Graco 332457C User's Manual


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Graco 332457C User's Manual | Manualzz

Installation

ProMix® PD2K Electronic

Proportioner

332457C

EN

Electronic positive displacement proportioner for fast-setting two-component materials. Manual system with Advanced Display Module. For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See page 3 for model part numbers and approvals information.

PROVEN QUALITY. LEADING TECHNOLOGY.

2

Contents

Related Manuals ................................................ 2

Models............................................................... 3

Warnings ........................................................... 5

Important Isocyanate (ISO) Information................ 8

System Control Drawing 16P577 ......................... 10

Configuring Your System .................................... 12

1. Select a Base Model ................................ 12

2. Select Hoses ........................................... 14

3. Select Mix Manifold.................................. 16

4. Select a Spray Gun.................................. 16

5. Select Color and Catalyst Change

Kits................................................ 17

6. Select Pump Expansion Kits..................... 17

General Information ............................................ 18

Location............................................................. 18

Install the Display Module.................................... 19

Install the Booth Control...................................... 20

Air Supply .......................................................... 21

Fluid Supply ....................................................... 22

Fluid Requirements...................................... 22

Single Color Connections ............................. 23

Color Change Connections........................... 23

TSL Cup Kit........................................................ 24

Solvent Meter Accessory..................................... 25

Light Tower Accessory........................................ 25

Electrostatic Air Hose Quick Disconnect Kit

24S004................................................. 25

Electrical Supply................................................. 26

Electrical Requirements................................ 26

Electrical Connections.................................. 26

Grounding.......................................................... 27

Electrical Schematics.......................................... 31

Optional Cables and Modules ....................... 37

Dimensions ........................................................ 38

Technical Data ................................................... 39

Graco Standard Warranty.................................... 40

Related Manuals

Manual No.

Description

3A2800 PD2K Proportioner Repair-Parts

Manual, Manual Systems

332562

3A2801

332339

PD2K Proportioner Operation

Manual, Manual Systems

Mix Manifold Instructions-Parts

Manual

Pump Repair-Parts Manual

Manual No.

Description

332454 Color Change Valve Repair-Parts

Manual

332455

332456

Color Change Kits Instructions-

Parts Manual

3rd and 4th Pump Kits

Instructions-Parts Manual

332457C

Models

Models

See Figs. 1–7 for component identification labels, including approval information and certification.

Part No.

Series Maximum Air Working

Pressure

Maximum Fluid Working

Pressure

Location of PD2K and

Electrical Control Box

(ECB) Labels

MC1000

MC2000

A

A

100 psi (0.7 MPa,

7.0 bar)

100 psi (0.7 MPa,

7.0 bar)

300 psi (2.068 MPa, 20.68 bar)

1500 psi (10.34 MPa,

103.4 bar)

0359

II 2 G

Figure 1 Model MC1000 (Low Pressure) Identification

Label

Figure 2 24M672 Control Box Identification Label

Continued on the next page.

332457C 3

Models

Figure 3 Model MC2000 (High Pressure)

Identification Label

Figure 4 Non-Intrinsically Safe Color Change Control (Accessory) Identification Label

Figure 5 Intrinsically Safe Color Change Control

(Accessory) Identification Label

Figure 6 Booth Control Identification Label

Figure 7 Pump Expansion Kit (Accessory) Identification Label

4 332457C

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.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail. 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.

332457C 5

6

Warnings

WARNING

INTRINSIC SAFETY

Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe equipment will create a hazardous condition and can cause fire, explosion, or electric shock.

Follow local regulations and the following safety requirements.

• Be sure your installation complies with national, state, and local codes for the installation of electrical apparatus in a Class I, Group D, Division 1 (North America) or Class I, 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 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.

• 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.

332457C

332457C

Warnings

WARNING

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 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.

7

Important Isocyanate (ISO) Information

Important Isocyanate (ISO) Information

Isocyanates (ISO) are catalysts used in two component materials.

Isocyanate Conditions

Keep Components A and B Separate

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

8

Some materials may become self-igniting if applied too thick. Read material manufacturer’s warnings and material MSDS.

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, and the temperature.

332457C

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.

Important Isocyanate (ISO) Information

332457C 9

System Control Drawing 16P577

System Control Drawing 16P577

Do not substitute or modify system components as this may impair intrinsic safety. For installation, maintenance, or operation instructions, read instruction manuals. 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.

NOTES FOR SYSTEM CONTROL DRAWING 16P577 (FM13ATEX0026 SYSTEM ASSEMBLY

CERTIFICATE)

Alternate M12 CAN Cables, for Hazardous Locations

Cable Part No.

Length ft (m)

16V423

16V424

2.0 (0.6)

3.0 (1.0)

16V425

16V426

16V427

16V428

6.0 (2.0)

10.0 (3.0)

15.0 (5.0)

25.0 (8.0)

16V429

16V430

50.0 (16.0)

100.0 (32.0)

2. The non-intrinsically safe terminals (power rail) must not be connected to any device which uses or generates more than Um = 250 Vrms or dc unless it has been determined that the voltage has been adequately isolated.

3. The electrical enclosure ground screw must be connected to a true earth ground using the supplied ground strap (223547) or by an equivalent 10 AWG or larger isolated conductor. Resistance from the electrical enclosure ground to the true earth ground shall not exceed 1 ohm.

4. Multiple earthing of components is allowed. Intrinsically safe apparatus provides isolation from earth to

500 Vrms.

Do not operate system with power barrier cover removed.

6. Installation should be in accordance with ANSI/ISA RP12.06.01 “Installation of Intrinsically Safe Systems for Hazardous (Classified) Locations” and the National Electrical Code® (ANSI/NFPA 70).

7. Installation in Canada should be in accordance with the Canadian Electrical Code, CAS C22.1, Part I,

Appendix F.

8. For ATEX, install per EN 60079–14 and applicable local and national codes.

9. For IECEx install per IEC 60079–14 and applicable local and national codes.

10 332457C

NON-HAZARDOUS LOCATION ONLY

System Control Drawing 16P577

HAZARDOUS (CLASSIFIED) LOCATION

Class 1, Div 1, Group D, T3 (USA and Canada)

Class 1, Zone 1, Group IIA, T3 (ATEX and IECEx)

Ta = 2°C to 50°C

NON-HAZARDOUS LOCATION ONLY

POWER IN

250 VAC MAXIMUM SUPPLY VOLTAGE

PROMIX PD2K

ELECTRICAL ENCLOSURE

(24M672)

POWER

BARRIER

(248192)

COMMUNICATION

BARRIER

(24M485)

FM13ATEX0026

IECEx FMG 13.0011

ASSOCIATED APPARATUS

J4

OR

J3

HAZARDOUS (CLASSIFED) LOCATION

CLASS 1, DIV 1, GROUP D, T3 (USA AND CANADA)

CLASS 1, ZONE 1, GROUP IIA, T3 (ATEX AND IECEx)

Ta = 2 C TO 50 C

CABLE (16V429)

COLOR CHANGE MODULE

(24R219, 24R220, 24R221, 24R222)

FM13ATEX0026

IECEx FMG 13.0011

INTRINSIC SAFE APPARATUS

COLOR CHANGE MODULE

(24R219, 24R220, 24R221, 24R222)

FM13ATEX0026

IECEx FMG 13.0011

INTRINSIC SAFE APPARATUS

BOOTH CONTROL

(24M731)

FM13ATEX0026

IECEx FMG 13.0011

INTRINSIC SAFE APPARATUS

Figure 8 System Control Drawing 16P577

332457C 11

Configuring Your System

Configuring Your System

1. Select a Base Model

Choose a PD2K base model that meets your application’s requirements. See

Component

Fluid Pumps (A, B)

Solvent Valve (C)

Booth Control (D)

Electrical Control Box (E)

Advanced Display Module (F)

Models, page 3 .

Base models include components A through F shown in the Typical Installation Drawing. Base unit components are described in the following table.

Description

The base models include two fluid pumps, one for resin and one for catalyst. Install in the non-hazardous area.

Dispenses solvent to the gun during purge.

The booth control enables the user to monitor and control the system.

Install the booth control in the hazardous location, near the painter.

The electrical control box includes a barrier board, intrinsically safe isolation board, 24 Vdc and 48 Vdc power supplies, Enhanced Fluid

Control Module, and Pump Control Modules. It accepts 90–250 Vac line power and converts that power to acceptable low voltage signals used by other system components. Install the electrical control box in the non-hazardous area.

The Advanced Display Module (ADM) enables the user to setup, monitor, and control the system. Install the ADM in the non-hazardous area.

12 332457C

HAZARDOUS (CLASSIFIED) LOCATION

Configuring Your System

NON-HAZARDOUS LOCATION ONLY

Figure 9 Typical Installation

Component Description

★ Components A through F are included with the base unit.

A★ Material A (Color) Pump

B★

C★

D★

E★

Material B (Catalyst) Pump

Solvent Valve

Booth Control

Electrical Control Box

G

H

F★ Advanced Display Module

Components G through K are included in optional color change kits.

Color Change Valves (accessory)

Color Change Module (accessory)

R

S

N

P

J

K

Catalyst Change Valves (accessory)

Catalyst Change Module (accessory)

L

M

Components L through S are accessories and must be ordered separately.

Fluid/Air Hose Bundle (accessory)

Mix Manifold (accessory)

Air Spray Gun (accessory)

Gun Air Hose (accessory)

Intrinsically Safe CAN Cable (to connect booth control to electrical control box)

Gun Fluid Hose (accessory)

332457C 13

Configuring Your System

2. Select Hoses

Hose Selection Tool

Use this chart to determine the proper size hose bundle for your mix ratio and viscosity, then select a hose bundle for your application from the tables on the following page.

NOTE: Always use Graco hoses.

NOTE: Shaded areas may use hose sizes from either of the two adjacent areas.

LOW PRESSURE SYSTEM, 0–300 psi (0–2.1 MPa, 0–21 bar)

Recommended Hose Sizes (internal diameter) for A and B

20 - 50

Mix

Ratio

(X:1)

18

16

14

12

10

8

6

4

2

3/8ʺ A

1/8ʺ B

3/8ʺ A

1/4ʺ B

0

10:1

Thick Resin (A)

Thin Catalyst (B)

7.5:1 5:1 2.5:1 1:1

Equal Viscosities

1:2.5

Viscosity Ratio (Resin [A] : Catalyst [B]

1:5

1/4ʺ A

1/4ʺ B

1:7.5

1/4ʺ A

3/8ʺ B

1:10

Thin Resin (A)

Thick Catalyst (B)

14 332457C

Configuring Your System

1/4 in. (6 mm) ID Hose Bundles

Select a hose bundle from the following table. Always use Graco hoses.

Application

Low Pressure

Conventional Air

Spray

Low Pressure

Electrostatic Air

Spray*

High Pressure

Conventional

Air-Assisted Spray

High Pressure

Electrostatic

Air-Assisted Spray*

Hose Bundle

Part No.

24T140

24T141

24T138

24T139

24T247

24T248

24T245

24T246

Length

25 ft (7.6 m)

50 ft (15.2 m)

25 ft (7.6 m)

50 ft (15.2 m)

25 ft (7.6 m)

50 ft (15.2 m)

25 ft (7.6 m)

50 ft (15.2 m)

Material Maximum

Fluid Working

Pressure

Nylon (A side and Solvent),

MPa, 16 bar)

Nylon (A side and Solvent),

Moisture Guard (B side),

Grounded Air Hose with left-hand thread

225 psi (1.6

MPa, 16 bar)

Nylon (A side and Solvent),

MPa, 138 bar)

Nylon (A side and Solvent),

Moisture Guard (B side),

Grounded Air Hose with left-hand thread

2000 psi (13.8

MPa, 138 bar)

* To use a quick disconnect on an existing electrostatic air hose, see

Electrostatic Air Hose Quick Disconnect Kit 24S004, page 25 .

3/8 in. (10 mm) ID Fluid Hoses

If 3/8 in. (10 mm) fluid hose is required for your application, order one of the following to replace the 1/4 in.

hose in your hose bundle. Always use Graco hoses.

Application

Low Pressure Air

Spray

Hose Part No.

Length

24T763 25 ft (7.6 m)

24T764 50 ft (15.2 m)

Material

Nylon

Fluid Whip Hoses

Select a fluid whip hose from the following table. Always use Graco hoses.

Maximum Fluid Working Pressure

200 psi (1.4 MPa, 13.8 bar)

Application

Low Pressure

High Pressure

Hose Part No.

24N641

24N305

24N641

24N348

Hose I.D.

0.125 in. (3 mm)

0.25 in. (6 mm)

0.125 in. (3 mm)

0.25 in. (6 mm)

Length Material

6 ft (1.8 m) Nylon

6 ft (1.8 m) Nylon

6 ft (1.8 m) Nylon

6 ft (1.8 m) PTFE

Maximum Fluid

Working Pressure

3200 psi (22 MPa,

220 bar)

225 psi (1.6 MPa,

16 bar)

3200 psi (22 MPa,

220 bar)

3000 psi (20.7 MPa,

207 bar)

332457C 15

Configuring Your System

3. Select Mix Manifold

The following mix manifold kits are available. The mix manifolds attach to the painter’s belt, allowing mixing to occur at the point of spray. See manual

3A2801 for further information.

Mix

Manifold

24R99

1

24R99

2

Description

Low pressure mix manifold

High pressure mix manifold

24T273 High pressure mix manifold, for acid-compatible materials

Maximum Fluid

Working Pressure

300 psi (2.1 MPa,

21 bar)

1500 psi (10.5

MPa, 105 bar)

1500 psi (10.5

MPa, 105 bar)

4. Select a Spray Gun

Spray Guns

Select a spray gun from the following table.

Application Gun Model

Conventional Air Spray

Electrostatic Air Spray

Conventional

Air-Assisted Spray

Electrostatic Air-Assisted

Spray

AirPro

Pro Xp

G15

Pro Xp AA

Gun Manual No.

312414

3A2494

3A0149

3A2495

Maximum Fluid Working

Pressure

300 psi (2.1 MPa, 21 bar)

100 psi (0.7 MPa, 7 bar)

1500 psi (10.5 MPa, 105 bar)

3000 psi (21 MPa, 210 bar)

16 332457C

Configuring Your System

5. Select Color and Catalyst Change Kits

Using the following table, choose color/catalyst change kits that meet your application’s requirements. The kits include a manifold with valves and a control module. See color change kit manual 332455 for further information.

Table 1 . Low Pressure Color/Catalyst Change Kits

(300 psi [2.068 MPa, 20.68 bar])

Kit Part No.

Kit Description

Low Pressure Non-Circulating Kits

24R915

24R916

24R917

24R918

2 color or 2 catalyst change valves

4 color or 4 catalyst change valves

6 color change valves

8 color change valves

Low Pressure Circulating Kits

24R919

24R920

24R921

24R922

2 color or 2 catalyst change valves

4 color or 4 catalyst change valves

6 color change valves

8 color change valves

Table 2 . High Pressure Color/Catalyst Change Kits

(1500 psi [10.34 MPa, 103.4 bar])

Kit Part No.

Kit Description

High Pressure Non-Circulating Kits

24R959

24R960

2 color or 2 catalyst change valves

4 color or 4 catalyst change valves

24R961

24R962

6 color change valves

8 color change valves

High Pressure Acid-Compatible Non-

Circulating Kits

24T579

24T580

24R963

2 catalyst change valves

4 catalyst change valves

High Pressure Circulating Kits

2 color or 2 catalyst change valves

24R964

24R965

24R966

4 color or 4 catalyst change valves

6 color change valves

8 color change valves

6. Select Pump Expansion Kits

The following table lists available kits to add a third or fourth pump to your system. Each kit includes one pump, a pump control module, solenoid, frame, mounting bracket, and cabling. See pump expansion kit manual 332456 for further information.

Kit Part No.

Kit Description

Low Pressure Pumps (300 psi [2.068

MPa, 20.68 bar])

24R968

24R970

Low pressure resin 70cc pump

Low pressure catalyst

35cc pump

High Pressure Pumps (1500 psi [10.34

MPa, 103.4 bar])

24R969 High pressure resin

70cc pump

24R971 High pressure catalyst

35cc pump

332457C 17

General Information

General Information

• Reference numbers and letters in parentheses in the text refer to numbers and letters in the illustrations.

• Be sure all accessories are adequately sized and pressure-rated to meet system requirements.

• To protect the screens from paints and solvents, clear-plastic protective shields (10 per pack) are available. Order Part No. 197902 for the Advanced

Display Module and Part No. 15M483 for the

Booth Control. Clean the screens with a dry cloth if necessary.

Location

To prevent tipping which can cause serious injury and equipment damage, the mounting stand must be securely anchored to the floor or to an appropriate base. The stand is not intended for free-standing use or wall mounting.

Mounting the PD2K Base Unit:

• Mount the PD2K in a non-hazardous location.

• Ensure that the mounting surface and mounting hardware are strong enough to support the weight of the equipment, fluid, hoses, and stress caused during operation.

• Do not mount to a wall.

• Secure the stand to the floor with 1/2 in. (13 mm) bolts which engage at least 6 in. (152 mm) into the floor to prevent the unit from tipping. See

Dimensions, page 38

.

• There must be sufficient space on all sides of the equipment for installation, operator access, maintenance, and air circulation. The fans at the back of the unit require a minimum of 6 in. (152 mm) clearance from the closest surface to ensure adequate air circulation.

Mounting the Booth Control:

Install the booth control in a hazardous area at a convenient location for the operator to view and operate. See

Install the Booth Control, page 20

.

18 332457C

Install the Display Module

Install the Display Module

1. Use the screws (11) to mount the bracket (10) for the Advanced Display Module (12) on the front of the Control Box or on the wall, as you prefer.

2. Snap the Advanced Display Module into the bracket.

Figure 10 Install Display Module

3. Connect one end of the 5 ft (1.5 m) CAN cable

(provided) to the Advanced Display Module

(M). The other end of the cable comes from the factory connected to the Enhanced Fluid Control

Module (EFCM).

NOTE: For a list of alternate cable lengths, see

Electrical Schematics, page 31

. The total length of all cable used in the system must not exceed 150 ft (45 m).

Figure 11 Advanced Display Module Connection

Ports

M

N

P

K

L

Item

J

R

Description

Battery Cover

Model Number

USB Drive Interface

CAN Cable Connection

ADM Status LEDs

Accessory Cable

Connection

Token Access Cover

332457C 19

Install the Booth Control

Install the Booth Control

1. Use screws (S) to mount the bracket (10) for the

Booth Control (13) on the wall. Connect a ground wire (G) to one of the screws. Connect the other end of the ground wire to a true earth ground.

2. Snap the Booth Control into the bracket.

3. Connect the Booth Control to the Isolation Board in the Electrical Control Box, using the 50 ft (15.2

m) intrinsically safe CAN cable (163).

NOTE: For a list of alternate cable lengths, see

Electrical Schematics, page 31 . The total length

of cable used in the hazardous location must not exceed 120 ft (36 m). The total length of all cable used in the system must not exceed 150 ft (45 m).

Figure 12 Ground the Booth Control Bracket

Figure 13 Install the Booth Control

20 332457C

Air Supply

Air Supply

Air Requirements

• Compressed air supply pressure: 85-100 psi

(0.6–0.7 MPa, 6.0-7.0 bar).

• Air hoses: use grounded hoses that are correctly sized for your system.

switch detects air flow to the gun and signals the controller when the gun is being triggered.

NOTE: If there is more than one gun (for example, a separate gun for each color), the atomizing air outlet (159c) must be branched to each gun. For ease of maintenance, install a ball valve at all air line tees.

Trapped air can cause a pump or dispense valve to cycle unexpectedly, which could result in serious injury from splashing or moving parts.

Use bleed-type shutoff valves.

• Air regulator and bleed-type shutoff valve: include in each air line to fluid supply equipment. Install an additional shutoff valve upstream of all air line accessories to isolate them for servicing.

To reduce the risk of fire and explosion if using a Graco electrostatic gun, a shutoff valve must be installed in the gun air line to shutoff the atomizing and turbine air to the gun. Contact your Graco distributor for information on air shutoff valves for electrostatic applications.

• Air line filter: to filter oil and water out of the air supply and help avoid paint contamination and clogged solenoids. See

Technical Data, page 39

for air filtration requirements.

Figure 14 Connect Atomizing Air

Air Connections

1. Tighten all system air and fluid line connections as they may have loosened during shipment.

2. Connect the main air supply line to the main air inlet (136). This air line supplies the solenoids, valves, and pumps. Do not use this line to supply the gun’s atomizing air.

3. Connect a separate, dedicated, clean air supply line to the air inlet (159a) of the air flow switch.

This air supplies gun atomizing air. The air flow

Figure 15 Air Manifold Connections

Key

Connection

A

C

M

S

Description

Air inlet

GFB/Air cutoff output

(plugged)

Exhaust muffler

Solvent cutoff output

332457C 21

Fluid Supply

Fluid Supply

Fluid Requirements

• To reduce the risk of equipment overpressurization and rupture which can cause injury, including skin injection, do not exceed the pressure rating of the lowest rated system component. See the identification label for the maximum working pressure of the equipment.

• To reduce the risk of injury, including skin injection, you must install a shutoff valve between each fluid supply line and the mix manifold. Use the valves to shut off fluid during maintenance and service.

Models are available to operate air spray (300 psi) or air-assisted (1500 psi) systems with a capacity of up to 800 cc/minute (depending on material viscosity).

• Fluid supply pressure tanks, feed pumps, or circulating systems can be used to supply fluid to the system.

• Materials can be transferred from their original containers or from a central paint recirculating line.

• Install a 100 mesh (minimum) fluid filter in the fluid supply line, with a drain valve.

NOTE: The fluid supply must be free of pressure spikes, which are commonly caused by pump stroke changeover. Read the supply pressure on the gauge

(P). Supply pressure must be as close as possible to the pressure setpoint:

• For low pressure systems, ± 100 psi (0.7 MPa, 7 bar) of setpoint.

• For high pressure systems, ± 300 psi (2.1 MPa,

21 bar) of setpoint.

If necessary, install pressure regulators or a surge tank on the pump fluid inlet lines to reduce pulsation.

Contact your Graco distributor for additional information.

22 332457C

Single Color Connections

NOTE: Check valves (J, L) are provided on the inlet and outlet manifolds of each pump.

1. Connect the color supply line to the pump fluid inlet fitting (S).

2. Connect the color outlet line to the pump fluid outlet fitting (R).

3. Make the same connections on the catalyst side.

NOTE: For isocyanate catalyst materials, moisture resistant hose is required to supply fluid to the system and also as a fluid line between the pump and the mix manifold.

Fluid Supply

Color Change Connections

If you are installing the color change accessory kit, make the fluid connections as described in manual

332455.

Figure 16 Pump Inlet and Outlet Connections

332457C 23

TSL Cup Kit

TSL Cup Kit

Throat Seal Liquid (TSL) lubricates the pump throat packings and dosing valves. The PD2K Proportioner includes two TSL Cup Kits, one for each pump.

The kits supply TSL to the upper and lower throat cartridges of each 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.

NOTE: If 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.

6. Cut the tubing (73c) to length as required.

Connect 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.

7. Fill the cup with TSL.

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.

4. Repeat for the lower throat cartridge.

5. 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.

Figure 17 Install TSL Cup Kit

24 332457C

Solvent Meter Accessory

To install Solvent Meter Kit 280555, see manual

308778.

NOTE: Install the solvent meter downstream of the solvent cutoff switch near the base unit.

Light Tower Accessory

To install Light Tower Kit 24K337, see manual

3A1906.

Solvent Meter Accessory

Electrostatic Air Hose

Quick Disconnect Kit

24S004

NOTE: To use a quick disconnect on an existing electrostatic air hose, order Part No. 24S004 Kit. You will also need to order Part No. 24U059 Electrostatic

Air Whip Hose (6 ft) [1.8 m].

Install the kit as follows.

1. Connect the quick disconnect (QD) to the existing electrostatic air hose (P). The quick disconnect is a 1/4 npsm(m) left-hand thread.

2. Screw the female end of adapter fitting (QF) onto the quick disconnect (QD).

3. Screw the 24U059 Electrostatic Air Whip Hose

(WH) onto the male end of the adapter fitting

(QF).

NOTE: Make the following ground connections to ensure air hose grounding continuity in the electrostatic system.

4. Connect the ground wire (PG) of the existing electrostatic air hose (P) to a true earth ground.

5. Connect the whip hose ground wire (WG) to the green ground lug (GND) of the mix manifold

(M). Connect a ground wire (MG) from the mix manifold ground lug to a true earth ground.

332457C

Figure 18 Electrostatic Air Hose Quick Disconnect Kit

25

Electrical Supply

Electrical Supply

Improper wiring may cause electric shock or other serious injury if work is not performed properly. All electrical wiring must be completed by a qualified electrician and comply with all local codes and regulations.

Electrical Requirements

Enclose all cables routed in the spray booth and high traffic areas in conduit to prevent damage from paint, solvent, and traffic.

The unit operates with 90-250 VAC, 50/60 Hz input power, with a maximum of 7 A current draw. The power supply circuit must be protected with a 15 A maximum circuit breaker.

• A power supply cord compatible to your local power configuration is not included. Wire gauge size must be 8-14 AWG.

• The input power access port is 22.4 mm (0.88

in.) in diameter. A strain relief is provided which accepts a cord diameter of 0.157–0.354 in. (4–9 mm). If another cord size is used, a user-supplied, appropriate size strain relief must be installed.

Electrical Connections

See

Electrical Schematics, page 31 .

1. Verify that electrical power at the main panel is shut off. Open the Control Box cover.

2. Thread the electrical cord wires through the strain relief (S).

3. Connect the wires (L, N, G) securely to the corresponding terminals of the terminal block (T), as shown.

4. Tighten the strain relief nut securely.

5. Close the Control Box. Restore power.

6. Follow instructions in

Grounding, page 27 .

Wire Key

N

G

Wire

L

Description

Line Power

Neutral

Ground

26

Figure 19 Control Box Electrical Connection

332457C

Grounding

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.

Electrical Control Box

The electrical control box has two ground points.

Both connections must be made.

• Connect the ground wire (Y) to the ground screw on the electrical control box. Connect the clamp end to a true earth ground.

• The power supply must be grounded according to local codes. Connect the power supply ground wire to the Ground terminal in the electrical control box. See

Electrical Connections, page 26 .

Figure 20 Ground Screw and Power Switch

Fluid Supply Container

Follow local code.

Booth Control

The booth control is grounded through intrinsically safe cable connections to the electrical control box.

Attach a separate ground wire to the booth control mounting bracket. See

Install the Booth Control, page 20 .

Color Change Module

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 true earth ground in the hazardous area.

Feed Pumps or Pressure Pots

Connect a ground wire and clamp from a true earth ground to the pumps or pots. See pump or pressure pot manual.

Air and Fluid Hoses

Use grounded hoses only.

Spray Gun

Follow the grounding instructions in your gun manual.

• Non-Electrostatic: Ground the spray gun through connection to a Graco-approved grounded fluid supply hose.

• Electrostatic: Ground the spray gun through connection to a Graco-approved grounded air supply hose. Connect the air hose ground wire to a true earth ground.

332457C 27

Grounding

HAZARDOUS LOCATION NON-HAZARDOUS LOCATION

Figure 21 System Grounding

Key

1

2

3

4

Electrical Control Box ground screw

Electrical Control Box ground wire

Color Change Module (CC) ground wires

Intrinsically Safe (IS) cable

28

5

6

7

True Earth Ground; check local code for requirements

Non-Intrinsically Safe cable

Booth Control (BC) mounting bracket ground wire

332457C

Grounding

Object Being Sprayed

Follow local code.

All Solvent Pails Used When Purging

Follow local code. Use only conductive metal pails/containers placed on a grounded surface. Do not place the pail/container on a nonconductive surface, such as paper or cardboard, which interrupts the grounding continuity.

Check Resistance

To ensure proper grounding, resistance between components and true earth ground must be less than 1 ohm.

332457C 29

Notes

Notes

30 332457C

Electrical Schematics

FAN

(24P658)

ENCODER AND MOTOR

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

PUMP V/P FOR

FLUID REG.

SOLENOID (16P812)

UP

DOWN

FLOW SENSOR

(120278)

OR G3000 METER

(239716, 258718

16M510, 16M519)

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 37

for a list of cable options.

2 POSITION

SWITCH

(16U725)

CABLE

16T658

LINE FILTER

(16V446)

CABLE

16H078

TERMINAL BLOCK

(114095)

POWER IN

24V

POWER

SUPPLY

(16T660)

RELAY

POWER MODULE

(24R257)

48V-10A POWER SUPPLY

(16U820)

TERMINAL BLOCKS WITH FUSES

065161, 065159

COMMUNICATION

MODULE

(24R910)

5

CABLE (121227)

COMMUNICATION

MODULE

(24R910)

5

CABLE (121227)

CABLE (121227)

16T072

CAN

IS BOARD

(24M485)

FAN

(24P658)

ENCODER AND MOTOR

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

PUMP V/P FOR

FLUID REG.

SOLENOID (16P812)

UP

DOWN

FLOW SENSOR

(120278)

OR G3000 METER

(239716, 258718

16M510, 16M519)

SPLITTER

(16P243)

CABLE (16T280)

BARRIER

BOARD

(248192)

4

CABLE (16T659)

CABLE (16T659)

CABLE (16T659)

CABLE (16T659)

FAN

(24P658)

ENCODER AND MOTOR

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

PUMP V/P FOR

FLUID REG.

FAN

(24P658)

ENCODER AND MOTOR

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

PUMP V/P FOR

FLUID REG.

SOLENOID (16P812)

UP

DOWN

SOLENOID (16P812)

UP

DOWN

FLOW SENSOR

(120278)

OR G3000 METER

(239716, 258718

16M510, 16M519)

FLOW SENSOR

(120278)

OR G3000 METER

(239716, 258718

16M510, 16M519)

Figure 22 Electrical Schematic, Sheet 1

2

CABLE

(15V206)

2 CABLE

(15V206)

MODULE 1 (24N935)

2

CABLE

(15V206)

MODULE 2 (24N935) MODULE 3 (24N935)

2

CABLE

(15V206)

MODULE 4 (24N935) MODULE 5 (24N935)

2

CABLE

(15V206)

MODULE 6 (24N935)

GCA

MODULE

EFCM

(24N913)

GUN TRIGGER INPUTS

119159

119159

119159

119159

SOLENOID (121324)

PRESSURE SWITCH

(121323)

SOLVENT FLOW SWITCH (120278)

SOLVENT METER (258718)

3

CABLE

(121003)

ADVANCED

DISPLAY MODULE

(24E451)

LIGHT

TOWER

(15X472)

1 CABLE (16V429) CABLE (16V426)

COLOR CHANGE MODULE 7

(24R219)

7

COLOR CHANGE MODULE 8

(24R219)

7

BOOTH CONTROL (24M731)

HAZARDOUS LOCATION

NON-HAZARDOUS LOCATION

CABLE (16V426)

332457C 31

Electrical Schematics

SPLITTER

(16P243)

5 4 3 2 1

UNUSED UNUSED UNUSED

CONTINUED ON PAGE 3 CONTINUED ON PAGE 3

1 2 3 4 5

2

4

1 2 3 4 5

3

CABLE (121227)

2

3

CABLE (15V206)

16T072

1 2 3 4 5

CAN IS BOARD

(NON IS)

(IS)

(24M485)

3

1 2 3 4 5

1

UNUSED

CABLE (16T280)

1 2 3

UNUSED UNUSED

BARRIER

BOARD

(248192)

CABLE

(121227)

3

3

5

SOLVENT CUTOFF

PWR (RED)

SIG (WHITE)

COM (BLACK)

SHIELD/GRN SOLVENT

METER

(258718)

UNUSED

UNUSED

10

UNUSED

CABLE

(121227)

3

+12VDC

COM

UNUSED

UNUSED

+12VDC

COM

+12VDC

COM

UNUSED

8

GCA MODULE

EFCM

(24N913)

1

2

6

7

4

5

8

9

10

12

5

1 2 3 4 5 6 7 8 9 10

1

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1 2 3 4 5 6 7 8 9

2

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

RED WIRE (065161)

BLACK WIRE (065159)

GROUND BAR

4

25 PIN D-SUB CABLE

(16T659)

24V

POWER

SUPPLY

(16T660)

L (BROWN) N (BLUE)

N03 N03

2 POSITION

SWITCH

(16U725)

N04 N04

CABLE

(16T658)

L N

LINE

FILTER

(16V446)

L GRND N

CABLE

(16H078)

L N GRND

TERMINAL

BLOCK

(114095)

L N GRND

GRND (GRN/YEL)

13 A1(+) A2(-)

RELAY

14

N L GRND

48V-10A

POWER SUPPLY

+ -

+ - + - + - + -

+ - + - + - + -

DETAIL A, LOW PRESSURE

PUMPS (24M706, 24M714)

2

1 2 3 4 5

BREAKOUT MODULE

(24N527)

3

1 2 3 4

WIRE HARNESS

(24P684) DRAIN/FOIL

1 2 3 4

BREAKOUT MODULE PUMP 1 (24N527)

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

1

2

1 2 3 4 5

3

1 2 3 4

4

1 2 3 4 5

5

1 2 3 4 5

6

1 2 3 4 1 2 3 4

7

5 6 7 8

8

1 2 3 4

1 2 3 4 5 6 7 8 9

BREAKOUT MODULE PUMP 2 (24N527)

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

1

2

1 2 3 4 5

3

1 2 3 4

4

1 2 3 4 5

5

1 2 3 4 5

6

1 2 3 4 1 2 3 4

7

5 6 7 8

8

1 2 3 4

+48V COM +48V COM

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 1

SEE DETAIL A OR B

TRANSDUCER PUMP TRANSDUCER PUMP

TWISTED PAIR CABLE (16W159)

PWR (RED) SIG (WHITE) COM (BLACK) SHIELD/GRN

1 UP

MANIFOLD

MAC SERIES 46 (16P812 QTY

G3000

METER

PUMP 1

(EITHER, 239716,

258718,16M510,

OR 16M519)

GRND

SCREW

+48V COM +48V COM

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 2

SEE DETAIL A OR B

TRANSDUCER PUMP TRANSDUCER PUMP

PWR (RED) SIG (WHITE) COM (BLACK) SHIELD/GRN

2 UP

MANIFOLD

MAC SERIES 46 (16P812 QTY

G3000

METER

PUMP 2

(EITHER, 239716,

258718,16M510,

OR 16M519)

GRND

SCREW

TWISTED PAIR CABLE (16W159)

DETAIL B, HIGH PRESSURE

PUMPS (24M707, 24M715)

2

1 2 3 4 5

BREAKOUT MODULE

(24N527)

3

1 2 3 4

WIRE HARNESS

(24P685) DRAIN/FOIL

MOTOR

MOUNTING

SCREW

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9

PUMP ENCODER AND MOTOR

(16P037)

10

MOTOR

MOUNTING

SCREW

1 2

Figure 23 Electrical Schematic, Sheet 2, Part 1

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9

PUMP ENCODER AND MOTOR

(16P036)

CONTINUED ON THE NEXT PAGE

10

32 332457C

Electrical Schematics

GCA MODULE

(24N913)

1 2 3 4 5 6 7 8

3

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

EFCM

1 2 3 4 5 6 7 8

4

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

9

6

4

5

2

1

9

10

7

8

7

9

10

6

7

4

5

2

1

3

4

1

2

5

GUN TRIGGER INPUTS

SIG

COM

SIG

COM

COM

SIG

COM

SIG

COM

SIG

COM

GFB PRESSURE SWITCH (121323)

SOLVENT FLOW SWITCH (120278)

FLOW RATE ANALOG IN 1

FLOW RATE ANALOG COMMON 1

FLOW RATE ANALOG IN 2

FLOW RATE ANALOG COMMON 2

FLOW RATE ANALOG IN 3

FLOW RATE ANALOG COMMON 3

FLOW RATE ANALOG IN 4

FLOW RATE ANALOG COMMON 4

UNUSED

UNUSED

UNUSED

UNUSED

CABLE

(121003)

3

3

4

2

1

5

ADVANCED

DISPLAY MODULE

(24E451)

4

5

2

1

LIGHT

TOWER

(15X472)

4

25 PIN D-SUB CABLE

(16T659)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

1

BREAKOUT MODULE PUMP 3 (24N527)

2

1 2 3 4 5

3

1 2 3 4

4

1 2 3 4 5

5

1 2 3 4 5

6

1 2 3 4 1 2 3 4

7

5 6 7 8

8

1 2 3 4

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 3

SEE DETAIL A OR B

TRANSDUCER PUMP

TRANSDUCER PUMP

PWR (RED) SIG (WHITE) COM (BLACK) SHIELD/GRN

3 UP

MANIFOLD

MAC SERIES 46 (16P812 QTY

G3000

METER

PUMP 3

(EITHER, 239716,

258718,16M510,

OR 16M519)

GRND

SCREW

TWISTED PAIR CABLE (16W159)

Figure 24 Electrical Schematic, Sheet 2, Part 2

CONTINUED ON THE NEXT PAGE

+48V COM +48V COM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

1

BREAKOUT MODULE PUMP 4 (24N527)

2

1 2 3 4 5

3

1 2 3 4

4

1 2 3 4 5

5

1 2 3 4 5

6

1 2 3 4 1 2 3 4

7

5 6 7 8

8

1 2 3 4

+48V COM +48V COM

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 4

SEE DETAIL A OR B

TRANSDUCER PUMP

TRANSDUCER PUMP

PWR (RED) SIG (WHITE) COM (BLACK) SHIELD/GRN

4 UP

MANIFOLD

MAC SERIES 46 (16P812 QTY

G3000

METER

PUMP 4

(EITHER, 239716,

258718,16M510,

OR 16M519)

GRND

SCREW

TWISTED PAIR CABLE (16W159)

332457C 33

Electrical Schematics

FROM CAN IS BOARD (24M485) ON PAGE 2 FROM CAN IS BOARD (24M485) ON PAGE 2

2

CABLE (15V206)

FLUSH

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

MANIFOLD

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

*FLUSH

COLOR 9

COLOR 10

COLOR 11

COLOR 12

COLOR 13

COLOR 14

COLOR 15

COLOR 16

MANIFOLD

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

3

4

1

2

5

6

3

4

1

2

5

6

J15

J8

1 2 3 4 5

COLOR

CHANGE

MODULE 1

(COLORS

1 THRU 8)

J9

6

J16

3

4

1

2

5

6

3

4

1

2

5

6

3

4

1

2

5

6

J14 J10

1 2 3 4 5

3

4

1

2

5

6

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

MANIFOLD

DUMP

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

3

4

1

2

5

6

3

4

1

2

5

6

J8

1 2 3 4 5

COLOR

CHANGE

MODULE 2

(COLORS

9 THRU 16)

J9

J15

6

J16

3

4

1

2

5

6

3

4

1

2

5

6

3

4

1

2

5

6

J14 J10

1 2 3 4 5

3

4

1

2

5

6

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

MANIFOLD

DUMP*

COLOR 9

COLOR 10

COLOR 11

COLOR 12

COLOR 13

COLOR 14

COLOR 15

COLOR 16

*FLUSH

COLOR 17

COLOR 18

COLOR 19

COLOR 20

COLOR 21

COLOR 22

COLOR 23

COLOR 24

MANIFOLD

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

3

4

1

2

5

6

3

4

1

2

5

6

1 2 3 4 5

COLOR

CHANGE

MODULE 3

(COLORS

17 THRU 24)

J8 J9

J15

6

J16

3

4

1

2

5

6

3

4

1

2

5

6

3

4

1

2

5

6

J14 J10

3

4

1

2

5

6

5 4 3 2 1

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

MANIFOLD

DUMP*

COLOR 17

COLOR 18

COLOR 19

COLOR 20

COLOR 21

COLOR 22

COLOR 23

COLOR 24

FLUSH

CATALYST 1

CATALYST 2

CATALYST 3

CATALYST 4

MANIFOLD

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

3

4

1

2

5

6

3

4

1

2

5

6

J8

CATALYST

CHANGE

MODULE 5

(CATALYST

1 THRU 4)

J9

6

3

4

1

2

5

6

J15 J16 3

4

1

2

5

6

3

4

1

2

5

6

J14 J10

3

4

1

2

5

6

1 2 3 4 5

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

MANIFOLD

DUMP

CATALYST 1

CATALYST 2

CATALYST 3

CATALYST 4

*FLUSH

COLOR 25

COLOR 26

COLOR 27

COLOR 28

COLOR 29

COLOR 30

MANIFOLD

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

3

4

1

2

5

6

1 2 3 4 5

COLOR

CHANGE

MODULE 4

(COLORS

25 THRU 32)

J8 J9

6

3

4

1

2

5

6

J15 J16

3

4

1

2

5

6

3

4

1

2

5

6

3

4

1

2

5

6

J14 J10

1 2 3 4 5

3

4

1

2

5

6

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

MANIFOLD

DUMP*

COLOR 25

COLOR 26

COLOR 27

COLOR 28

COLOR 29

COLOR 30

2

CABLE (15V206)

Figure 25 Electrical Schematic, Sheet 3

* May be unused in some configurations.

CONTINUED ON THE NEXT PAGE

34 332457C

Electrical Schematics

FLUSH

CATALYST 3

CATALYST 4

MANIFOLD

COM

+12VDC

+12VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

3

4

1

2

J8

CATALYST

CHANGE

MODULE 6

(CATALYST

3 THRU 4)

J9

3

4

1

2

3

4

1

2

5

6

J15

6

J16 3

4

1

2

5

6

4

5

6

1

2

J14 J10

4

5

6

1

2

1 2 3 4 5

FLUSH

CATALYST 1

CATALYST 2

MANIFOLD

COM

+12VDC

+12VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

4

5

6

1

2

3

4

1

2

J8

5 4 3 2 1

CATALYST

CHANGE

MODULE 5

(CATALYST

1 THRU 2)

J9

3

4

1

2

3

4

1

2

J15

6

J16 3

4

1

2

J14 J10 4

5

6

1 2 3 4 5

1

2

1 2 3 4 5

COLOR

CHANGE

MODULE 4

(COLORS

25 THRU 32)

Figure 26 Electrical Schematic, Sheet 3, Alternate

Configuration for Catalyst Change Control

CONTINUED ON THE NEXT PAGE

+12VDC

COM

+12VDC

COM

MANIFOLD

DUMP

CATALYST 3

CATALYST 4

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

+12VDC

COM

+12VDC

COM

MANIFOLD

DUMP

CATALYST 1

CATALYST 2

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

332457C 35

Electrical Schematics

FROM CAN IS BOARD (24M485) ON PAGE 2

NON-HAZARDOUS LOCATION

HAZARDOUS LOCATION

COLOR FLUSH

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

MANIFOLD

+12VDC

COM

+12VDC

COM

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

3

4

1

2

5

6

3

4

1

2

J15

1 2 3 4 5

COLOR

CHANGE

MODULE 7

(COLORS

33 THRU 40)

J8 J9

7

J16

3

4

1

2

5

6

3

4

1

2

3

4

1

2

5

6

J14 J10

1 2 3 4 5

3

4

1

2

5

6

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

MANIFOLD

CATALYST FLUSH

CATALYST 1

CATALYST 2

CATALYST 3

CATALYST 4

COLOR 9

COLOR 10

COLOR 11

COLOR 12

COLOR 13

COLOR 14

COLOR 15

COLOR 16

COLOR 17

COLOR 18

COLOR 19

COLOR 20

COLOR 21

MANIFOLD

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

4

5

6

1

2

3

4

1

2

5

6

1 2 3 4 5

COLOR

CHANGE

MODULE 8

(COLORS

41 THRU 48)

J8 J9

J15

7

J16

4

5

6

1

2

3

4

1

2

5

6

3

4

1

2

J14 J10

3

4

1

2

5 4 3 2 1

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

MANIFOLD

COLOR 22

COLOR 23

COLOR 24

COLOR 25

COLOR 26

COLOR 27

COLOR 28

COLOR 29

COLOR 30

5 4 3 2 1

BOOTH CONTROL

(24M731)

Figure 27 Electrical Schematic, Sheet 3, Hazardous

Location

36 332457C

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 31

.

M12 CAN Cables, for Hazardous Locations

NOTE: The total length of cable used in the hazardous location must not exceed 120 ft (36 m).

Cable Part No.

16V423

Length ft (m)

2.0 (0.6)

16V424

16V425

16V426

16V427

3.0 (1.0)

6.0 (2.0)

10.0 (3.0)

15.0 (5.0)

16V428

16V429

16V430

25.0 (8.0)

50.0 (16.0)

100.0 (32.0)

15U531

15U532

M12 CAN Cables, for Non-Hazardous

Locations Only

2.0 (0.6)

3.0 (1.0)

15V205

15V206

15V207

15V208

15U533

15V213

6.0 (2.0)

10.0 (3.0)

15.0 (5.0)

25.0 (8.0)

50.0 (16.0)

100.0 (32.0)

CAN Cables, for Non-Hazardous

Locations Only

Cable Part No.

125306

123422

121000

121227

Length ft (m)

1.0 (0.3)

1.3 (0.4)

1.6 (0.5)

2.0 (0.6)

121001

121002

3.0 (1.0)

5.0 (1.5)

121003

120952

121201

121004

121228

10.0 (3.0)

13.0 (4.0)

20.0 (6.0)

25.0 (8.0)

50.0 (15.0)

16T659

16V659

25 Pin D-SUB Cables, for Non-Hazardous

Locations Only

2.5 (0.8)

6.0 (1.8)

Alternates for Communication Module

24R910, for Non-Hazardous Locations Only

Module Part No.

15V759

15V760

Module Part No.

15V761

15V762

Alternates for Color Change Modules by Part Number (Factory Configuration), for

Non-Hazardous Locations Only

Module Part No.

Description

24T557

24T558

24T559

24T560

2 color/2 catalyst

4 color/4 catalyst

6 color/6 catalyst

8 color/8 catalyst

Alternates for Color Change Modules by Part Number (Factory Configuration), for

Hazardous Locations Only

24T571

24T572

2 color/2 catalyst

4 color/2 catalyst

24T573

24T574

6 color/2 catalyst

8 color/2 catalyst

332457C 37

Dimensions

Dimensions

Figure 28

Figure 29

38

A

58.20 in.

(1478 mm)

B with ADM without

ADM

14.5 in.

(368 mm)

11.12 in.

(282 mm)

C

22.0 in.

(559 mm)

D

Figure 30

19.26 in.

(489 mm)

E

2.0 in.

(51 mm)

F G H

18.0 in.

(457 mm)

17.26 in.

(438 mm)

0.52 in.

(13 mm)

332457C

Technical Data

Technical Data

Positive Displacement

Proportioner

Maximum fluid working pressure:

MC1000 Air Spray

Systems

MC2000 Air-Assisted

Spray Systems

Maximum working air pressure:

Air supply:

Air filter inlet size:

Air filtration for air logic

(user-supplied):

Air filtration for atomizing air (user-supplied):

Mixing ratio range:

Fluids handled:

U.S.

300 psi

1500 psi

100 psi

85–100 psi

3/8 npt(f)

Metric

2.1 MPa, 21 bar

10.5 MPa, 105 bar

0.7 MPa, 7.0 bar

0.6–0.7 MPa, 6.0–7.0 bar)

5 micron (minimum) filtration required; clean and dry air

30 micron (minimum) filtration required; clean and dry air

0.1:1 — 50:1, ±1% one or two component:

• solvent and waterborne paints

• polyurethanes

• epoxies

• acid catalyzed varnishes

• moisture sensitive isocyanates

20–5000 centipoise

100 mesh minimum

Viscosity range of fluid:

Fluid filtration

(user-supplied):

Maximum fluid flow:

Fluid outlet size:

External power supply requirements:

800 cc/minute (depending on material viscosity)

1/4 npt(m)

90 - 250 Vac, 50/60 Hz, 7 amps maximum draw

15 amp maximum circuit breaker required

8 to 14 AWG power supply wire gauge

36 to 122°F 2 to 50°C Operating temperature range:

Storage temperature range:

Weight (approximate):

Sound data:

Wetted parts:

—4 to 158°F

195 lb

Less than 75 dB(A)

—20 to 70°C

88 kg

17–4PH, 303, 304 SST, Tungsten carbide (with nickel binder), perfluoroelastomer; PTFE, PPS, UHMWPE

332457C 39

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

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, free of charge any defective parts. The equipment will be returned to the original purchaser transportation made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

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.

manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of these warranties.

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 and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en

Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

For the latest information about Graco products, visit www.graco.com.

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 332457

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 November 2013

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