes valve plug IS solenoid fittings and tubing Manifold with two non circulating valves Includes valves IS solenoids fittings and tubing Manifold with two circulating valves Includes valves IS solenoids fittings and tubing High Pressure Expansion Kits Without Manifold 24T712 24T713 With Manifold 24T714 24T715 24T716 24T717 Kit Description One non circulating valve replaces a plug Includes valve IS solenoid fittings and tubing One circulating valve replaces a plug Includes valve IS solenoid fittings and tubing Manifold with one non circulating valve Includes valve plug IS solenoid fittings and tubing Manifold with one circulating valve Includes valve plug IS solenoid fittings and tubing Manifold with two non circulating valves Includes valves IS solenoids fittings and tubing Manifold with two circulating valves Includes valves IS solenoids fittings and tubing High Pressure Acid Compatible Expansion Kits Kit No Without Manifold 24T718 With Manifold 24T719 24T720 Kit Description One non circulating acid compatible valve replaces a plug Includes valve IS solenoid fittings and tubing Manifold with one non circulating acid compatible valve Includes valve plug IS solenoid fittings and tubing Manifold with two non circulating acid compatible valves Includes valves IS solenoids fittings and tubing
54. nnect the static mixer to the outlet valve of the to the corresponding color valve fitting C1 C2 remote mix manifold etc on the outlet color valve stack Connect the other end of each line to the corresponding color valve fitting on the remote color stack 14 Connect a fluid line from the static mixer to the automatic dispense device 7 Connect supply line from the outlet valve on the bottom of the remote color valve stack to inlet A on the remote mix manifold 8 Connect the supply line for each catalyst to the corresponding catalyst valve fitting on the inlet catalyst valve stack 9 Connect a supply line from the bottom fitting of the inlet catalyst valve stack to the inlet manifold of the material B dosing pump 10 Connect a supply line from the outlet manifold of the material B dosing pump to the bottom fitting 21737 2 of the outlet catalyst valve stack Figure 11 Color Change Connections 11 Connect a dedicated supply line for each catalyst Non Circulating System to the corresponding catalyst valve fitting on the KEY outlet catalyst valve stack Connect the other end of each line to the corresponding catalyst valve fitting on the remote catalyst valve stack Seal weep and NOTE If your system uses more colors than lubrication port catalysts branch the catalyst line to connect it to Solvent fitting each mix manifold Install a check valve on each Color 1 fitti branch of the catalyst line
55. ol Modules 304 311 332 324 315 318 319 302 315 307 312 310 321 322 Ole e e oda 305 309 309 e e 308 T 0 2 8 0 ui U 303 302a ti21639a 333282B Ref Part Description No No 301 302 24 566 BOARD circuit 302a FUSE 125 mA 303 SCREW machine pan head 4 40 x 0 25 in 6 mm 304 COVER 305 119162 CONNECTOR 6 position 307 SCREW ground M5 x 0 8 308 123691 HOLDER fuse 309 241563 MANIFOLD 310 16P316 SOLENOID 311 117831 SCREW machine pan head 6 32 x 0 5 in 13 mm 312 103833 SCREW machine pan head 10 32 x 0 375 in 10 mm 313 24T565 PLUG 5 8 32 includes item 314 314 113418 O RING buna N 315 100139 PLUG pipe 1 8 Non IS Control Module Part Quantities A Ref Part Description Qty No No 317 115671 FITTING connector 1 8 1 npt m x 1 4 in 6 mm OD tube 318 112698 ELBOW 1 8 npt m x 1 4 in 6 mm OD tube 319 590332 TUBE polyethylene 1 4 in 6 1 mm OD 598095 TUBE nylon 5 32 in 4 mm OD sme 22 Cem 324 114263 FITTING connector 1 8 npt m x 5 32 in 4 mm OD tube 151395 WASHER See the following table to determine the quantity of each part in your control module Kit Parts labeled
56. old Kits Maximum Fluid Working Pressure 300 psi 2 07 MPa 20 7 bar Number of Color Solvent Valves Number of Catalyst Solvent Valves eres A 2 24V166 24V167 24V336 24V309 24V338 24V348 24V326 24V339 24V349 2 javszr 24V340 24350 manifolds valves and a CAN cable 13 18 24328 13 24 239 13 30 2430 TC Table 3 High Pressure Non Circulating Remote Mix Manifold Kits Maximum Fluid Working Pressure 1500 psi 10 34 MPa 103 4 bar Number of Color Solvent Valves Number of Catalyst Solvent Valves 2 DR NN avos 24v381 E J zavas 24v382 24385 2 vans 24537 24V347 24V363 24V384 24V398 24V385 24V309 Control Module Expansion Kits Use to add a second control module includes all needed solenoids manifolds valves and a CAN cable Models continue on next page 333282B 7 Models Table 4 High Pressure Circulating Remote Mix Manifold Kits Maximum Fluid Working Pressure 1500 psi 10 34 MPa 103 4 bar Number of Color Solvent Valves poa ee 7 wwe j R js 5 E g 24V392 24V404 2 4 24393 24V405 Control Module Expansion Kits Use to add a second control module includes all needed solenoids manifolds valves and a CAN cable 13 18 247375 I j 13 24 24V376 E 13 30 24V377 r j NOTE Systems can use 1 to 30 colors and up to 4 catalysts To add colors catalysts If current control module is full
57. olenoid Valves NOTE Refer to Electrical Schematics page 36 If the color change valves are not turning on or off correctly it could be caused by one of the following 1 Air regulator pressure Check that air pressure is at least 85 psi 0 6 MPa 6 0 bar Do not go above 100 set too high or too low psi 0 7 MPa 7 0 bar 2 Air or electrical lines Visually inspect air and electrical lines for kinks damage or loose connections damaged or connections Service or replace as needed are loose 3 Solenoid failure Check the applicable solenoid s LED see Color Change Board page 34 If lit proceed with the following checks If not lit go to Cause 4 Remove the connector for the applicable solenoid and measure voltage across the pins on the board In a non hazardous location replace the solenoid if voltage is 24 Vdc In a hazardous location replace the solenoid if voltage is between 9 15 Test the valves as explained under Maintenance Screen 4 in your PD2K Operation manual Valves should open and close quickly If the valves actuate slowly it could be caused by Air pressure to the valve actuators is too low See Cause 1 Solenoid is clogged Make sure the air supply has a 5 micron filter installed Something is restricting the solenoid or tubing Check for air output from the air line for the corresponding solenoid when the valve is actuated Clear the restriction 32 333282B Troubleshooting 4 Cont
58. or death if splashed in the eyes or on skin inhaled or swallowed e Read MSDSs 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 dispensing or cleaning equipment 10 333282B Rs 333282B Warnings PERSONAL PROTECTIVE EQUIPMENT Wear appropriate protective equipment when in the work area to help prevent serious injury including eye injury hearing loss inhalation of toxic fumes and burns This protective equipment includes but is not limited to Protective eyewear and hearing protection Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer 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 from distributor or retailer Do not leave the work area while equipment is energized or under pressure Turn off all equipment and follow the Pressure
59. otective equipment including chemically impermeable gloves boots aprons and goggles is also required for everyone in the work area Keep Components A and B Separate Cross contamination can result in cured material in fluid lines which could cause serious injury or damage equipment To prevent cross contamination Never interchange component A and component B wetted parts Never use solvent on one side if it has been contaminated from the other side Moisture Sensitivity of Isocyanates Exposure to moisture such as humidity will cause ISO to partially cure forming small hard abrasive crystals which become suspended in the fluid 12 Eventually a film will form on the surface and the ISO will begin to gel increasing in viscosity NOTICE Partially cured ISO will reduce performance and the life of all wetted parts Always use a sealed container with a desiccant dryer in the vent or a nitrogen atmosphere Never store ISO in an open container Keep the ISO pump wet cup or reservoir if installed filled with appropriate lubricant The lubricant creates a barrier between the ISO and the atmosphere Use only moisture proof hoses compatible with ISO Never use reclaimed solvents which may contain moisture Always keep solvent containers closed when not in use Always lubricate threaded parts with an appropriate lubricant when reassembling NOTE The amount of film formation and rate of c
60. owing kits are available to add color valves in a non IS area Order a kit without a manifold if you have room for a valve on an existing manifold Order a kit with a manifold if all ports on your existing manifolds have valves already See Install an Expansion Kit page 30 for instructions Low Pressure Expansion Kits Without Manifold 247443 247444 With Manifold 333282B Kit Description One non circulating valve replaces a plug Includes valve solenoid fittings and tubing One circulating valve replaces a plug Includes valve solenoid fittings and tubing Manifold with one non circulating valve Includes valve plug solenoid fittings and tubing Manifold with one circulating valve Includes valve plug solenoid fittings and tubing Manifold with two non circulating valves Includes valves solenoids fittings and tubing Manifold with two circulating valves Includes valves solenoids fittings and tubing High Pressure Expansion Kits Without Manifold 24T584 24T585 With Manifold 24T586 247587 247588 247589 Kit Description One non circulating valve replaces a plug Includes valve solenoid fittings and tubing One circulating valve replaces a plug Includes valve solenoid fittings and tubing Manifold with one non circulating valve Includes valve plug solenoid fittings and tubing Manifold with one circulating valve Includes valve plug solenoid f
61. ration manual 2 Engage the pins of the tool 114 with the notches in the retainer 5 and unscrew the retainer 333282B Repair 114 C1 s ti22080a O Figure 21 Remove Retainer Using the other end of the tool 114 screw it all the way onto the valve 3 Pull the valve from the manifold ti22081a Figure 22 Remove the Valve NOTE See manual 332454 to repair the valve Install the valve in the reverse order of disassembly Be sure all o rings are in place and lubricated and that the valve is seated completely in the manifold Return the system to service 43 Repair Replace a Solenoid o 44 Remove electrical power from the system Remove air supply pressure from the system Remove the color change module cover 304 Disconnect the two solenoid wires from the color change board 302 See the color change board wiring diagrams in the Electrical Schematics page 36 Remove the solenoid 310 from the manifold 309 Install the new solenoid Connect the two solenoid wires to the color change board 302 See the color change board wiring diagrams in the Electrical Schematics page 36 Reinstall the cover Replace the Color Change Board Fuse NOTE Replacing the fuse with a non Graco fuse voids the IS system safety approval F1 123690 Fuse 125 mA intrinsically safe 1 Remove electrical power from the system 2 Remove the color change module cover 30
62. rol board or cable failure 333282B If there is no voltage across the pins on the board or it is less than 9 Vdc check LEDs D8 09 and 010 If they are lit and functioning properly or other solenoids in the module are working properly replace the color change board If D9 is not lit Verify the condition of the fuse F1 and replace if necessary See Replace the Color Change Board Fuse page 44 Check if the cable is disconnected or damaged Check the isolation board See the PD2K Repair Parts manual If D8 is not blinking Cycle the system power Check if the cable is disconnected or damaged Check the isolation board See the PD2K Repair Parts manual If D10 is not occasionally blinking Check if the cable is disconnected or damaged Check the isolation board See the PD2K Repair Parts manual 33 Troubleshooting Color Change Board NOTICE To avoid damaging the circuit boards wear Part No 112190 grounding strap on your wrist and ground appropriately To avoid electrical component damage remove all System power before plugging any connectors
63. rystallization varies depending on the blend of ISO the humidity and the temperature Changing Materials NOTICE Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime When changing materials flush the equipment multiple times to ensure it is thoroughly clean Always clean the fluid inlet strainers after flushing Check with your material manufacturer for chemical compatibility When changing between epoxies and urethanes or polyureas disassemble and clean all fluid components and change hoses Epoxies often have amines on the B hardener side Polyureas often have amines on the A resin side 333282B Setup the Modules Setup Non IS Control Modules NOTE The PD2K System can use up to four pumps and six color change modules in the non hazardous area Use the following table to understand how many color change modules are needed for the number of pumps in your system and which module should be associated to which pump Setup the Modules All Non IS modules ship from the factory as Module 1 Colors 1 8 Labels for Modules 2 through 6 are provided with the module kit Affix the labels according to your system configuration Table 5 Relationship of Non IS Color Change Control Modules to Pumps System Pump Configuration Catalyst 5 Module 1 Pe Pump 2 Pump 2 333282B Not U Not Applicable 1 Pu
64. s Non IS Color Change Kits ti22087a Detail of Back Pressure Regulator High Pressure Outlet Stack only ti22620a 46 333282B Ref Part Description Qty No No 24U237 BRACKET mounting KIT manifold valve Ref Part Description Qty N No 115 598095 TUBE nylon 5 32 in 4 mm E 2 103 100157 SCREW cap hex head 222290 REGULATOR back pressure 4 420 x 0 375 in 10 used on high pressure kits FERES 10 mm only see detail drawing see 10 103195 SCREW cap hex head manual 307892 1 4 20 x 4 0 in 101 mm 105 100016 WASHER lock 1 4 100015 NUT hex 1 4 20 113070 NIPPLE 3 8 x 1 4 npt sst used on high pressure kits 7 only see detail drawing 107 24N346 HOSE fluid 1 4 npsm fbe 2 5 ft 0 76 m ptfe 05 m 110290 TEE 1 4 npt f sst used on high pressure kits only see detail drawing 112564 GAUGE pressure fluid used on high pressure kits only see detail drawing See the following tables for the part number used your color change kit o 120 121 122 123 108 KIT module control 109 15V206 CABLE CAN 5 pin female 10 ft 3 05 m 4 16V819 GROMMET cable 111 24U236 TOOL repair valve not shown 114 TOOL installation valve not shown Low Pressure Non IS Kits Kit Description Standard Valve Control Module Tool 114 Tube Length Manifold Kits Kit 108 see 11
65. se pail liners unless they are antistatic or conductive Stop operation immediately if static sparking occurs or you feel a shock 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 or installing 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 333282B Warnings 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 Be sure your installation complies with national state and local codes for the installation of electrical apparatus in a Class I Group D Division 1 North America or Class Zones 1 and 2 Europe Hazardous Location including all of the local safety fire codes for example NFPA 33 NEC 500 and 516 OSHA 1910 107 etc To help prevent fire and explosion Do not install equipment approved only for a non hazardous location in a hazardous location See model ID label for the intrinsic safety
66. secure the grommet to the side of the electrical control box Locate J4 on the IS side of the isolation board in the electrical control box Connect the cable C1 to J4 See Electrical Schematics page 36 22 333282B e ane IS 1i21938a Figure 10 Detail of Isolation Board Cable Connections If your system includes a second remote color control module mount it as described in Mounting the Control Modules page 18 Connect the supplied hazardous location cable C2 from 333282B Installation J11 on the first color control module to J7 on the second module Replace the cover of the PD2K electrical control box before turning on power to the system Install the Remote Valve Manifolds 1 Using the equipment as a template mark the mounting holes on the wall at a convenient height for the operator and so the equipment is easily accessible for maintenance Mount the remote valve manifolds near the remote color module and the automatic dispensing device Install the mounting brackets for the color valve manifolds and the catalyst valve manifolds See Dimensions page 71 Use bolts to attach the equipment securely Install the color and catalyst valve manifolds to the brackets with four screws washers and nuts Connect
67. stall a new o ring 2 the valve 3 and retainer 5 using the valve installation tool See Replace a Color Valve page 43 b Fora manifold kit with one valve install the o ring 2 valve 3 and retainer 5 Expansion Kits are available to add valves or using the valve installation tool See manifolds to your system For each additional Replace a Color Valve page 43 Install the color catalyst desired order a Non IS Expansion plug 4 in the unused manifold port Kit and a corresponding IS Expansion Kit See c Fora manifold kit with two valves install Expansion Kits page 69 for available kits the o rings 2 valves 3 and retainers NOTE Remember that you may need up to 6 Non IS 5 using the valve installation tool See control modules and up to 2 IS control modules Replace a Color Valve page 43 Follow Steps 1 7 to install solenoids manifolds and 7 Install the o ring s 12 and fluid fitting s 13 valves first in the Non IS area and then in the IS 8 For each color catalyst connect fluid lines from area the source to the input color catalyst stack Then connect fluid lines from each output valve to the corresponding remote color change valve nstall 2 Relieve pressure as described in your PD2K the air fitting s 14 Operation Manual 1 Remove electrical power from the system 9 Connect the tubing from the solenoid valve s 3 Open the control module cover Install the see step 3 to the fitting
68. t Stack 21 Installation Hazardous Location Connect Remote Color Change Control Module 108 NOTE IS color change control modules provide control for remote color catalyst change valves located in the hazardous location for use with automatic spray systems A maximum of two IS control modules may Z be installed in the hazardous location See IS Color Change Control Modules page 66 for a list of modules approved for installation in a hazardous location NOTICE To avoid damaging the circuit boards wear Part 112190 grounding strap on your wrist Figure 8 Intrinsically Safe Cable Connections ground appropriately 3 Connect the hazardous location cable C1 to J7 To avoid electrical component damage remove all on the remote color control module 108 system power before plugging any connectors Only approved cables may be used in the hazardous location Hazardous location cables are marked with a light blue flag next to each connector See Optional Cables and Modules page 42 for a list of M12 CAN cables for use in a hazardous area 1 Remove electrical power from the system 2 Mount the first remote color change control module as described in Figure 9 Cable Connectors J7 and J11 at IS Mounting the Control Modules page 18 Color Control Module 4 Remove the cover from the PD2K electrical control box Install the grommet G on the supplied cable C1 and
69. wall at a convenient height for the operator and so the equipment is easily accessible for maintenance NOTE The smaller color change control modules must be mounted in the Non IS area The larger remote color change module may be mounted in the IS area 4 Drill mounting holes in the wall Install anchors as needed 5 Bolt the equipment securely Air Supply Connect a clean and dry air supply to the air inlet fitting 317 of each color change control module in the non hazardous area and each remote module in the hazardous area The fitting is for 1 4 in 6 mm OD tubing Use a 5 micron filter Regulate the air pressure to 85 100 psi 0 6 0 7 MPa 6 0 7 0 bar Grounding This equipment must be grounded to reduce the risk of static sparking and electric shock Electric or static sparking can cause fumes to ignite or explode Improper grounding can cause electric shock Grounding provides an escape wire for the electric current Connect a ground wire from each color change module in the non hazardous area to a true earth ground Intrinsically safe remote color change modules located in the hazardous area must be connected to a true earth ground in the hazardous area 333282B Non Hazardous Location Connect the Color Change Control Modules NOTE Non IS color change control modules provide control for the pump s inlet and outlet color catalyst change valves Depending on the number of valves in the system as
70. 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
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