Graco 332455F User's Manual
Contents
1. 3 FLOWRATE ANALOG COMMON 1 4 COMMON2 24N913 B 1 E 3 7 9 12345678 9101 12 13 M 15 16 17 18 19 20 2122 23 24 25 123456 78 9 10 12 13 14 15 16 17 18 19 20 2122232425 7 IIIIIIIIIIIIIIIIIIIIIIII 200950549 P 1 BREAKOUT MODULE PUMP 3 24N527 1 BREAKOUT MODULE PUMP 4 24527 2 zi Na 8 the 18 s 3 2 34 9197 AS III _ lt i Il ME WIRE HARNESS amp 55 823 588 WARE HARNESS 5 55 55 BHB 405 3 8 ri E ig dn E 8 H 5 Gs ig 985 IL 888 28 1 i manran fs2. CONTINUED ON PAGE 3 CONTINUED ON PAGE 3 a 3110 lt AE 1 m 48 48 3 8 8 1 2 GE GCAMODULE 8 12345 12345 E 8 2 CANISBOARD 1 1 lt EFCM 4 Danni 3 LIO 12345 12345 24N913 1 04 EB Havoc 1 5 22 INTERFACE 5 SEG SOLVENT CUTOFF m4 8 5 10 p 2 ALII 248192 freien 12313973 331LBABEIBSZZZZAZ 12345678 910 111213 11516 17181920 2122232415 BR 258718 55 5 LIIIIIIIIIIIIIIIIIIIIII IIIIIIIIIIII III III II I II REDWRE 065161 uj BLACK WRE 065159 Tr 3 8 25 PIN D SUB CABLE De alts 167659 Aas 4 LEL CELL Ges BREAKOUT MODULE PUMP 1 24N527 1 BREAKOUT MODULE PUMP 2 245527 1 2 3 4 5 6 7 8 2 3 4 5 6 7 8 1 4 13 AIAX a l i III LI NL n j B ENCCCERNDTOR A FR 5 ENCODERMOTOR A d POWER SUPPLY 9
3. Uses JS EE Jas e D34 d 5 m D33 n m u29 0247 B20 D31 1 E zi Mc i M RO 3 029 E m 1 sa E ran J9 1 J15 1 m 8 zm D39 D41 T age M ELT D32 ED P Ji U 035 Li D38 D27 4 9 p E 164 MI pe NL 14 1 8 D37 i 37 D30 IR 045 028 grs u20 u25 ce D46 24 Lia e I I I malam um e Vo 52 56 X 5 ugumum Pi E imi cmo DS m 244 mU D8 RIS Bia GL Mam D10 Rit R5 R3 e EN 72 575 mm EM EN EM run F1 e ojd Tje e e La NEL ti22013a J7 J11 Figure 15 Color Change Board 32 332455F Troubleshooting Color Change Board Diagnostics Component or Description Diagnosis Indicator 08 LED green Blinks heartbeat during normal operation LED green Turns on when power is supplied to the board D10 LED yellow Turns on when board is communicating with electronic control
4. 12345 COLOR CHANGE gt D MODULE 1 MANIFOLD Ta 1 COLORS i MANIFOLD FLUSH AD imua 34 GM DUMP COLOR 1 AA Hijs 9 jq COOR2 gt SAX 2 m 109082 axx 11 1 HDC CVC 3 2 2 COM COLOR3 VDC H2VDC caora I AM 4 5 116 coon4 COLORS ME He DC coLors 1 1 coors 2 2L COM lcoon6 COLOR 7 al J10 com COLOR7 COLORS aT XX He 0 ME COLORS Ie 17345 a 12345 COLOR CATALYST CHANGE CHANGE MANIFOI D MODULE 2 Im MODULE 5 MANFOLD 1 Caos i MANFOLD MANFOLD i CNAYS anne MANFOLD FLUSH 45 9THRUI9 2 GREC DUMP FLUSH 2 INDC 3 cm AMOC 3 3 COLOR 9 AMC 3J8 9121 RI caog CATALYST1 7 5 Hal 8 194 COLOR 10 AMT H 2 BOC Rf 1 CoLor 10 CATALYST 2 E T 1 2VDC 2VDC 1 1 2VDC 2 2 I COLOR 11 caTaLysT3 L ADM 12 2 com coor 2 L 1 PNN 4 15 1 CON
5. DUMP CATALYST 1 CATALYST 2 CATALYST 3 CATALYST 4 DUMP COLOR 25 COLOR 26 COLOR 27 COLOR 28 COLOR 29 COLOR 30 37 Electrical Schematics FLUSH CATALYST CATALYST 4 FLUSH CATALYST 1 CATALYST 2 MANIFOLD UNUSED OUBWNE OUBWNE CATALYST CHANGE MODULE 6 CATALYST 3 THRU 4 J8 19 JD 16 J14 J10 12345 OAUBWNE 54321 CATALYST CHANGE MODULE 5 CATALYST 1THRU2 J8 OUBWNE ODUBWNE OUBWNE 11 OUBWNE OUBWNE 25THRU 32 Figure 20 Electrical Schematic Sheet 3 Alternate Configuration for Catalyst Change Control CONTINUED ON THE NEXT PAGE 38 DUMP CATALYST 3 CATALYST 4 DUMP CATALYST 1 CATALYST 2 332455F FROM IS BOARD 24 485 ON PAGE 2
6. 74 332455F Related Manuals Related Manuals Manual Description 3A2800 PD2K Proportioner Repair Parts Manual Manual Systems 332457 PD2K Proportioner Installation Manual Manual Systems Manual No 332339 Pump Repair Parts Manual 332454 Color Change Valve Repair Parts Manual 332456 3rd and 4th Pump Kits Instructions Parts Manual 332562 PD2K Proportioner Operation Manual Manual Systems 3A2801 Mix Manifold Instructions Parts Manual 332455F 3 Models Models Non Intrinsically Safe Kits See the module identification label for product part number maximum air working pressure and approval information and certification ProMix PD2K COLOR CHANGE CONTROL PART NO SERIES SERIAL MFG YR MAX AIR WPR 7 7 100 MPa bar PSI GRACO INC P O Box 1441 7 Minneapolis MN eraco 55440 U S A Artwork No 294057 Rev B Figure 1 Non Intrinsically Safe Color Change Control Module Label Kit No Series Kit Description Maximum Air Working Pressure Maximum Fluid Working Control Module Pressure Valves Low Pressure Non Circulating Color Change Kits 24R915 300 psi 2 068 MPa 20 68 bar 24R916 300 psi 2 068 MPa 20 68 bar 24R917 300 psi 2 068 MPa 20 68 bar 24R918 300 psi 2 068 MPa 20 68 bar Low Pressure Circulating Color Change Kits 24R921 300 psi 2 068 MPa 20 68 bar 4 332455F Models Control Module Pressure Valves High Pressure Non Cir
7. Electrical Schematics NON HAZARDOUS LOCATION HAZARDOUS LOCATION 2345 COLOR _ CHANGE _ MANIFOLD MODULE 7 MANIFOLD COLOR FLUSH UNDC 1 m 1 1 aC CATALYST FLUSH LE COM 2 33THRU 40 2 CCM le HMC COLOR 1 gt MC 1J8 19 am lt CATALYST1 COLOR2 z AND 2 0 Me CATALYST 2 1 1 COLOR 3 2 2H cov X CATALYST 3 COLOR 4 4 15 J16 4 de TDI CATALYST 4 COLOR 5 2 SN He COLOR 9 2VLC 1 1 caone COM 2 2 N COLOR 10 COLOR 7 e COM 4 J 14 J 10 5 COLOR 11 COLOR8 SAU TR COLOR 12 12345 lt 9 13 2345 COLOR CHANGE J MANFOLD MANIFOLD COLOR 13
8. 22 332455F 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 75 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 Screw the tee 122 onto the dump valve fitting of the outlet manifold stack 2 Assemble the two nipples 121 to the back pressure regulator 120 Screw the regulator assembly into the tee 122 as shown 3 Install the gauge 123 in the open port of the tee 122 4 Connecta 1 4 npt f dump line to the downward facing nipple 121 5 Connectthe fluid supply lines to the valves See Connect the Fluid Lines page 24 332455F Installation ti22620a Figure 12 Install Back Pressure Regulator at Dump Valve of Outlet Stack Connect the Valve Air Lines 1 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 the color control module as a guide See Setup the Modules page 12 2 Repeat for the outlet valves 23 Installation Connect the
9. e 415 1164 ar 266 6 dom N cotor 13 UNUSED 16 6 UNUSED AADC 1 1 UNUSED 1 17 UNUSED maus 8 SS coni I COLOR 16 UNUSED 6 6 UNUSED 12345 12345 12345 12345 COLOR COR CHANGE HANGE TVANEA D MODULE 3 DO 31 MODULE 4 MANIFOLD MANIFOLD MANIFOLD MANIFOLD j Colors 1 GAB MX CL 1 6005 i game FLUSH COM 2 17THRU24 2 COM DUMP FLUSH COM 2 25THRU2 2 COM 17 sane i J8 193 dM CLC 2 gt 9MX 92 mM COLOR18 FAT ZEA COLOR 18 COLOR 26 gt AMT 2 A lt JA 6 AADC 1 1 H2VDC 1 1 2VDC COLOR 19 COM 2 2H com COLOR 19 COLOR 27 COM 2 COLOR 20 AM 115 1164 COM COLOR 20 COLOR 28 426 2 5 16 4 aye COLOR 21 CI ME 81 43 i COLOR 21 COLOR 29 SS Ha u_u 1 10 4X4NDC 1 1 aM 1 COLOR22 f 2 2 CM COLOR22 COLOR 30 2 2 2 0M 00 IX COLOR 23 __ HAM 4 1 104 COM E UNUSED 2 14 0 4 UN SED COLOR 24 mi 9455 He ei CN COLOR 24 UNUSED 6 6 VM566 mL 54321 ca 7 12345 J De 15V206 Figure 19 Electrical Schematic Sheet 3 May be unused in some configurations CONTINUED ON THE NEXT PAGE 332455F
10. gt 2 5 ft 0 76 m ptfe detail drawing 1 KIT module control 112564 GAUGE pressure fluid used 109 15V206 CABLE CAN 5 pin female 1 on high pressure kits only see 10 ft 3 05 m detail drawing 16V819 GROMMET cable 1 See the following tables for the part number used 111 24U236 TOOL repair valve not 1 in your color change kit shown 114 TOOL installation valve not 1 shown Low Pressure 15 Kits Kit Description Standard Valve Control Module Tool 114 Tube Length Manifold Kits Kit 108 see 115 102 see Non IS Color Low Pressure Change Control Valve Manifold Modules page Kits page 49 for 60 for parts all available kits Low Pressure Non Circulating Color Change Kits 24R915 2 color or 2 241458 241557 24 239 60 ft 18 3 m catalyst o 120 121 122 123 24R916 4 color or 4 241460 241558 24 239 120 ft 36 6 m catalyst 24R917 241462 241559 240239 210 ft 64 05 248918 241464 241560 240239 360 109 8 Low Pressure Circulating Color Change Kits 332455F 45 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 55 for 60 for parts all available kits High Pressure Non Circulating Color Change Kits 24R959 2 color or 2 24T648 24T557 24U240 60 ft
11. 4 1 ADC COLOR 22 COM 2 41 THRU 48 2 COM N HAVOC COLOR 14 AMT 418 19 ini lt COLOR 23 COLOR 15 a ME 2 A ol dance Tr COLOR 24 1 1 COLOR 16 COM 2 2 COLOR 25 COLOR 17 I 4 15 116 4 20 TR coon26 COLOR 18 ME Ha COLOR 27 1 1 19 2 2 REND TN COLOR 28 COLOR 20 4 0 ADEN COLOR 29 COLOR 21 HAD He eo OMS COLOR 30 5 3 21 45 4 54321 BOOTHCONTROL 24M731 Figure 21 Electrical Schematic Sheet 3 Hazardous Location 332455F 39 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 34 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 A M12 CAN Cables for Non Hazardous Locations Only A Alternates for Communication Module 24R910 for Non Hazardous Locations Only Module Part No Module Part No 15V759 15V761 15V760 15V762 40 A CAN Cables for Non Hazardous Locations Only AN 25 Pin D SUB Cables for Non Hazardous Locations Only 16T659 2 5 0 8 16V659 6 0 1 8 A Alternates for Color Change Modules by Part Number Factory Configuration for Non Hazardous Locations Only Alternates for Color Change Modules by Part Number Factory Configuration for Hazardous Locati
12. D27 D39 LED green Turn on when a signal is sent to actuate the 041 043 046 related solenoid valve 332455F 33 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 page 40 for a list of cable options 2 r 065161 065159 CABLE 2 CABLE RELAY 5 T 15 26 2POSITION OWER MODUI 248257 COMMINCATON l lt lt s lt s lt CABLE 24R910 F
13. ME 5 x 3 PW ms 3 gs gu NB SEE DETAILAORB Zo 5 52558 28 SEE DETAILAOR za 5 58 I 58 I HOW Eis da 3 li nos Ec 3 lol x AS GO 55 GO 9589 B BG mn 28 CUNT v L N BEE FILTER TWISTED PAIR CABLE 16159 n amp 16 446 1 TWISTED PAIR CABLE 16159 L N DETAILA LOW PRESSURE DETAIL B HGH PRESSURE PUMPS 24M706 24 714 PUMPS 24M707 24M715 L N GRND BREAKOUT MODULE BREAKOUT MODULE TERMNAL 24N527 24N527 BLOCK 3 2 114095 L NGRND MEN CRANFOL 25155 a 55 PUMP ENCODER AND MOTOR ra PUMP ENCODER AND MOTOR Ed 16P037 16P036 Figure 17 Electrical Schematic Sheet 2 Part 1 CONTINUED ON THE NEXT PAGE 332455F 35 Electrical Schematics GUN TRIGGER INPUTS SIG 2 COM e 3 a 5 SIG 5 com 6 7 SIG E TA __ e 107 GFB PRESSURE SWITCH 121323 GCAMODULE m eas EFCM
14. h o r h 3 e fo 9 2 2 avass 5 ho fo t Je r h 3 2 far o 190 209496 6 fe p fs a 242975 12 u o per fi 3 2 lo 240208 2 2 h u Je r 3 Jar gt ho 20490 7 a o ra fe i 20 a o pe p pep r p p s 3 hs fe o c 24505 pepe pep r r 3 as he o p p 240502 s p re fro fas 7 3 245035 ir o he fio Ji p p gt far he p 24504 o po ps p po r 3 so fs fo 2 2 240506 o m m o po ti a a foo fis fo p 240506 22 p p p p p 3 43 fis p 24507 2 21 Jo 22 2 Ji p 3 45 as 22 rs lo fo 240508 2 m 22 p 24 io ar fos fo 2 24509 t 29 Jo p fis 3 pe pepe p o p peso ps 24 p ps u p 3 15 ot 2 2 12 eene 26 ps p ps fra i o 59 ps e Jo p 245124 ps 20 p ps ps p fe ps os 7 n o 2 12 24053 ps pr o pe ps p 5 sr s ps ar fo Ji fo 24054 o ps p o fre i p p 2 arsts 16 so 29 o o pe 3 lor or 2 p p p o 2516 o 5 Jos ze do 2 332455F 53 Parts Notes 54 332455F Parts High Pressure Valve Manif
15. o T fo T 12 N 3324557 51 Parts C L oO O re N N N N a CV o CC I IL C C2 CI CV CVI CVI CV CVI CV CI OO CI 5 IL CC L oO C N CI CV CV CVI O NE CI 5 CC L C C N lt CI CV CI O em CI zt bus lt O CI CV CV CV a 5 a 241482 evaso s as Jo 2s D 1s o 20 1 20 16 nas 15 ao o 20 1s r 332455F 52 Parts Low Pressure Circulating Valve Manifold Kit Part Quantities 4 2 4 5 6 II e o a e 2 r Jo 2 2 h 5 2 F 5 2 2 2 4 3 0 4 3 Ji 9 9 4 5 fo fo fo 2 h 6 h nts mme 5 o 6 Ji h 3 o 3 6 3 fo mme h 5 C 3 e hs r 6 90 esp 7 fe h 3 IV Jo Jo h mme
16. 1 3 ss 5 27 7 0 2 2 h 241703 4 28 27 28 js 1 3 57 57 2e fo jo 1 241704 15 0 28 1 fso 16 3 99 so 29 7 1 2 2 h 241705 15 30 29 o 30 16 3 jet jet jso 7 t 0 jo 241706 2 so 1 jr 1 fs Jes ja 2 2 h 332455F 59 60 Parts Color Change Control Module Kits Non IS Color Change Control Modules 304 311 332 324 315 318 319 302 315 307 312 310 321 322 sni Ole e e 0 oda 305 309 309 e e 308 0 gt 0 2 8 gt 0 L1 U LI 303 302a ti21639a 332455F Ref Part Description N No 1 301 6 855 PANEL Ref Part Description Qty No No 302 24T566 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 24T563 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 241565 PLUG 5 8 32 includes item 314 314 143418 O RING buna N 315 100139 PLUG pipe 1 8 Non IS Control Module Part Quantities 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
17. N N N N N E E B N N E N N gt ae N 332455F 58 Parts High Pressure Circulating Valve Manifold Kit Part Quantities e RE P P Tu Numbers 1 2 3 k lb 6 f j _ 4 prem Ji 2 1 0 p p n 241678 2 2 14 3 241079 2 o 3 24680 6 n p 241681 3 241682 a 8 h 5 hh 24068 4 7 s hh 241684 5 10 a h 10 t n 1 241685 5 to 9 to fe t h 2 9 2 241687 e 2 4 Jo 12 y jh h fs 25 25 241688 7 4 112 ji t h 2 2 241689 7 14 M3 o 14 h 29 29 bee s pe h pe S p IC F Jar Jar pe 2 241691 8 16 15 so 16 9 1 1 ss 16 4 247692 18 116 fs ho h 1 35 135 17 4 EE 2 10 2 238090 3 241693 9 fis 17 jo Jor 97 He la 1 241694 20 18 t 20 t 1 3 9 Mo 5 0 2 241695 0 22 19 o f 1 3 4 41 20 5 fo fo 241696 4 2 20 t 2 M2 j 1 3 ja 43 21 5 t 2 h 241697 2 21 0 2 M2 j h 3 45 45 22 5 h 0 jo 1 241698 12 24 22 1 3 7 Jar 23 6 0 2 h 241699 2 24 23 0 24 M3 9 ao 24 e 0 0 jo 241700 26 4 t 26 M4 1 3 st st 25 6 t P2 2 1 24 701 26 25 o 26 14 3 53 53 26 Jo I 241702 4 28 26 i 28 M5
18. el n T i4 8 5 8 3 167658 568 589 565 uerum POWER 48410 POWER SUPPLY lt E B 282 B RES 06 49 16820 SB 8 8 8 o 9 8 5 5 m CABLE 3 COMMUNICATION CABLE CABLE 16078 MODULE A 2 15v206 A 15V206 2 15V206 lt 24R910 TERMINAL BLOCK 114088 TERMINAL BLOCKS WITH FUSES E 1 5 GUNTRIGGER INPUTS POWERIN 3 2 2 2 lt 167072 119159 119159 CAN e IS BOARD FAN ST SOLENOID 121324 i 24P658 24P658 MODULE PRESSURE SWITCH TENOR ae 8 POPE 2 24N913 SOLVENT FLOW SWITCH 120278 16 289 16P290 16 289 16 290 SPLITTER BARRIER PUMP OUTLET LI PUMP OUTLET uj 16P243 Gan SOLVENT METER 258718 POR ER n 8 2 8 A CABLE ADVANCED LIGHT 21003 9272 3 gt 8 0 99 92 0 98 aa zl zl zl z 98 paz 988 ala 5 5 n FLOWSENSOR FLOWSENSOR COLOR CHANGE MODULE 7 EIER u lt 239716 258718 239716 258718 amp k SS g 16M510 16V519 164510 164519 CABLE 167659 CABLE 167659 2 g COLOR CHANGE MODULE 8 N CABLE 061659 248219 s5 CABLE 161659 8 A FAN FAN A 16 429 5 240658 240658 lt BOOTH CONTROL 24M731 16P036 16P037 VRE HARNESS m NRE HARNESS 240684 240685 240684 240685 amp mE HAZARDO
19. ia peu I gt Spem 0 Low Pressure Valve Manifolds 1 80 in 0 48 in 1 50 in 0 64 in 5 03 in 3 35 in 0 24 in 0 32 in 0 28 in 1 4 46 mm 12 mm 38 mm 16 mm 128 85 mm 6 mm 8mm 7 mm npt m mm High Pressure Valve Manifolds 2 00 in 0 61 in 1 66 in 0 61 in 5 4 3 35 in 0 28 in 1 4 51 mm 15 mm 42 mm 15 mm 137 85 mm 7 mm npt m mm 332455F 67 Dimensions 3 84 in 98 11 44 in 291 0 312 in 8 mm mm mm diameter 1 0 O 0 ti22181a Figure 28 Manifold Mounting Bracket 68 332455F Weights Low Pressure Non Circulating Valve Manifold Kits 241457 em 24T474 24T475 24T476 24T477 24T478 24T479 24T480 24T481 24T482 24T483 24T484 24T485 24T486 14 46 6558 14 44 6550 15 35 6964 332455F Weights Low Pressure Circulating Valve Manifold Kits 241487 24 505 24 514 241515 241516 69 Weights High Pressure Non Circulating Valve Manifold Kits High Pressure Circulating Valve Manifold Kits Kit No Kit No N N NIN C1 C1 C NI I O O NI OQ O gt C C C2 2 Ns I I O C2 gt NIOJN N N 1 C1 C1 I C C2 NIojo cC O O o C
20. includes item 2 24T582 VALVE for circulating kits includes item 2 24T583 VALVE for non circulating acid compatible kits includes item 2 6 PLATE ens manto 10 111820 SCREW cap socket head 10 24 x 0 75 in 19 mm High Pressure Non Circulating Valve Manifold Kit Part Quantities 1 111328 CONNECTOR tube 10 32 m x 5 32 in 4 mm OD tube 15 24T729 ROD connecting 3 290 in 84 mm 16 24T728 ROD connecting 1 645 in 42 mm 557716 PLUG 7 16 20 19 104644 PLUG screw 10 32 x 0 156 in 4 mm 22 24T581 VALVE for circulating kits includes item 2 See the following tables to determine the quantity of each part in your valve manifold kit Kit No Reference Numbers 1 2 7 fhs 14 15 46 19 247647 t 2 2 o 2 2 Jt M s 2 jo 1 fo fo 247648 2 t 1 1 s j4 4 4 jo fe 247649 2 1 1 3 5 5 1 fo fo 247650 3 6 5 1 1 1 fe 5 1 241651 6 o o h h 7 7 1 5 t t a 8 8 7 247608 4 o js t t o o 247654 5 t to e 4 1 fio 10 Jo 247655 s 10 1 o to je fa 4 1 10 2416 12 11 fa t t a 12 12 11 2467 6 12 12 o 12 7 1 1 13 13 12 247658 7 14 13 1 1
21. 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 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 332455 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2013 Gr
22. 115671 FITTING connector 1 8 npt m x 1 4 in 6 mm OD tube 112698 ELBOW 1 8 npt m x 1 4 in 6 mm OD tube 31 31 2 8 9 590332 TUBE polyethylene 1 4 in 6 1 mm OD 598095 TUBE nylon 5 32 in 4 mm 1 OD m sere 324 ELBOW connector 10 32 m x 5 32 in 4 mm OD tube 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 Solenoid 310 quantity used in your control module kit 6 Position Connector Kit No Kit Description 305 24T571 2 color and 2 2 catalyst 24T572 4 color and 4 10 2 catalyst 24T573 6 color and 14 2 catalyst 24T574 8 color and 18 4 36 18 2 catalyst 332455F Plug 313 Connector Fitting 324 Tie Strap 321 Ee oue EE 63 Parts Expansion Kits Non IS Expansion Kits The following kits are available to add color valves in a non IS area See Install an Expansion Kit page 28 for instructions Low Pressure Expansion Kits 241443 One non circulating valve replaces a plug Includes valve solenoid fittings and tubing 24T444 One circulating valve replaces a plug Includes valve solenoid fittings and tubing 241445 Manifold with one non circulating valve In
23. 300 psi 2 068 MPa 20 68 bar 300 psi 2 068 MPa 20 68 bar 300 psi 2 068 MPa 20 68 bar 300 psi 2 068 MPa 20 68 bar Low Pressure Circulating Color Change Kits 300 psi 2 068 MPa 20 68 bar 300 psi 2 068 MPa 20 68 bar 300 psi 2 068 MPa 20 68 bar 300 psi 2 068 MPa 20 68 bar High Pressure Non Circulating Color Change Kits 1500 psi 10 34 MPa 103 4 bar 1500 psi 10 34 MPa 103 4 bar 1500 psi 10 34 MPa 103 4 bar 1500 psi 10 34 MPa 103 4 bar High Pressure Circulating Color Change Kits 241355 1500 psi 10 34 MPa 103 4 bar 24T343 24T344 24T345 24T346 24 347 24 348 24 349 24 350 24T351 241352 24T353 24T354 6 332455F 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 p
24. C6 I1 C gt C2 C2 C O O gt 241651 7154 241681 7167 241652 8861 241682 8876 241653 8980 241683 8997 241654 241684 241655 241685 241656 241686 241657 12631 241687 12656 241658 14338 241659 14457 241660 16163 241661 16282 241662 17989 241663 18108 241664 19814 241665 19933 241688 14365 241689 14486 241690 16195 241691 16316 241692 18024 241693 18145 241694 19854 241695 19975 241666 21640 24T667 21759 241668 23465 241669 241670 241671 241672 241673 600 241674 63 8 1 241675 241845 acid 5210 catalyzed 241846 acid 15 5 7036 catalyzed 70 332455F Non IS Color Change Control Modules e sem 332455F Weights Non IS Color Change Control Modules 71 Notes Notes 72 332455F 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 0 6 0 7 MPa 6 0 7 0 bar Viscosity range of fluid 20 5000 centipoise Fluid inlet size Fluid outlet size Air inlet size 5 32 in OD tube 4 mm OD tube Weights Wetted parts iii Valve manifold Valve 332455F 73 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco
25. 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 systems see Install the Back Pressure Regulator High Pressure Systems Only page 23 1 24 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 ti22182a Valve Manifold Stack Schematic 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 332455F 10 11 Connect a dedicated gun supply line for each color to the corresponding color valve fitting C1 C2 etc on the outlet color valve stack Connect the other end of this line to the A side of the mix manifold at the gun Connect the supply line for each catalyst to the corresponding catalyst valve fitting on the inle
26. Mount the first color control module as described in Mounting the Color Change Control Module page 17 108 ti22189a G Figure 8 Intrinsically Safe Cable Connections 20 3 Connect hazardous location cable to J7 on the color control module 108 ti22188a Figure 9 Cable Connectors J7 and J11 at IS Color Control Module 4 Remove the cover from the PD2K electrical control box Install the grommet G on the supplied cable C1 and 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 34 NON IS IF al Je J2 J1 4 nee IS ti21938a Figure 10 Detail of Isolation Board Cable Connections 332455F 5 Mounta second color control module as described in Mounting the Color Change Control Module page 17 Connect the supplied hazardous location cable C2 from 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 Valve Manifolds NOTE Always label the color connections to prevent cross connections Label the inlet
27. OFF as shown in the following table IS Control Module Switch Settings Control S5 S4 Module Module 7 ON Module 8 ON Use the following figure and tables to determine the solenoid valve assigned to each valve in the valve manifold ON ON ON S6 50 54 OFF OFF OFF 0 0 1 I S CC 2 Ha 4 5 ie j s 7 8 ovo i 9 n 9 0 2 Figure 4 IS Control Module 332455F ti22011a 15 Setup the Modules Solvent Solvent 52 s Catalyst 3 Catalyst 4 Colors Coloro Bo Color 26 i CHAME Color 27 Color 12 Color 29 Color 30 16 332455F 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 press
28. Troubleshooting MPa bar PSI NOTE Check all possible remedies before disassembling the system Color Change Solenoid Valves NOTE Refer to Electrical Schematics page 34 If the color change valves are not turning on or off correctly it could be caused one of the following Solution 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 32 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 Vdc 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
29. 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 Install the valves as follows a For a one valve kit remove the plug 4 and o ring 2 Install a new o ring 2 the valve 3 and retainer 5 using the valve installation tool See Replace a Color Valve page 41 For a manifold kit with one valve install the o ring 2 valve 3 and retainer 5 using the valve installation tool See Replace a Color Valve page 41 Install the plug 4 in the unused manifold port For a manifold kit with two valves install the o rings 2 valves 3 and retainers 5 using the valve installation tool See Replace a Color Valve page 41 Install the o ring s 12 and fluid fitting s 13 Connect fluid lines to the fittings Install the air fitting s 14 Connect the tubing from the solenoid valve s see step 3 to the fitting s Install the control module cover Return the unit to service 332455F Installation Install an Expansion Kit Low Pressure Valve Manifold Shown 17 619 Non Circulating Circulating ti21641a 332455F 29 Troubleshooting
30. circulation line is shut off The color is directed through the material A dosing pump and out to the gun to be mixed and sprayed as in normal operation 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 23 1 Connect all fluid lines as described in Connect Non Circulating Fluid Lines page 24 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 circulation 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 b Install a Y fitting D in the A side of the mix manifold F Install a fluid shutoff valve E in one branch of the Y fitting Connect a fluid 26 return line H to the shutoff valve to circulate the color back to the color supply A NOTE The fluid shutoff valve E must be closed when spraying to allow proper ratio mixing and flow from the gun G c Connect a dedicated gun supply line for each color to the corresponding color valve C1 C2 etc on the outlet color valve stack Connect the other end of this line
31. 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 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 ti22858a 103 SN Ts T 101 332455F Figure 11 Install the Valve Manifolds Installation 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 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 valves See Connectthe Valve Air Lines page 23 NOTE On high pressure systems see Install the Back Pressure Regulator High Pressure Systems Only page 23 Connect the fluid supply lines to the valves See Connect the Fluid Lines page 24 P 103 104 122079 21 Installation Notes
32. 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 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 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 8 332455F 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 ra
33. 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 17 Cem I 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 A 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 Plug 313 Tie Strap Ferrule Connector 321 322 Fitting 324 Kit 6 Position Description Connector E 36 Solenoid 332455F 61 Parts IS Color Change Control Modules 304 ti22012a 332455F 62 Ref Part Description No No 301 16U742 PANEL 302 24T566 BOARD circuit 302a 123690 FUSE 125 mA 112324 SCREW machine pan head 4 40 x 0 25 in 6 mm 24U567 COVER 303 304 305 119162 CONNECTOR 6 position 307 116343 SCREW ground M5 x 0 8 308 123691 HOLDER fuse 309 151636 MANIFOLD 310 121324 SOLENOID 311 16M00 SCREW machine serrated 7 head 10 32 x 0 5 in 13 mm 312 103833 SCREW machine pan head 10 32 x 0 375 in 10 mm 313 SCREW self sealing 4 40 x 0 25 in 6 mm 314 O RING buna N 315 PLUG pipe 1 8 npt 316 MUFFLER IS Control Module Part Quantities A 317
34. 109 8 m 24T654 48 332455F Valve Manifolds Low Pressure Valve Manifold Kits Non Circulating Valve Manifold Kits Kit No 241457 241458 241459 241460 24T461 24T462 241463 24T464 241465 241466 241467 241468 241469 24T470 24T471 24T472 24T473 24T474 24T475 24T476 24T477 24T478 24T479 24T480 24T481 24T482 24T483 24T484 24T485 24T486 KitNo Series ____ 2449 1 24487 ja 2445 A 240488 1 1 A 247460 ja 2 A 24400 ja 24741 24402 1 240499 A 240403 A 488 A 2444 1 2444 1 247465 Ja 24495 A 466 1 2449 24407 ja 24497 24409 1 240499 MT499 1 2440 1 247500 JA 2441 247501 2442 1 241800 A 24473 1 24808 A 2444 1 4 1 2445 1 2400 A 2446 1 46 JA 2447 1 2457 A 2448 a 24808 A 2449 1 24509 1 240480 A 244081 ja 1 1 2452 JA 240483 A 2453 da 2448 1 2454 24145 1 24115 Ja 24486 a 6 332455F Parts Circulating Valve Manifold Kits 241487 241488 241489 241490 241491 241492 241493 247494 247495 247496 247497 247498 241499 241500 241501 241502 241503 241504 241505 241506 241507 241508 241509 241510 241511 241512 241513 241514 241515 241516 49 Parts Valve Manifold Kit Parts Non Circulating Kits Circulat
35. 18 3 m catalyst 24R960 4 color or 4 24T650 24T558 24U240 120 ft 36 6 m catalyst 24R961 24T652 241559 241240 210 ft 64 05 m 24R962 24T654 24T560 24U240 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 46 332455F Parts IS Color Change Kits Ref Part Description Qty No No 101 240237 BRACKET mounting 102 KIT manifold valve must 109 16V426 CABLE CAN intrinsically 1 be ordered separately See safe 5 pin female 10 ft 3 05 Valve Manifolds page 49 for m m 16819 GROMMET cable 1 100157 SCREW cap hex head 4 1 4 20 x 0 375 in 10 mm 24U236 TOOL repair valve EDS 103195 SCREW cap hex head 4 114 TOOL installation valve 1 4 20 x 4 0 in 101 mm 598095 TUBE nylon 5 32 in 4 mm EX 100016 WASHER lock 1 4 56 100015 NUT hex 1 4 20 4 See the following tables for the part number used 107 24N346 HOSE fluid 1 4 2 in your color change kit 2 5 ft 0 76 m ptfe Low Pressure IS Kits Kit Description Standard Valve Control Mod Tool 114 Tube Length Manifold Kits ule Kit 108 115 102 see see IS Color Low Pressure Change Control Valve Manifold Modules page Kits page 49 for 62 for parts all available kits Low Pressure Non Circulating Color Change Kits 24T343 2
36. 4 t t 14 13 247659 7 14 114 o t 1 fis fis 14 247660 e_ 16 115 t fre fo 1 1 3 16 16 15 247660 8 16 16 o 16 jo t 1 faz 17 fre 247662 18 fjar 1 18 fio t fa fhe 18 far 4 2 247669 9 18 18 o fis to 1 1 3 19 18 4 fi 0 241664 10 20 19 1 20 11 t 1 3 20 20 f 15 Jo fi 2 241665 10 20 20 o 20 11 t 1 21 20 5 0 fo fo 2 2 2 2 2 2 a Jo oj o foe _ a fo X o 3324557 57 Parts Reference Numbers TET T e r s o e 5 e 1 5 5 esr 2 2 22 o 1 1 a 2 1 fo Jo 1 so 1 so s fi fs o s foo 7 fe es s T5 T 1 1 fe fe 6 s o se ie 1 at 9 z 1 u f 28 o 20 is 1 5 20 20 26 r o fo To eee pe T ee 1 fo fi gt _ f er poe p r 26 or o gt 2 LO as o 26 ar 2 26 fi fo To 24T67 24T67 24T67 rese v 24 2 1 24 ro fi a 2 oe fe o fi 2 _ v 24 24 o 24 o 1 a 2 25 2 o o o aereo 5 1 26 e fi 1 26 p 1 ws fs T B 1 4
37. 4 Remove the seven mounting screws 303 and the board 302 5 Install the new board Reinstall the screws Reconnect the cables to the proper connectors as noted in step 3 See Electrical Schematics page 34 7 Reinstall the cover 304 Restore electrical power to the system 317 315 318 319 302 315 307 312 310 321 322 sr Ta 313 314 3 9 se 9 e 309 _ qor 309 of 308 0 0 4 L e e g g 303 302a Figure 24 Control Module Repair Non IS Module Shown 332455F ti21639a 43 Parts Parts Non IS System Shown ti22087a Detail of Back Pressure Regulator High Pressure Outlet Stack only ti22620a 44 332455F Parts Non IS Color Change Kits No No 4 4 4 Ref Part Description Qty N No 145 598095 TUBE nylon 5 32 in 4 mm 2 103 100157 SCREW cap hex head 3222007 REGULATOR pack pressure 1 4 20 x 0 375 in 10 mm used on high pressure kits only see detail drawing see 104 103195 SCREW cap hex head 4 manual 307892 1 4 20 x 4 0 in 101 mm 100016 WASHER lock 1 4 4 100015 NUT hex 1 4 20 4 113070 NIPPLE 3 8 npt x 1 4 npt sst used on high pressure kits only see detail drawing 110290 TEE 1 4 npt f sst used 24N346 HOSE fluid 1 4 npsm fbe 2 high Li
38. Instructions Parts GRACO To add optional color change function to ProMix PD2K Electronic Proportioners Kits include low or high pressure color catalyst change valves and a Non IS or IS control module For professional use only Important Safety Instructions Read all warnings and instructions in this manual and in your PD2K proportioner manual Save these instructions See page 4 for model part numbers and approvals information ti21646a PROVEN QUALITY LEADING TECHNOLOGY Contents Related Manuals 3 C C 4 Non Intrinsically Safe Kits 4 Intrinsically Safe Kits sees 6 ette Eee rnb e ese te 7 Important Isocyanate ISO Information 10 Isocyanate Conditions 10 Material 10 Keep Components A and B Separate 10 Moisture Sensitivity of Isocyanates 10 Changing Materials 11 Setup the ModuleS 12 Setup Non IS Control Modules 12 Setup IS Control Modules 15 C 17 Mounting the Color Change Control patita 17 pe etse LEA 17 aaas i anans
39. Na 17 Non Hazardous Location 18 Hazardous Location 20 Install the Valve Manifolds 21 Install the Back Pressure Regulator High Pressure Systems 23 Connect the Valve Air Lines 23 2 Connect the Fluid 24 Install an Expansion 28 30 Color Change Solenoid Valves 30 Color Change Board 32 Electrical 34 Optional Cables and Modules 40 Repair 41 Replace a Color 41 Replace a Solenoid 42 Replace the Color Change Board Fuse 42 Replace the Color Change Board 43 44 Non IS Color Change Kits 45 IS Color Change 47 Valve Manifolds 49 Color Change Control Module Kits 60 Expansi n Kits rr ben 64 66 ntc cM 69 Technical Data 2 4 73 Graco Standard
40. PUPS AS PUPA O TWISTED PAIR CABLE 164759 D 1 TWISTED CABLE 16159 Figure 18 Electrical Schematic Sheet 2 Part 2 CONTINUED ON THE NEXT PAGE 36 332455F FROM CAN IS BOARD 24M485 ON PAGE 2 Electrical Schematics FROM CAN IS BOARD 24 485 ON PAGE 2
41. US LOCATION 16P289 16 290 gt 16 289 160290 uj m NON HAZARDOUS LOCATION TRANSDUCER TRANSDUCER n 8 16P289 16P290 16 289 169290 PUMP V P FOR PUMP VP FOR g FLUID REG N FLUID REG 5 N qe aa 5 585 Ema lt 55 Gama FLOWSENSOR FLOWSENSOR 120278 OR G3000 METER OR G3000 METER 239716 258718 239716 258718 16 510 16V519 16510 16V519 Figure 16 Electrical Schematic Sheet 1 34 332455F Electrical Schematics
42. aco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Revision F March 2014
43. al 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 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 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 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 Check hoses and couplings daily Replace worn
44. and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepa
45. ays 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 and the temperature 332455F 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 332455F Important Isocyanate ISO Information 11 Setup the Modules Setup the Modules Setup Non IS Control Modules NOTE The PD2K System can use up to four pu
46. ches S4 S5 and S6 on the control module board The switches are shipped in the OFF position Module 4 ON ON ON S6 S5 54 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 Usethe following figure and tables to determine the solenoid valve assigned to each valve in the valve manifold NOTE There can be only one solvent valve and one dump valve per pump Inlet Manifold Outlet Manifold 1 LL 6 C 1 ds i RI Ed _ 4 LL 5 D _ 6 Pa 5 ae el 8 D 8 9 O CL 9 odit iji G J7 J11 ti22010a Figure 3 Non IS Control Module 332455F 13 Setup the Modules Non IS Control Module 4 Outlet Manifold Inlet Manifold Outlet Manifold Color 27 Color 27 Color 28 Color 28 Colo
47. cludes valve plug solenoid fittings and tubing 241446 Manifold with one circulating valve Includes valve plug solenoid fittings and tubing 24T447 Manifold with two non circulating valves Includes valves solenoids fittings and tubing High Pressure Expansion Kits 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 24T448 Manifold with two circulating 24T589 Manifold with two circulating valves Includes valves solenoids valves Includes valves solenoids fittings and tubing fittings and tubing High Pressure Acid Compatible Expansion Kits 64 24T590 24T591 24T592 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 332455F IS Expansion Kits Parts The following kits are available to add color valv
48. color or 2 241458 2 241571 240239 60 ft 18 3 m catalyst 24T344 4 color or 4 24T458 24T572 24U239 120 ft 36 6 m catalyst 24T460 24T345 6 color 241458 241573 24 239 210 ft 64 05 m 241462 241346 8 color 241458 241574 24 239 360 ft 109 8 m 241464 Low Pressure Circulating Color Change Kits 241347 2 color 241458 241571 241239 60 ft 18 3 m 24T488 241348 4 color 241458 241572 241239 120 ft 36 6 m 241490 241349 6 color 241458 241573 241239 210 ft 64 05 24T492 241350 8 color 241458 241574 241239 360 ft 109 8 m 24T494 332455F 47 Parts High Pressure IS Kits Kit No Kit Description Standard Valve Control Mod Tool 114 Tube Length Manifold Kits ule Kit 108 115 102 see see IS Color High Pressure Change Control Valve Manifold Modules page Kits page 55 for 62 for parts all available kits High Pressure Non Circulating Color Change Kits 241354 2 color or 2 24T648 2 24T571 24 240 60 ft 18 3 m catalyst 241353 4 color 4 24T648 241572 24 240 120 ft 36 6 m catalyst 24T650 24T353 6 color 24T648 241573 24 240 210 ft 64 05 m 24T652 High Pressure Circulating Color Change Kits 247355 2 color 24T648 24T571 24U240 60 ft 18 3 m 24T678 241356 4 color 24T648 241572 24 240 120 ft 36 6 m 24T680 24T357 6 color 24T648 24T573 24U240 210 ft 64 05 m 24T682 24T358 8 color 24T648 241574 24 240 360 ft 109 8 m 24T684 241354 8 color 24T648 241574 24 240 360 ft
49. culating 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 1500 psi 10 34 MPa 103 4 bar 1500 psi 10 34 MPa 103 4 bar 1500 psi 10 34 MPa 103 4 bar 1500 psi 10 34 MPa 103 4 bar 332455F 5 Models Intrinsically Safe Kits See the module identification label for product part number maximum air working pressure and approval information and certification ProMix PD2K COLOR CHANGE CONTROL PART NO SERIES SERIAL MFG YR MAX AIR WPR B o US 2 C to 50 C FM13 ATEX 0026 h APPROVED Install per 16P577 IECEx FMG 13 0011 P O Box 1441 Minneapolis MN Artwork No 294055 Rev A 0359 eraco 55440 U S A Intrinsically safe equipment 126 bar PSI for Class I Div 1 Group D T3 Ex ia IIA T3 Gb GRACO INC Figure 2 Intrinsically Safe Color Change Control Module Label CE US 0359 2G APPROVED Kit No Series Kit Description Maximum Air Working Pressure Maximum Fluid Working Control Module Pressure Valves Low Pressure Non Circulating Color Change Kits
50. d 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 applied too thick Read material manufacturer s warnings and material MSDS 10 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 Alw
51. es in an IS area See Install an Expansion Kit page 28 for instructions Low Pressure Expansion Kits 241449 One non circulating valve replaces a plug Includes valve IS solenoid fittings and tubing 24T450 One circulating valve replaces a plug Includes valve IS solenoid fittings and tubing 24T451 Manifold with one non circulating valve Includes valve plug IS solenoid fittings and tubing 241452 Manifold with circulating valve Includes valve plug IS solenoid fittings and tubing 24T453 Manifold with two non circulating valves Includes valves IS solenoids fittings and tubing 24T454 Manifold with two circulating valves Includes valves IS solenoids fittings and tubing 332455F High Pressure Expansion Kits 24 712 One non circulating valve replaces a plug Includes valve IS solenoid fittings and tubing 241713 One circulating valve replaces a plug Includes valve IS solenoid fittings and tubing 241714 Manifold with one non circulating valve Includes valve plug IS solenoid fittings and tubing 241715 Manifold with one circulating valve Includes valve plug IS solenoid fittings and tubing 241716 Manifold with two non circulating valves Includes valves IS solenoids fittings and tubing 241717 Manifold with two circulating valves Includes valves IS solenoids fittings and tubing High Pressure Acid Compatible Expansion Kits 24T718 One non circulat
52. from the air line for the corresponding solenoid when the valve is actuated Clear the restriction 30 332455F Troubleshooting 4 Control board or cable failure 332455F If there is no voltage across the pins on the board or it is less than 9 Vdc check LEDs D8 D9 and D10 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 42 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 31 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
53. id If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND SE KT 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
54. ing Kits 50 332455F 15 24T525 ROD connecting 3 in 76 mm 16 24T524 ROD connecting 1 5 in 38 mm Ref Part Description Qty Ref Part Description Qty No No No No 16P259 MANIFOLD 104893 O RING ptfe 111450 O RING chemically resistant 241523 FITTING fluid 7 1620 x 1 4 t 3 241441 VALVE for non circulating NEL kits includes item 2 14 111328 CONNECTOR tube 10 32 m x 5 32 4 24T442 VALVE for circulating kits mm OD tube includes item 2 n Ei 2 E 19 104644 PLUG screw 10 32 x 0 156 in 4 mm 22 24T441 VALVE for circulating kits includes item 2 See the following tables to determine the quantity of each part in your valve manifold kit 24R051 PLUG cc valve 10 24 x 0 625 in 16 mm 100179 NUT hex 10 24 Low Pressure Non Circulating Valve Manifold Kit Part Quantities Reference Numbers ax XIX N gt N e gt E O C C1 CO N N Q N N RES o o o o N NIA CI aao r T 4 o u 8 naro s pe s 1 8 ean s Te 16 o r 3 V 6 12 r na s pe V po 9 p r p 7 12 3 pe pe o 16 o r r 3 8 12 r uana o o r T2 T T D 2
55. ing acid compatible valve replaces a plug Includes valve IS solenoid fittings and tubing 241719 Manifold with one non circulating acid compatible valve Includes valve plug IS solenoid fittings and tubing 241720 Manifold with two non circulating acid compatible valves Includes valves IS solenoids fittings and tubing 65 Dimensions Dimensions si 0 II II III D B m 0 5 T en TU C ti22017a Figure 25 Non IS Control Module L c 5 E 11 in i i I d 9 8 in 249 mm 5 70 in 145 0 31 in 8 mm 5 80 in 147 mm mm A m F E 0 D B d 0 US m EU TE C ti22018a Figure 26 IS Control Module a B j c E 16 57 in 421 8 22 in 209 15 07 in 383 6 70 in 170 0 31 in 8 mm 4 52 in 115 mm mm mm mm mm 66 332455F Dimensions NOTE Total height of valve stack J x number of manifold blocks in your stack po 6 M B LI 14 i N m XN H L I _ K O ti22180a Figure 27 Manifold
56. lastic 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 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 332455F 7 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 electric
57. mps 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 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 1 Relationship of Non IS Color Change Control Modules to Pumps System Pump Configuration Module 1 Colors 12 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 Applicable Pump 1 Pump 1 Module 5 Pump 2 Module 5 Pump 2 Pump 3 Not Applicable Pump 3 Pump 2 Pump 4 Module 5 Pump 2 pump Not Applicable Not Applicable 332455F Setup the Modules Configure each module according to its designated Non IS Control Module Switch Settings number as follows Control 55 54 NOTICE S To avoid damaging the circuit boards wear Part Module 1 oh 1 No 112190 grounding strap on your wrist and Wu ground appropriately To avoid electrical component damage remove all Module 2 system power before plugging any connectors Remove electrical power from the system Module 3 2 Openthe color change module Locate swit
58. old Kits Non Circulating Valve Manifold Kits Circulating Valve Manifold Kits Kit No Kit No 24T647 241677 241648 241678 241649 241679 241650 241680 241654 241681 241652 241682 241653 241683 241654 241684 241655 241685 241656 241686 241657 241687 241658 241688 241659 241689 241660 241690 241661 241691 241662 241692 241663 241693 241664 241694 241665 241695 241666 241696 241667 241697 241668 241698 241669 241699 241670 241700 241671 241701 241672 241702 241673 241703 247674 241704 24T675 241705 24T676 241706 24T845 acid 3 valves catalyzed 24T846 acid 5 valves catalyzed 332455F 55 _____ Series 24607 ja 2468 A 2469 ja 1 1 2762 A O a 24T684 2418 A 24788 241687 247688 247888 JA 246900 A 24691 A 247692 24T698 66 A 24 695 1 246900 24607 A 2476908 Ja 28 A 24 00 ja 24 1 410 709 247 JA Parts Valve Manifold Kit Parts Non Circulating Kits Circulating Kits 5 ti21642a 56 332455F Parts Ref Part No Description Qty No 104893 O RING ptfe 13 24T523 FITTING fluid 7 16 20 x 1 4 npt m 4 Ref Part No Description No 16N271 MANIFOLD for circulating kits 111450 O RING chemically resistant 3 24T581 VALVE for non circulating kits
59. ons Only 332455F 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 MPa bar PSI 1 Flush and relieve pressure as described in your PD2K operation manual 2 Engage the pins of the tool 114 with the notches in the retainer 5 and unscrew the retainer 332455F Repair 114 C1 ti22080a Figure 22 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 C1 ti22081a Figure 23 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 41 Repair Replace a Solenoid Replace the Color Change Board MPa bar PSI Remove electrical power from the system Fuse NOTE Replacing the fuse with a non Graco fuse voids the IS system safet
60. r 30 Color 30 Not Used Not Used Not Used Not Used Non IS Control Module 5 Inlet Manifold Outlet Manifold Solvent 1 Color 4 pa e_ Corzo ____ 29 LED __ BR Valve Dump e le 9 Color 12 Color 15 Color 15 Color 16 Color 16 3 s Catalyst 1 Catalyst 2 Catalyst 3 Catalyst 4 Not Used Not Used e weruses Valve Dump Catalyst 3 Catalyst 4 Not Used Not Used LONE d 8 o Not Used 7 Not Used There should be only one solvent valve and one dump valve per pump 14 332455F Setup IS Control Modules NOTE Two color change control modules may be installed in the hazardous area The modules are labeled 7 or 8 An alternate label is provided with the module kit for Module 8 Colors 13 30 Affix the label according to your system configuration Configure each module according to its designated number as follows 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 1 Remove electrical power from the system 2 Open the color change module Locate switches 54 S5 and S6 on the control module board The Switches may be shipped in the OFF position Setup the Modules For each module set the switches to ON or
61. rom J11 18 of the previous color control module to J7 of the next control module Replace the cover of the 2 electrical control box before turning on power to the system 110 ti22183a Figure 6 Cable Connection at PD2K Electrical Control Box NON IS IS ti21938a Figure 7 Detail of Isolation Board Cable Connections 332455F Notes Installation 332455F 19 Installation Hazardous Location NOTE IS color change control modules provide control for color catalyst change valves located in the hazardous location A maximum of two IS control modules may be installed in the hazardous location See IS Color Change Control Modules page 62 for a list of modules approved for installation in a hazardous location 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 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 40 for a list of M12 CAN cables for use in a hazardous area 1 Remove electrical power from the system 2
62. t catalyst valve stack Connect a supply line from the bottom fitting of the inlet catalyst valve stack to the inlet manifold of the material B dosing pump Connect a supply line from the outlet manifold of the material B dosing pump to the bottom fitting of the outlet catalyst valve stack Connect a dedicated gun supply line for each catalyst to the corresponding catalyst valve fitting on the outlet catalyst valve stack Connect the other end of this line to the B side of the mix manifold at the gun NOTE If your system uses more colors than catalysts branch the catalyst line to connect it to each mix manifold Install a check valve on each branch of the catalyst line NOTE For ease of maintenance install a ball valve at all fluid line tees The mix manifold is belt mounted Connect a fluid hose between the manifold outlet and the gun inlet 332455F Installation 21737 C2 Figure 13 Color Change Connections Non Circulating System KEY W Seal weep and lubrication port 25 Installation Connect Circulating Fluid Lines Circulation valves enable constant circulation of a color when that color is not being sprayed When color valve is closed the system bypasses the dosing pump by directing that color from the inlet color valve to the outlet color valve through a circulation line then to a Y fitting at the mix manifold then back to the color supply e When a color valve is open the
63. ted system component See Technical Data in all equipment manuals Ns 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 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 332455F 9 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 atomize
64. to the open branch of the Y fitting D f ra 7 ti21984a C2 R2 Figure 14 Valve Manifold Connections Circulating System KEY Color 1 circulation fitting Color 2 circulation fitting 332455F Installation ti22193a 5 meteora Y fitting at mix manifold Return line to fluid A port supply 332455F 27 Installation Install an Expansion Kit Expansion Kits are available to add valves or manifolds to your system See Expansion Kits page 64 for available kits 1 2 28 Remove electrical power from the system Relieve pressure as described in your PD2K Operation Manual Open the control module cover Install the solenoid s and air fitting s at the appropriate position s in the solenoid manifold See Setup the Modules page 12 Connect one end of the tubing to the solenoid s air fitting Connect the solenoid wires to the appropriate pins on the control module board See Electrical Schematics page 34 8 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 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
65. true earth ground in the hazardous area 17 Installation Non Hazardous Location 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 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 Color Change Control Module page 17 2 Connect the 5 pin CAN cable 109 to J7 on the color control module 108 324 ti22187a Figure 5 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 4 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 34 for a list of M12 CAN cables for use in a non hazardous area 7 install additional color control modules six maximum mount the module s as described in Mounting the Color Change Control Module page 17 Connect a 5 pin CAN cable f
66. ure 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 Color Change Control Module 1 See Dimensions page 66 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 332455F Installation 3 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 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 color change control module air inlet fitting 317 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 the color change module to a true earth ground Intrinsically safe color change modules located in the hazardous area must be connected to a
67. y approval Remove the color change module cover 304 Fuse Part Description Disconnect the two solenoid wires from nd i the color change board 302 See the color change board wiring diagrams in the 12369 Fuse 125 mA intrinsically safe Electrical Schematics page 34 5 Remove the solenoid 310 from the manifold 309 Install the new solenoid Remove air supply pressure from the system Bow gt Remove electrical power from the system 2 Remove the color change module cover 304 3 Locate fuse F1 302a on the color change board Connect the two solenoid wires to the Pull the fuse away from the board color change board 302 See the color change board wiring diagrams in the 4 Install the new fuse 5 Reinstall the cover Restore electrical power to 8 Reinstall the cover the system 42 332455F Replace the 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 1 Remove electrical power from the system 2 Remove the color change module cover 304 304 311 332 324 Repair 3 Note where each cable is connected then disconnect all cables from the color change board connectors
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