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Graco 332456B User's Manual

1. Al M CATALYST 1 15 50 DC CATALYST 2 _ Ran CATALYST 2 L A Con 6 6 Go EL UNUSED 1 1 UNUSED UNUSED 2 2 UNUSED UNUSED 3 3 UNUSED UNUSED 4 4 UNUSED UNUSED 5 5 UNUSED UNUSED 6 6 UNUSED UNUSED 1 l UNUSED UNUSED 2 21 UNUSED UNUSED 13 3 UNUSED UNUSED 14 4 UNUSED UNUSED 15 5 UNUSED UNUSED 6 6 UNUSED Figure 26 Electrical Schematic Sheet 3 Alternate Configuration for Catalyst Change Control CONTINUED ON THE NEXT PAGE 332456B 25 Electrical Schematics FROM CAN IS BOARD 24M485 ON PAGE 2 COLOR FLUSH 7 COLOR 1 L NLIS COLOR 2 DC s coaons 22 0 COLOR4 AT u COLORS HM cooRZ L caonS pa S2 NON HAZARDOUS LOCATION HAZARDOUS LOCATION MANIFOLD SH CATALYST FLUSH ee CATALYST 1 s HDC CATALYST 2 6 COM Tam 2 04 caTALYST 3 ad LE caavsr4 5 HDC 6l COM S 1n oon Tu 4 llcoaonn 6 COM NI COLOR 12 MANIFOLD MANIFOLD 1 l 42VvDC COLOR B pa PADS Hal 4THRU49 C 1149082 COLOR 14 eA 1 PE COLOR 23 COLOR 15 05
2. E ti22348a Figure 2 Install the Frame and Pump 332456B Installation TSL Cup Kit Throat Seal Liquid TSL lubricates the pump throat packings and dosing valves The TSL Cup Kit supplies TSL to the upper and lower throat cartridges of the pump and to the four pump dosing valves NOTE TSL must be ordered separately Order Part No 206995 1 quart 0 95 liter 1 Slide the kit mounting bracket onto any side of the pump s hex nut 2 Place the TSL cup 73 into the bracket 73a NOTE The pump s upper throat cartridge has three ports two are plugged Install the barbed fitting 73b in the port closest to the TSL cup by moving a plug if necessary 3 Check that the o ring is in place on the barbed fitting 73b Apply low strength thread adhesive and install the fitting in the upper throat cartridge port Repeat for the lower throat cartridge If you are lubricating the dosing valves remove the plug and gasket from the valve port closest to the TSL cup Check that the o ring is in place on the barbed fitting 73b Apply low strength thread adhesive and install the fitting in the valve port 70 Figure 3 Install TSL Cup Kit NOTE you are not lubricating the dosing valves remove the unused barbed fittings 73b from the bottom of the TSL cup 73 Apply low strength thread adhesive and install the plugs and gaskets supplied with the kit Cut the tubing 73c to length as required Connec
3. Pump Size ite ____ Inlet Pressure Disabled 3 Color Change X Materials Total Hose Length 4 ft Pump Hose Diameter 0 250 in Available Colors 17 24 Figure 12 Third Color Pump Screen 332456B Installation 08 10 13 Pump 3 Calibrate Purp Off Active Errors Pump Size 35icc Inlet Pressure Disabled E Color Change Available Catalysts 3 3 Figure 13 Fourth Catalyst Pump Screen The Home Screen will now show animations and information for the added pumps 5 10 13 22 949 Errors Events Spray Fill Standby C Active Errors LI ce rnin psi Figure 14 PD2K Home Screen Advanced Display Module See the PD2K Operation Manual to return the system to service 17 Repair Repair Dose Valve Tubing Connections NOTE Red and green 5 32 in 4 mm tubing connects the solenoid manifold to the pump s dosing valves See the Pump Tubing Schematic on the next page Tubing lengths must be 18 in 1 2 in 457 mm 13 mm for all connections Always use equal lengths of tubing to balance the timing of the valves Lengths longer than 18 in 457 mm will increase valve response time 1 On the bottom of the solenoid manifold are four ports with tube fittings UP OPEN UP CLOSED DOWN OPEN and DOWN CLOSED These ports provide air to open and close the pump s inlet dosing valves jf N a OPEN
4. 6 8 Install the dual grommet 11 shipped loose on the free end of the D SUB cable 8 Fasten the grommet 11 to the side of the electrical control box using two screws 31 Reinstall the covers on the PD2K electrical control box and on the fluid panel 332456B Installation Grounding Verify that the added pump Is grounded by taking a resistance reading from the ground screw 7 on the added pump kit s back panel 2 to the system s true earth ground This equipment must be grounded to reduce the Resistance must be less than 1 ohm 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 1 Verify that the PD2K base unit is properly grounded See the PD2K installation manual for complete grounding instructions 2 Ground the expansion kit pump s as follows a Ifthe added pump is mounted to the PD2K main unit verify that the added pump is grounded by taking a resistance reading from the ground screw 7 on the added pump kits back panel 2 to the system s true earth ground Resistance must be less than 1 ohm b Ifthe added pump is NOT mounted to the PD2K main unit connect a ground wire to the ground screw 7 on the added pump kit s back panel 2 Connect the other end of the 9 ground wire to the same true earth ground Figure 9 Grou
5. go GA TER corona a 543 FROM CAN IS BOARD 24485 ON PAGE 2 CATALYST CHANGE MANIFOLD Aerie s MANIFOLD FLUSH bat 9MX M3 rug 2H Due 3 H2VDC CATALYST 1 coi iH Gon CATALYST 1 12VDC 2VDC CATALYST 2 MX He 2H aw CATALYST2 12vDc i 1 cara ysr 3 22 H2 27 J cataysr3 cxwYsr4 22 12 an cATAIYST4 UNUSED 5 5 UNUSED UNUSED C16 60 UNUSED TT LITE AUBWNE MANIFOLD MANIFOLD FLUSH 2H doe COLOR 25 SAX H 1 ZH 9085 memi E ED D COLOR 27 Da A SC COLOR 27 coor 28 0 4 ae Ei caoz COLOR 29 He NN ORA QU WIND n 15V206 Figure 25 Electrical Schematic Sheet 3 May be unused in some configurations CONTINUED ON THE NEXT PAGE 24 332456B Electrical Schematics CATALYST CHANGE MANIFOLD DS MANIFOLD CATALYST ne FLUSH 3 THRU 4 Dune 3 CATALYST 3 4 de CATALYST 3 Ql __ CATALYST 4 CATALYST 4 926 w QUOwNPFP HDUBWNE r OUBWNE CATALYST CHANGE LE _ MANIFOLD Cae i MANIFOLD FLUsH 2 1TRUJ 2 COM IN __ puvp CATALYST 1
6. 18 8 SEE 5 27222 lt M GFB 1 INTERFACE LLLI eM 15 UNUSED UNUSED 4 Hs s SOLVENT CUTOFF PWR RED 19 SIG WHTE 10 COM BLACK 11 SOLVENT SHIELD GRN UNUSED METER 258718 GROUND BAR L TWISTED PAIR CABLE 16150 DETAIL B HIGH PRESSURE PUMPS 24707 24M715 DRAINFOIL UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED PUMP ENCODER AND MOTOR 16P036 Electrical Schematic Sheet 2 Part 1 123456 7 8 9 10 1112 13 141516 17 18 19 20 212 23 24 25 25 PIN D SUB CABLE 24P 658 FAN PUMP 1 CONTINUED ON PAGE 3 1 WRE HARNESS PUMP 2 SEE DETAILAOR B E EITHER 239716 258718 16 510 SERIES 46 2 Eza 5 16 812 2 OR 16519 TWSTED PAIR CABLE 16150 332456B 123456 7 8 9 10 11 22 13 14 15 16 17 18 19 20 2122 23 24 25 FAN PUMP 2 7 Electrical Schematics GUNTRIGGER INPUTS SIG GOM e _ GFB PRESSURE SWITCH 121323 622 ___1 SOLVENT FLOW SWITCH 120278 Peoria ge M E FLOWRATE ANALOG IN 1 DE FLOWRATE ANALOG COMMON 1 FLOWRATE ANALOGIN 2 FLOWRATE ANALOG COMVON2 FLOWRATE ANALOG IN 3 FLOWRATE ANALOG COMM
7. 3A2801 Mix Manifold Instructions Parts Manual Fluid Connections 12 Electrical Connections 13 Ol OU QI 15 Complete the Installation 16 tmm 18 Dose Valve Tubing Connections 18 Replace Pump Control Module 20 Electrical 21 Pump Expansion Kit 27 Technical b ke y ba e l n ke 31 Graco Standard 32 ManualNo Deseriston T7 332339 Pump Repair Parts Manual 332454 Golor Change Valve Repair Parts Manual 332455 Color Change Kits Instructions Parts Manual 332456B Models Models Kit Part No Maximum Fluid Working Pressure 24R968 70 cc Low Pressure Color Pump Kit 300 psi 2 068 MPa 20 68 bar 24R969 A 70 cc High Pressure Color 1500 psi 10 34 MPa 103 4 bar Pump Kit 24R970 A 35 cc Low Pressure Color or 300 psi 2 068 MPa 20 68 bar Catalyst Pump Kit 24 971 35 cc High Pressure Color 1500 psi 10 34 MPa 103 4 bar Catalyst Pump Kit ProMix PD2K EXPANSION PUMP PART NO SERIES SERIAL MFG YR MAX AIR WPR MPa bar PSI MAX FLUID WPR GRACO INC MAX TEMP 2m soc 1227 eraco 55440 U S A Artwork No 294116 Rev B MPa bar PSI Figure 1
8. 5 5 5 5 COLOR CHANGE MODULE 7 G3000 METER G3000 METER 5 E 248219 A uj 239716 258718 239716 258718 gl gi gig 16 510 16 519 16 510 16 519 3 2 ui zc FAN 24P658 ENCODER AND MOTOR CABLE 16 429 5 E 24P684 24P685 24P684 24P685 PUMP INLET PUMP INLET TRANSDUCER TRANSDUCER 16P289 16P290 16P289 16P290 PUMPOURET PUP OUTLET NON HAZARDOUS LOCATION ER PUMP VP FOR FLUID REG PUMP V P FOR FLUID REG AE 5 24527 BE Be BREAKOUT MODULE PUMP 3 SERIES 46 SOLENOID 16P812 HIS N N MAC SERIES 46 SOLENOID 16P812 HIS N N FLOWSENSOR FLOWSENSOR 120278 120278 G3000 METER 239716 258718 16M510 16M519 16M510 14519 Figure 22 Electrical Schematic Sheet 1 332456B 27 Electrical Schematics CONTINUED ON PAGE 3 KAN CABLE 16 429 12345 bd 58 22 123 SPUTTER me a 54321 BARRIER 00000 BOARD 1 Eesha UNUSED RED WARE 065161 BLACK WIRE 065159 GRND GRN YEL AND WRE HARNESS PUMP 1 3 DETAILA LOW PRESSURE PUMPS 24 706 24M714 POWER IN DRAINFOIL UNUSED UNUSED UNUSED 123456 89 aan 123456 89 7 PUMP ENCODER AND MOTOR 16P037 Figure 23 CONTINUED ON THE NEXT PAGE 22 SEE DETAILAOR B UNUSED UNUSED CABLE UNUSED 2 1 2
9. Pump Expansion Kit Identification Label 332456 3 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 use 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 t
10. and the temperature 332456B Important Isocyanate ISO Information 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 332456B 7 Installation Installation Before Installing the Kit Servicing the electrical control box exposes you to high voltage 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 Follow the Pressure Relief Procedure in your PD2K manual whenever you see this symbol 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 your system manual when
11. 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 du pr sente document sera 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
12. 314 COLOR 1 Ta S svoc COLOR 2 ME n 6b 1 ADC COLOR 3 Ez Co 2 N __ COLOR 4 ON i MX CER coon4 ox a amp 1 GM HORE l H2VDC ume Coa 2 COM RJ s E LII COM 4 COLOR 7 caon8 BT 00 COLOR CHANGE u MANIFOLD COLORS MANIFOLD FLUSH 8245 H3 omru 3H pues JAXNDC 3 4XNDC COLOR 9 oi 4 4 ie N U COLOR 9 COLOR 10 op 77 NDC He ot en NT COLOR 10 412 DC 1 1 AH2VDC L2 COM 2 2 CoM lt 12 4 4 12 COLOR 6 a dS coor 13 si E 1 2 c COLOR n 2 2 2 com N__ colon 14 VC COLOR 15 14 4 N __ coLoR 15 16 C BAT eom fea A 12345 COLOR _ CHANGE _ MANIFOLD n MANIFOLD 206 H3 zmnu2a 3H GAP NS puvpx L 13 37 voc COLOR 17 oi Ha K T coloR 17 ANC 906 He 2 m COLOR 18 1 1 ADC COLOR 19 CON 2 2 4 com N __ 19 3 3H H2V DC COLOR 20 Ea 4 co N __ coLoR 20 COLOR a a 6 ava 21 1 1 colon 22 DE HA 2 2 zen co onz3 oi 4 14 jJ102L c n COLOR 23 24 pa
13. 5 aavoc COLOR 24 i im AN 16 AT 0 2 2 ZANE TST 25 coor 17 AT Xew ada colon 26 COLOR 18 BAD H at aoc 5 COLOR 27 1 l jue ean 2 2 EUN COLOR 20 C BaT AB 0000 TN caon29 COLOR 21 aT 400 Ha coLor 0 8 g 0001 54321 BOOTH CONTROL 24M731 Figure 27 Electrical Schematic Sheet 3 Hazardous Location 26 332456B Pump Expansion Kit Parts 2 lt 7 lt K 332456B Pump Expansion Kit Parts ti22245a 2 Pump Expansion Parts Part No 24R968 70 cc Low Pressure Color Pump Kit Part No 24R969 70 cc High Pressure Color Pump Kit Part No 24R970 35 cc Low Pressure Catalyst Pump Kit Part No 24R971 35 cc High Pressure Catalyst Pump Kit Ref 1 A N 10 11 12 13 14 15 16 28 Part 241712 241770 24N527 16V659 241790 241791 241788 241789 16 858 C19798 Description BRACKET mounting pump PANEL back MANIFOLD solenoid KIT fan MODULE control pump SCREW cap socket head 10 32 x 1 5 in 38 mm SCREW ground M5 x 0 8 CABLE D SUB 25 pin 6 ft 1 83 m PUMP 70 cc A side low pressure for Kit 24R968 see manual 332339 PUMP 70 cc A side high pressure for Kit 24R969 see manual 332339 PUMP 35 cc B side low pressure for Kit 24R970 see manual 332339 PUMP 35 cc B side hig
14. Description Qty f d PLUG screw 10 32 4 to replace unused item 73b at TSL cup not shown 73 GASKET for item 4 73d not shown ltems marked are not available separately 29 Notes Notes 30 332456B Technical Data Technical Data Pump Expansion Kit Maximum fluid working pressure Kits 24R968 and 24R970 300 psi 2 1 MPa 21 bar Kits 24R969 and 24R971 1500 psi 10 5 MPa 105 bar Maximum working air 100 psi 0 7 MPa 7 0 bar pressure Wetted parts oee Pump manual 332339 332456B 31 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 su
15. Installation Parts gt g GRACO To add a third or fourth pump to a ProMix PD2K Proportioner Each kit includes one pump and associated parts PD2K is shown with two kits added For professional use only Important Safety Instructions e Read all warnings and instructions in this manual and in your PD2K manual Save these instructions See page 3 for model part numbers and approvals information A a o E e SA Xt 7 AY 2 NE E gt Oe eam Xe N AR A es SEER OA ti22244a PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 2 cox HH H 3 VV NN 4 Important Isocyanate ISO Information 6 Isocyanate Conditions 6 Material 6 Keep Components and B Separate 6 Moisture Sensitivity of Isocyanates 6 Changing Materials 7 ES 8 Before Installing the Kit es 8 Install the Frame 8 HS U N cet esate tee 10 Related Manuals Manual No Description 3A2800 PD2K Proportioner Repair Parts Manual Manual Systems 332457 PD2K Proportioner Installation Manual 332562 PD2K Proportioner Operation Manual Manual Systems
16. ON 3 FLOWRATE ANALOG IN 4 FLOWRATE ANALOG COMVON4 UNUSED Boo AS01JS QUN UNUSED UNUSED UNUSED CABLE SE ADVANCED LIGHT DISPLAY MODULE TOWER 24E451 15X472 UBWNE 12345678 9 10 I1 22 13 14 15 16 17 18 19 20 2122 23 24 25 1 2 3 4 5 6 7 8 9 10 11 22 13 14 15 16 17 18 19 20 2122 23 24 25 121003 25 PIN D SUB CABLE 161659 12345678 91011 D B 1415 16 1 18 19 20 2122 23 24 52 12345678 9 1011213 1415 16 1 18 19 20 212 23 2225 BREAKOUT MODULE PUMP 4 24N527 5 ERN D 5 a 2 Q WIRE HARNESS 25 2z WRE HARNESS 25 2 PUMP 3 TR 5 QE m PUMP 4 eg 5 585 GEO E amp grag za SEE DETAILAOR B zs 5 g zu 28 SEE DETAILAORB zs 5 g zu 28 OS amp 0557 amp UOu amp rt HOU amp N IN Bi VAN SON SON n n PUMP 3 g PUMP 4 EITHER 239716 5 8 0 zB Wu GRND SCREW TWISTED PAIR CABLE 16W159 TWSTED PAIR CABLE 16W159 Figure 24 Electrical Schematic Sheet 2 Part 2 CONTINUED ON THE NEXT PAGE 332456B 23 Electrical Schematics FROM CAN IS BOARD 24 485 ON PAGE 2 CABLE 15V206 12345 COLOR CHANGE TMANIIE MODULE 1 MANIFOLD __ COLORS Y IFOLD FLUSH COM lTHUS 2H AN Due COLOR 1
17. OPEN O Figure 15 Tubing Connections at Solenoid Manifold to Pump Inlet Manifold a Connect green tubing G from the UP OPEN fitting to the 90 tube fitting on the side of the INLET UP dosing valve b Connect red tubing R from the UP CLOSED fitting to the 90 tube fitting on the end of the INLET UP dosing valve c Connect green tubing G from the DOWN OPEN fitting to the 90 tube fitting on the side of the INLET DOWN dosing valve d Connect red tubing R from the DOWN CLOSED fitting to the 90 tube fitting on the end of the INLET DOWN dosing valve 78 ti21943a Figure 16 Inlet Manifold Tubing Connections On the side of the solenoid manifold are four ports with 90 tube fittings not shown UP OPEN UP CLOSED DOWN OPEN and DOWN CLOSED These ports provide air to open and close the 5 outlet dosing valves ti21940a Ss 21 Figure 17 Tubing Connections at Solenoid Manifold to Pump Outlet Manifold a Connect green tubing G from the UP OPEN fitting to the 90 tube fitting on the side of the OUTLET UP dosing valve b Connect red tubing R from the UP CLOSED fitting to the 90 tube fitting on the end of the OUTLET UP dosing valve ti21942a Figure 18 Outlet Manifold Tubing Connections 332456B Repair c Connect green tubing G from the DOWN Table 1 Dose Val
18. applied too thick Read material manufacturer s warnings and material MSDS 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 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 crystallization varies depending on the blend of ISO the humidity
19. bstitution 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
20. et fitting S 2 Connect a 1 4 npt f fluid outlet hose from the pump s fluid outlet fitting to the gun s fluid supply ti22345a Figure 5 Pump Fluid Connections 12 332456B Electrical Connections NOTICE To avoid electrical component damage remove all system power before plugging any connectors NOTE See the Electrical Schematics page 21 1 Verify that electrical power is removed from the system 2 Remove the cover from the PD2K electrical control box 3 Remove the knockout K from the side of the electrical control box 4 Thread the cable into the electrical control box and connect to the appropriate connection port on the enhanced fluid control module Pump 3 to P3 and Pump 4 to P4 Installation ti22349a Figure 6 Install Grommet in Electrical Control Box ti22347a Figure 7 Enhanced Fluid Control Module Connection Points 332456B 13 Installation 14 The PD2K fluid panel cover was previously removed in Air Connections page 11 Thread the 2 wire cable 22 through the grommet 42 on the bottom of the fluid panel and up into the electrical box through an existing grommet and the wireway Connect the cable 22 to the appropriate terminals on the top of the 48 Vdc power supply P3 for pump 3 P4 for pump 4 red wire to terminal black wire to terminal 52580201 ti22346a Figure 8 48 Vdc Power Supply Connection Points
21. fy 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 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 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 protective equipment including chemically impermeable gloves boots aprons and goggles is also required for everyone in the work area Material Self ignition Some materials may become self igniting if
22. h pressure for Kit 24R971 see manual 332339 BRACKET mounting pump GROMMET dual cable COVER FRAME SCREW cap socket head 1 4 20 x 3 8 in 10 mm SCREW cap hex head 3 8 16 x 7 8 in 22 mm SCREW cap hex head 3 8 16 x 3 75 in 95 mm Qty 1 Ref 18 19 22 25 27 30 31 32 33 34 35 36 37 41 42 46 24P684 24P685 101550 105209 114231 115287 16X048 Description NUT lock 3 8 16 PLUG tube square CABLE 2 wire WIRE HARNESS for Kits 24R968 and 24R970 WIRE HARNESS for Kits 24R969 and 24R971 TIE WRAP not shown SCREW cap socket head 1 4 20 x 1 2 in 13 mm SCREW cap socket head 10 32 x 7 8 in 22 mm NUT lock 10 32 TUBE nylon red for control air to turn valves off 5 32 in 4 mm OD x 18 in 457 mm TUBE nylon green for control air to turn valves on 5 32 in 4 mm OD x 18 in 457 mm TUBE polyethylene 1 4 in 6 mm OD x 6 ft 1 83 m Y FITTING 1 4 in 6 mm OD tubing SCREW cap hex head 3 8 16 x 2 75 in 70 mm LABEL notice GROMMET WASHER 3 8 332456B gt gt Ref 73 73a 73b 13C Part 241302 24U617 332456B Description Qty KIT cup TSL 1 includes items 73a 73e BRACKET 1 KIT barbed fittings 1 includes o rings package of 12 TUBE polyurethane 1 1 4 in 6 mm OD 10 ft 3 05 m cut to fit Pump Expansion Kit Parts Ref Part
23. he work area 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 Do not spray without tip guard and trigger guard installed Engage trigger lock when not spraying Do not point gun at anyone or at any part of the body MPa ber PS Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Follow the Pressure Relief Procedure when you stop spraying dispensing and before cleaning checking or servicing equipment Tighten all fluid connections before operating the equipment Gheck hoses and couplings daily Replace worn or damaged parts immediately 4 332456B A MPa bar PSI MPa bar PSI 332456B Warnings 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 TOXIC FLUID OR FUMES Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed Read MSDSs to know the specific hazards of the fluids you are using Store hazardo
24. latest information about Graco products visit www graco com 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 For patent information see www graco com patents Original Instructions This manual contains English MM 332456 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2013 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revised December 2013
25. nding the Pump Expansion Kit that the main PD2K unit is connected to 332456B 15 Installation Complete the Installation 1 Install the cover 12 on the expansion kit using the screw 37 and nut 18 MBSA ti22353a Figure 10 Install Expansion Kit Cover 2 Restore electrical power to the PD2K 16 Turn on the control box power switch Press and navigate to System Screen 1 on the Advanced Display Module Change the number of Color Pumps and Catalyst Pumps as needed based on the kit installation 08 10 13 23 18 Advanced Recipe Standby Active Errors Diagnostic Color Pumps 3 Catalyst Pumps 1 Mon Mix Pressure Solvent Meter X solvent K Factor 0 021 ce pulse 2 Gun Flush Figure 11 System Screen 1 332456B 5 Goto the Pump Screens The menu bar at the top of the screen will now show separate tabs for the added pump s 3 and 4 Each pump has three screens Enter the required information as explained in the PD2K Operation Manual NOTE At a minimum you must enter the Pump Size on Pump Screen 1 and transducer calibration data Outlet Offset Factor and Outlet Sensitivity Factor on Pump Screen 2 see your PD2K Operation Manual Also create a recipe using the new material number which can be found on Pump Screen 1 under Available Colors or Catalysts 08 10 13 23 31 Pump 2 Purp 4 Standby r 1 Active Errors
26. t the TSL cup fittings to the fittings on the pump and valves TSL is gravity fed from the cup to the pump and valves position the fittings and tubing to prevent kinks and enable the TSL to flow freely Fill the cup with TSL 332456B Air Connections NOTE A 6 ft 1 83 m length of 1 4 in 6 mm OD polyethylene tubing 35 is supplied with the kit to supply air to the expansion pump s solenoid manifold 3 1 See the PD2K Repair Parts Manual Remove the PD2K fluid panel cover to expose the air supply tubing to the two existing solenoid manifolds Cut the air supply tubing upstream of the Y fitting Install the Y fitting 36 supplied in the kit as shown to restore the air supply to the two existing solenoid manifolds 35 36 La ti22354a Figure 4 Supplying Air to the Expansion Pump solenoid Manifold TT yy 190 3324568 p b Installation Connect the supplied 1 4 in 6 mm OD tubing 35 between the open branch of the Y fitting 36 and the air inlet of the solenoid manifold 3 This supplies air to the expansion pump solenoid manifold as shown in the detail of the illustration NOTE If you are installing a fourth pump make a second splice in the main solenoid air supply line and plumb as explained above EN TI 11 Installation Fluid Connections 1 Connect a 1 4 npt f fluid hose from the fluid source to the pump s fluid inl
27. the pre installed D SUB Cable 8 is securely attached to connection port 1 on the pump control module 5 Connect the pump s outlet pressure transducer T to port 5 If an inlet pressure transducer accessory is used connect it to port 4 Install the valve wiring V in port 7 See Electrical Schematics page 21 332456B Electrical Schematics Electrical Schematics NOTE 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 for a list of cable options 2 POSITION SWITCH 16U725 CABLE 161658 16 446 TERMINAL BLOCK 114095 TERMINAL BLOCKS WTH FUSES ce Noa 15 206 15 206 4 MODULE 4 LA MODULE 1 24N935 A TAL 5 5 CABLE 15 206 15 206 Am POVER IN GUN TRIGGER INPUTS mm FAN GCA ___ SOLENOID 121324 d 2 lt MODULE PRESSURE SWITCH IPOS 121323 PUMP INLET 24N913 SOLVENT FLOW SWITCH 120278 BARRIER SPLITTER BOAR DT el SOLVENT METER 258718 CABLE ADVANCED DISPLAY MODULE 121003 24451 TRANSDUCER PUMP OUTLET TRANSDUCER 16P289 16P290 PUMP V P FOR FLUID REG PUMP V P FOR FLUID REG BREAKOUT MODULE PUMP 1 BREAKOUT MODULE 2 Sa Slo ia
28. us fluid in approved containers and dispose of it according to applicable guidelines Always wear chemically impermeable gloves when spraying dispensing or cleaning equipment 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 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 modi
29. ve Actuation OPEN fitting to the 90 tube fitting on the side of the OUTLET DOWN dosing valve Pump Up Inlet Stroke Valve d Connect red tubing R from the DOWN CLOSED fitting to the 90 tube fitting on the end of the OUTLET DOWN dosing valve 3 Repeat these steps for each pump in your system see the following table to understand the relationship between pump stroke and dose valve actuation UP ex DOWN ex PIN 2 oe DX PIN 6 INLET DOWN OUTLET DOWN Figure 19 Pump Tubing Schematic 332456B 19 Repair Replace Pump Control Module If the pump control module needs replacement install a new module as follows NOTICE To avoid electrical component damage remove all system power before plugging any connectors NOTE See the Electrical Schematics page 21 1 Connect the motor cable connectors 25 to connection ports 2 and 3 on the pump control module 5 and to the pump motor N NOTE The wire harness has two cables one for the motor control and the other for encoder feedback The connectors are keyed differently to ensure correct installation Attach the two ground wires to the ground screw on the pump motor N ti21743a Figure 20 Pump Control Module Connection Points 20 ti22356a Figure 21 Pump Control Module Connections Connect the 2 cable 22 to connection port 8 on the pump control module 5 red wire to pin 1 and black wire to pin 2 Ensure that
30. you stop spraying and before cleaning checking or servicing the equipment 1 Flush the system as explained in your PD2K Operation Manual Follow the Pressure Relief Procedure in your PD2K manual 2 Close the main air shutoff valve on the air supply line 3 Remove electrical power from the system Install the Frame 1 Follow the steps in Before Installing the Kit page 8 2 Install the frame 13 to the upright of the PD2K stand A using three screws 16 and nuts 18 3 Install the back panel bracket assembly B in the outermost position on the frame 13 to allow clearance for the color change manifold C Fasten the panel to the frame 13 using four screws 15 and nuts 18 Install the top screws from the front and the bottom screws from the back NOTE The illustration shows a resin 70 pump expansion kit being installed on the left color side of the PD2K proportioner The pump control module and dual grommet 11 are preassembled at the factory so the cable 8 is facing to the right allowing easier access to connections inside the PD2K electrical control box D Install a catalyst 35cc pump expansion kit on the right side of the proportioner with the pump control module and dual grommet 11 preassembled in the opposite direction so the cable 8 is facing to the left 332456B Installation gt _ 9 TE OO JIN Z N N O 28 2 cu X

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