Graco 3A2800F, ProMix PD2K Electronic Proportioner, Repair-Parts Owner's Manual

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Graco 3A2800F, ProMix PD2K Electronic Proportioner, Repair-Parts Owner's Manual | Manualzz

Repair-Parts

ProMix® PD2K Electronic Proportioner

3A2800F

EN

Important Safety Instructions

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

PROVEN QUALITY. LEADING TECHNOLOGY.

2

Contents

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

Related Manuals ................................................ 6

Warnings ........................................................... 7

Important Isocyanate (ISO) Information................ 10

Important Acid Catalyst Information ..................... 12

Acid Catalyst Conditions............................... 12

Moisture Sensitivity of Acid Catalysts ............ 12

Troubleshooting.................................................. 13

System Troubleshooting............................... 13

Error Code Troubleshooting.......................... 14

Booth Control Troubleshooting...................... 27

Power Barrier Board Troubleshooting............ 28

Isolation Board Troubleshooting.................... 29

Enhanced Fluid Control Module

Troubleshooting.............................. 30

Pump Module Troubleshooting ..................... 31

Advanced Display Module

Troubleshooting.............................. 32

Electrical Schematics.......................................... 33

Standard Models (MC1000, MC2000,

MC3000, MC4000) ......................... 33

Dual Panel Models (MC1002, MC2002,

MC4002)........................................ 39

Optional Cables and Modules ....................... 45

Communications Options (for PLC and

AWI) .............................................. 46

Repair................................................................ 47

Before Servicing .......................................... 47

Pressure Relief Procedure............................ 48

Repairing the Advanced Display Module

(ADM)............................................ 49

Servicing the Control Box ............................. 50

Servicing the Fluid Section ........................... 59

Parts.................................................................. 63

Proportioner Parts (Standard Models) ........... 63

Proportioner Parts (Dual Panel

Models).......................................... 66

Control Box Parts (Standard Models) ............ 69

Control Box Parts (Dual Panel Models)........... 72

Solenoid Manifold Parts................................ 75

Technical Data ................................................... 76

3A2800F

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

MC0500

MC0502

A

A

100 psi (0.7 MPa, 7.0 bar)

100 psi (0.7 MPa, 7.0 bar)

With low–pressure pumps:

300 psi (2.068 MPa,

20.68 bar)

With high–pressure pumps:

1500 psi (10.34 MPa,

103.4 bar)

300 psi (2.068 MPa,

20.68 bar)

MC1000

MC1002

MC3000

Acid-based

Material

MC2000

MC2002

MC4000

MC4002

Acid-based

Material

A 100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa,

103.4 bar)

0359

II 2 G

ProMix

Electronic Proportioner

II 2 G

Ex ia IIA T3

FM13 ATEX 0026

IECEx FMG 13.0011

.7

®

PD2K / PD1K

MAX AIR WPR

7

FM16US0241

FM16CA0129

Intrinsically safe equipment for Class I,

Div 1, Group D, T3

Ta = 2°C to 50°C

100

MPa bar

MAX FLUID WPR

PSI

Intrinsically Safe (IS) System. Install per IS Control Drawing No. 16P577.

Control Box IS Associated

Apparatus for use in non hazardous location, with IS Connection to color change and booth control modules

Apparatus for use in:

Class I, Division 1, Group D T3

Hazardous Locations

Read Instruction Manual

Warning: Substitution of components may impair intrinsic safety.

PART NO.

SERIES SERIAL

2.068 20.68

300

MPa bar PSI

MAX TEMP 50°C (122°F)

Figure 1 Model MC1000, MC1002, & MC3000 (Low

Pressure) Identification Label

MFG. YR.

GRACO INC.

P.O. Box 1441

Minneapolis, MN

55440 U.S.A.

Continued on the next page.

3A2800F 3

Models

ProMix ® PD2K / PD1K

PART NO.

SERIES NO. MFG. YR.

POWER REQUIREMENTS

VOLTS 90-250 ~

GRACO INC.

P.O. Box 1441

Minneapolis, MN

55440 U.S.A.

AMPS 7 AMPS MAX

Intrinsically safe connections for Class I, Div 1, Group D

Ta = 2°C to 50°C

Install per 16P577

FM16US0241

FM16CA0129 Um: 250 V

50/60 Hz

II (2) G

[Ex ia] IIA Gb

FM13 ATEX 0026

IECEx FMG 13.0011

Figure 2 24M672 & 26A188 Control Box Identification

Label

ProMix

Electronic Proportioner

II 2 G

Ex ia IIA T3

FM13 ATEX 0026

IECEx FMG 13.0011

.7

®

PD2K / PD1K

MAX AIR WPR

7

FM16US0241

FM16CA0129

Intrinsically safe equipment for Class I,

Div 1, Group D, T3

Ta = 2°C to 50°C

100

MPa bar

MAX FLUID WPR

PSI

Intrinsically Safe (IS) System. Install per IS Control Drawing No. 16P577.

Control Box IS Associated

Apparatus for use in non hazardous location, with IS Connection to color change and booth control modules

Apparatus for use in:

Class I, Division 1, Group D T3

Hazardous Locations

Read Instruction Manual

Warning: Substitution of components may impair intrinsic safety.

PART NO.

SERIES SERIAL

10.34 103.4

1500

MPa bar PSI

MAX TEMP 50°C (122°F)

Figure 3 Model MC2000 & MC2002 (High Pressure)

Identification Label

MFG. YR.

GRACO INC.

P.O. Box 1441

Minneapolis, MN

55440 U.S.A.

Figure 4 Non-Intrinsically Safe Color Change Control

(Accessory) Identification Label

ProMix ® PD2K / PD1K

PART NO.

COLOR CHANGE CONTROL

SERIES SERIAL MFG. YR.

MAX AIR WPR

Intrinsically safe equipment for Class I, Div 1, Group D, T3

Ta = 2°C to 50°C

Install per 16P577

FM16US0241 FM16CA0129

Artwork No. 294055 Rev. C

Figure 5 Intrinsically Safe Color Change Control

(Accessory) Identification Label

II 2 G

Ex ia IIA T3 Gb

FM13 ATEX 0026

IECEx FMG 13.0011

.7

7

MPa

100 bar PSI

GRACO INC.

P.O. Box 1441

Minneapolis, MN

55440 U.S.A.

Continued on the next page.

4 3A2800F

Figure 6 Booth Control Identification Label www.graco.com/patents

12 VDC FM16US0241

FM16CA0129

II 2 G

Ex ia IIA T3 Gb

FM13 ATEX 0026

IECEx FMG 13.0011

Intrinsically safe equipment for

Class I, Div 1,

Group D, T3

Install per 16P577

Ta = 2°C to 50°C

Figure 7 Pump Expansion Kit (Accessory)

Identification Label

Models

3A2800F 5

Related Manuals

Related Manuals

Manual No.

Description

332457 PD2K Proportioner Installation

Manual, Manual Systems

332562

3A4186

PD2K Proportioner Operation

Manual, Manual Systems

PD2K Dual Panel Proportioner

Operation Manual, Manual

Systems

3A2801

332339

Mix Module 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

334512

3A4497

PD1K Pump Expansion Kits

Instructions-Parts Manual

Air Control Module Kit Instructions

Manual

6 3A2800F

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

WARNING

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent flowing through the equipment can cause static sparking. 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).

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

• Never spray or flush solvent at high pressure.

• 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.

• 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.

3A2800F 7

8

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.

3A2800F

3A2800F

Warnings

WARNING

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 Safety Data Sheet (SDS) for handling instructions and to know the specific hazards of the fluids you are using, including the effects of long-term exposure.

• When spraying, servicing equipment, or when in the work area, always keeps work area well ventilated and always wear appropriate personal protective equipment. See Personal Protective

Equipment warnings in this manual.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

PERSONAL PROTECTIVE EQUIPMENT

Always wear appropriate personal protective equipment and cover all skin when spraying, servicing equipment, or when in the work area. Protective equipment helps prevent serious injury, including long-term exposure; inhalation of toxic fumes, mists, or vapors; allergic reactions; burns; eye injury and hearing loss. This protective equipment includes, but is not limited to:

• A properly fitting respirator, which may include a supplied-air respirator, chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority.

• Protective eyewear, and hearing protection.

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 SDS 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.

9

Important Isocyanate (ISO) Information

Important Isocyanate (ISO) Information

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

Material Self-ignition

Isocyanate Conditions

Some materials may become self-igniting if applied too thick. Read material manufacturer’s warnings and Safety Data Sheet (SDS).

Spraying or dispensing fluids that contain isocyanates creates potentially harmful mists, vapors, and atomized particulates

• Read and understand the fluid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific hazards and precautions related to isocyanates.

• Use of isocyanates involves potentially hazardous procedures. Do not spray with the equipment unless you are trained, qualified, and have read and understood the information in this manuals and in the fluid manufacturer’s application instructions and SDS.

• Use of incorrectly maintained or mis-adjusted equipment may result in improperly cured material. Equipment must be carefully maintained and adjusted according to instructions in the manual.

• To prevent inhalation of isocynate mists, vapors, and atomized particulates, everyone in the work area must wear appropriate respiratory protection. Always wear a properly fitting respirator, which may include a supplied-air respirator. Ventilate the work area according to instructions in the fluid manufacturer’s SDS.

• Avoid all skin contact with iscocyanates.

Everyone in the work area must wear chemically impermeable gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local regulatory authority.

Follow all fluid manufacturer recommendations, including those regarding handling of contaminated clothing. After spraying, wash hands and face before eating or drinking.

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.

10 3A2800F

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.

Important Isocyanate (ISO) Information

NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.

Changing Materials

NOTICE

Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime.

• When changing materials, flush the equipment multiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

• When changing between epoxies and urethanes or polyureas, disassemble and clean all fluid components and change hoses. Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the A (resin) side.

3A2800F 11

Important Acid Catalyst Information

Important Acid Catalyst Information

The PD2K MC3000 and MC4000 Proportioner is designed for acid catalysts (“acid”) currently used in two-component, wood-finishing materials. Current acids in use (with pH levels as low as 1) are more corrosive than earlier acids.

More corrosion-resistant wetted materials of construction are required, and must be used without substitution, to withstand the increased corrosive properties of these acids.

Acid Catalyst Conditions

Acid is flammable, and spraying or dispensing acid creates potentially harmful mists, vapors, and atomized particulates. To help prevent fire and explosion and serious injury:

• Read and understand the acid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific hazards and precautions related to the acid.

• Use only genuine, manufacturer’s recommended acid-compatible parts in the catalyst system (hoses, fittings, etc). A reaction may occur between any substituted parts and the acid.

• To prevent inhalation of acid mists, vapors, and atomized particulates, everyone in the work area must wear appropriate respiratory protection. Always wear a properly fitting respirator, which may include a supplied-air respirator. Ventilate the work area according to instructions in the acid manufacturer’s SDS.

• Avoid all skin contact with acid. Everyone in the work area must wear chemically impermeable gloves, protective clothing, foot coverings, aprons, and face shields as recommended by the acid manufacturer and local regulatory authority. Follow all acid manufacturer recommendations, including those regarding handling of contaminated clothing. Wash hands and face before eating or drinking.

• Regularly inspect equipment for potential leaks and remove spills promptly and completely to avoid direct contact or inhalation of the acid and its vapors.

• Keep acid away from heat, sparks, and open flames. Do not smoke in the work area. Eliminate all ignition sources.

• Store acid in the original container in a cool, dry, and well-ventilated area away from direct sunlight and away from other chemicals in accordance with acid manufacturer’s recommendations. To avoid corrosion of containers, do not store acid in substitute containers. Reseal the original container to prevent vapors from contaminating the storage space and surrounding facility.

Moisture Sensitivity of Acid Catalysts

Acid catalysts can be sensitive to atmospheric moisture and other contaminants. It is recommended the catalyst pump and valve seal areas exposed to atmosphere are flooded with ISO oil, TSL, or other compatible material to prevent acid build-up and premature seal damage and failure.

NOTICE

Acid build-up will damage the valve seals and reduce the performance and life of the catalyst pump. To prevent exposing acid to moisture:

• Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere.

Never store acids in an open container.

• Keep the catalyst pump and the valve seals filled with the appropriate lubricant. The lubricant creates a barrier between the acid and the atmosphere.

• Use only moisture-proof hoses compatible with acids.

• Always lubricate threaded parts with an appropriate lubricant when reassembling.

12 3A2800F

Troubleshooting

Troubleshooting

NOTE: Check all possible remedies before disassembling the system.

System Troubleshooting

Problem

Unit will not operate.

Pump output low on both strokes.

Pump output low on only one stroke.

No output.

Pump operates erratically.

Cause

Inadequate power supply.

Power switch is off.

Main power is shut off.

Solution

See

Technical Data, page 76

.

Turn switch on.

Turn main power switch on.

Exhausted fluid supply.

Refill and reprime pump.

Clogged fluid outlet line, valves, etc.

Clear.

Fluid dried on piston rod.

Disassemble and clean pump. See pump manual. In future, stop pump at bottom of stroke.

Inadequate power supply.

Exhausted fluid supply.

See

Technical Data, page 76

.

Refill and reprime pump.

Clogged fluid outlet line, valves, etc.

Clear.

Worn piston packings.

Held open or worn dosing valves.

Replace. See pump manual.

Check and repair. See valve manual.

Worn piston packing.

Replace. See pump manual.

Improperly installed dosing valves.

Check solenoid connections to valves. See pump manual.

Exhausted fluid supply.

Held open or worn dosing valves.

Worn piston packing.

Refill and reprime pump.

Check and repair. See pump manual.

Replace. See pump manual.

3A2800F 13

Troubleshooting

Error Code Troubleshooting

System errors alert you of a problem and help prevent off-ratio spraying. There are three types:

Advisory, Deviation, and Alarm.

NOTE: Dual Panel Systems (MC0502, MC1002,

MC2002, MC4002) have most of the same error codes, but many are specific to one of two mix units. Refer to the PD2K Dual Panel Proportioner

Operation manual for the specific error codes. See

Related Manuals, page 6

.

An Advisory records an event in the system, and will clear itself after 60 seconds. The four-digit error code will be followed by “-V”.

A Deviation records an error in the system but does not shut down the equipment. The deviation must be acknowledged by the user. The four-digit error code will be followed by “-D”.

If an Alarm occurs, operation stops. The four-digit error code will be followed by “-A”.

If any of the three system error types occur:

• Alarm buzzer sounds (unless in silent mode).

• Alarm popup screen shows the active alarm code.

• Status bar on the Advanced Display Module shows the active alarm code.

• Alarm is saved in the date/time stamped log.

NOTE: A Record saves relevant system events in the background. These are informational only and can be reviewed on the Events screen, which displays the 200 most recent events, with date, time, and description.

NOTE: When an error occurs be sure to determine the code before resetting it. If you forget which code occurred, the Errors screen displays the 200 most recent errors, with date, time, and description.

NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable pump number, which can vary. The unit’s display will show the applicable pump number as the last digit in the code.

14 3A2800F

Troubleshooting

Purge Errors

Code

ETD1

ETE0

Type

Deviation

Description Problem

Autodump

Color (A)

Passed

System has completed an auto dump of the contents from the pump all the way out to the gun.

Record Purge Not

Complete

The system was unable to complete a purge sequence.

ETO1

ETS1

Alarm

Deviation

Autodump

Failed

Autodump

Solvent

Passed

Potlife time has expired and the system attempted to flush the mixed material contents out of the gun. The solvent flow meter or solvent flow switch did no indicate any flow taking place during the attempted purge.

System has completed an auto dump of the gun contents only.

Cause

Potlife time has expired and the system was not purged, so the system refilled with color.

An indication that the system either could not complete or was interrupted before completing a gun purge.

Solvent flow switch not working.

Gun is not in gun flush box.

F7P1

SGD1

SPD1

Alarm

Alarm

Alarm

Air Flow

Switch On

Gun Flush

Box Open

Gun Purge

Incomplete

The air flow switch is indicating unexpected atomizing air flow.

GFB was left open when the system was trying to attempt a purge.

The system timed out without reaching the user-specified volume of solvent for a purge.

Solution

No action required.

No action required.

Replace the switch.

Ensure the gun is replaced in the gun flush box and cover is closed when not in use.

Potlife time has expired and the system was not purged, so the system performed an autodump with solvent.

Air flow switch is stuck in flow position.

Leak downstream in air line or fitting.

Air supply pressure fluctuation.

Gun is not in gun flush box.

GFB pressure switch not wired/working.

No action required.

Clean or replace switch.

Check for leaks and tighten fittings.

Eliminate pressure fluctuations.

Ensure the gun is replaced in the gun flush box and cover is closed when not in use.

Double check that the pressure switch is wired properly to the EFCM.

Replace switch.

Solvent flow switch not working.

Solvent flow is too low to actuate the solvent switch.

Gun is not triggered.

Mix manifold was not set to flush position, blocking solvent flow to the spray gun.

Increase solvent pressure to drive a high purge flow rate

Operator must continue flushing for configured time, until the booth control indicates purge is completed.

Set manifold to flush position.

3A2800F 15

Troubleshooting

Mix Errors

Code

F7S1

Type

Alarm

F7S2

QPD1

QP##

SND1

Alarm

Alarm, then

Deviation

Deviation

Alarm

Description

Flow

Detected

Solvent Gun

Flow

Detected

Solvent Mix

Potlife

Expired

Potlife

Expired

Recipe ##

Mix Fill

Incomplete

Problem

The solvent flow switch is indicating unexpected solvent flow.

The solvent flow switches indicate that both are flowing solvent at the same time.

*This only applies to systems with mix-at-wall.

Potlife time has expired before the system has moved the required amount of material

(potlife volume) through the mixed material line.

Potlife time has expired before the system has moved the required amount of material

(potlife volume) through the mixed material line in an inactive gun loaded with recipe ##.

*This only applies to systems with multiple guns.

The system timed out before the mix fill cycle loaded the gun with mixed material.

Cause

Solvent flow switch is stuck in flow position.

There is a leak through the solvent cutoff valve.

One or both solvent flow switches are stuck in flow position.

There is a leak through one or both of the solvent cutoff valves.

Purge process was not completed.

Solvent supply shut off or empty.

Solution

Clean or replace switch.

Check for leaks and repair valve.

Clean or replace the switch(es).

Check for leaks and repair valve(s).

Make sure purge process is completed.

Verify solvent supply is available and on, supply valves are open.

Purge the inactive gun.

An inactive gun has mixed material for recipe

## loaded and has not dispensed enough material in the required amount of time.

Mix manifold not set to spray position.

Spray gun was not triggered.

Restrictions in mixer, manifold, or spray gun.

Set manifold to spray.

Allow flow through gun during fill process until the fill complete LED stops flashing.

Fix restrictions.

16 3A2800F

Troubleshooting

Pumping Errors

NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable component number, which can vary. The unit’s display will show the applicable number as the last digit in the code. For example, the F1S# code listed in this table will be displayed as F1S1 if the affected component is pump

1, F1S2 for pump 2, and so on.

Code

DA0#

DE0#

Type

Alarm

Description

Alarm Exceeded

Maximum

Flow Pump

#

Leak

Detected

Pump #

Problem

Pump was driven to its maximum allowed speed.

This is a manual stall test failure when the pump cannot build pressure to the target “Stall Test

Pressure.” Will fault after

30 seconds.

Cause

System has a leak or open valve that is allowing unrestricted flow.

Pump is cavitating, cycling without restriction.

Viscosity of material is too thin for nozzle size.

System pressure or

Flow Setpoint is too high

(causing the pump to work too hard).

No material in the pump or line.

Leak in the system.

Solution

Inspect system for leaks.

Verify that the pump is being supplied with material.

Reduce nozzle size to create more restriction.

Reduce paint pressure to lower the flow rate.

Reduce the pressure or the Flow Setpoint.

DF0#

DG0#

DH0#

Alarm

Alarm

Alarm

No Stall Up

Pump #

No Stall

Down Pump

#

No Stall

Pump #

Pump failed the stall test; did not stall on the upstroke.

Pump failed the stall test; did not stall on the downstroke.

Pump failed the stall test; did not stall on either the upstroke or the downstroke.

Valve failure, seal failure, worn rod or cylinder.

Valve failure, seal failure, worn rod or cylinder.

Valve failure, seal failure, worn rod or cylinder.

Make sure the pump and down stream color line are loaded with material.

Determine if leak is external or internal by visually inspecting the system for fluid leakage.

Fix all loose or worn hoses, fittings, and seals.

Inspect all valve seats and needles for wear, and replace worn piston or throat seals.

Replace inlet and outlet valve and seal for up stroke. Replace piston and throat seals.

Replace rod and cylinder as necessary.

Replace inlet and outlet valve and seal for down stroke. Replace piston and throat seals.

Replace rod and cylinder as necessary.

Replace inlet and outlet valve and seal for up and down strokes. Replace piston and throat seals.

Replace rod and cylinder as necessary.

3A2800F 17

Troubleshooting

Code

DKD#

DKF#

EBH#

EF0#

EF1#

F1D#

Type

Alarm

Record

Alarm

Alarm

Description

Alarm Position

Failed

Pump #

Position

Overspeed

Pump #

Home

Complete

Pump #

Timeout

Startup

Pump #

Timeout

Shutdown

Pump #

Alarm Flow Low Mix

Pump #

Problem

Pump was unable to reach it’s drive position.

Pump moved beyond it’s drive position.

Record of pump homing is complete.

Pump tried but was not able to move to the home position within a specified amount of time.

Pump tried but was not able to move to the park position within a specified amount of time.

The pump was unable to maintain it's target flow rate.

Cause

Not enough air is supplied to the dosing valves.

The pressure at the pump outlet is too high.

The pump was knocked out of position.

An indication on the display that the pump completed the home function

Pump dose valves did not actuate.

Motor could not drive pumps and linear actuator.

Pump stroke length is shortened by mechanical system tolerance.

Verify air pressure to solenoid valves. Verify the valves are actuating.

Verify motor is driving the pump.

Pump dose valves did not actuate.

Pump is filled with thick paint and could not drive piston to end of stroke.

Motor or drive is worn or damaged.

There is a restriction in the hose or gun that is preventing the pump from dispensing at it's target rate.

Solution

Ensure that at least 85

PSI is being supplied to the dosing valves.

Check for an obstruction downstream of the pump that would increase pressure. Ensure the feed pressure is within

1/2 – 1/3 of the target pressure.

There is no fluid pressure at the outlet of the pump, run the pump at a lower pressure to fill the lines.

Check that the feed pressure is not more than 1/2 – 1/3 greater than the target pressure.

No action required.

Verify correct assembly of linear actuator and pump piston rods. See pump manual.

Visually inspect valves to ensure they are operating properly; verify they have air pressure above 85 psi (0.6 MPa,

6.0 bar).

Observe motor and drive assembly to verify that the motor is generating force.

Check that the gun is triggered and for restrictions in the hose.

18 3A2800F

Code

F1F#

F1S#

F7D#

F8D1

F9D#

SAD1

Troubleshooting

Type Description

Alarm Flow Low Fill

Pump #

Alarm

Alarm

Alarm

Alarm

Alarm

Flow Low

Purge Pump

#

Flow

Detected

Pump #

Flow Not

Detected

Flow

Unstable

Pump #

Atomizing

Solvent

Problem

There has been no flow or low flow during a pump fill operation.

Cause

There is a restriction on the outlet side of the pump or color stack.

Thick viscosity paint requires more pressure to pump.

There has been no flow or low flow during a pump purge operation.

The pumps do not have to move for the system to build enough pressure to meet the setpoint.

Restriction in the outlet side of the pump or color stack resulting in the solvent flow being too low.

The pump flow exceeded

20 cc/min flow coming into Idle mode.

No flow while mixing.

The pump flow rate did not stabilize while entering Idle mode.

Air flow switch is active while solvent, diluted material, or an unknown material is in the gun.

There is a leak in the system or the gun was open when the system went into Idle mode.

Restriction in the outlet side of the pump or color stack.

Potential leak in the system.

Atomizing air supply was not shut off before purging or filling spray gun.

Solution

Make sure there are no restrictions in the color stack and that the dump valve is actuating.

Increase non-mix pressure if necessary to create flow during the fill function.

Increase non-mix pressure if necessary to create flow during the fill function.

Make sure there are no restrictions in the system. Increase non-mix pressure if necessary to create flow during the purge function.

Verify there are no leaks in the system. Make sure the air flow switch is actuating properly.

Do not trigger the gun without atomizing air.

Make sure there are no restrictions in the system.

Check the system for leaks and run manual stall test.

Make sure atomizing air is shut off before purging or filling the spray gun.

Use an AA cutoff valve on the atomizing air supply.

3A2800F 19

Troubleshooting

Pressure Errors

NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable component number, which can vary. The unit’s display will show the applicable number as the last digit in the code. For example, the P6F# code listed in this table will be displayed as P6F1 if the affected component is pump

1, P6F2 for pump 2, and so on.

Code

F6F#

P1F#

Type Description

Alarm Press. Sens.

Removed

Inlet #

Problem

No inlet pressure transducer is detected when the system is expecting one.

Cause

Disconnected transducer.

Solution

Verify transducer is connected properly.

Replace if reconnecting does not eliminate the alarm.

Increase inlet pressure.

P2F#

P3D#

P3F#

P4D#

P4F#

P4P#

P6D#

Alarm Pressure

Low Inlet

Pump #

Deviation

Pressure

Low Inlet

Pump #

Deviation

Deviation

Alarm

Alarm

Alarm

Alarm

Pressure

High Outlet

Pump #

Pressure

High Inlet

Pump #

Pressure

High Outlet

Pump #

Pressure

High Inlet

Pump #

Pressure

High Supply

Pump #

Press. Sens.

Removed

Outlet #

The inlet pressure on pump # is less than the user-entered alarm limit.

The inlet pressure on pump # is less than the user-entered deviation limit.

The outlet pressure on pump # is greater than the user entered deviation limit.

The inlet pressure on pump # is greater than the user-entered deviation limit.

The outlet pressure on pump # is greater than the user entered alarm limit.

The inlet pressure on pump # is greater than the user-entered alarm limit.

The supply pump fluid pressure for pump # is greater than 90% of the user-entered Stall Test

Pressure.

No outlet pressure transducer is detected when the system is expecting one.

The supply pump pressure is too high.

Disconnected transducer.

Increase inlet pressure.

Relieve system pressure.

Decrease inlet pressure.

Relieve system pressure.

Decrease inlet pressure.

Check supply for pump

#, decrease supply pressure.

P6F#

P9D#

P9F#

Alarm

Alarm

Alarm

Press. Sens.

Removed

Inlet #

Press. Sens.

Failed Outlet

#

Press. Sens.

Failed Inlet #

No inlet pressure transducer is detected when the system is expecting one.

Outlet pressure transducer has failed.

Inlet pressure transducer has failed.

Disconnected transducer.

Outlet pressure transducer has failed or the pressure is above the readable range.

Inlet pressure transducer has failed or the pressure is above the readable range.

Verify transducer is connected properly.

Replace if reconnecting does not eliminate the alarm.

Verify transducer is connected properly. Replace if reconnecting does not eliminate the alarm.

Relieve system pressure.

Verify connections, or replace if reconnecting does not eliminate the alarm.

Relieve system pressure.

Verify connections, or replace if reconnecting does not eliminate the alarm.

20 3A2800F

Code Type Description

QADX Alarm Differential

Pressure A

Over B

QBDX Alarm Differential

Pressure B

Over A

Troubleshooting

Problem

Low differential pressure.

This alarm is active only during Mix mode.

Cause

There is a leak on the B side.

The B side pump is cavitating.

High differential pressure. This alarm is active only during Mix mode.

There is a leak on the A side.

The A side pump is cavitating.

Solution

Check the system for internal and external leaks on all catalyst manifolds and plumbing.

Check paint supply on the B side, increase paint supply pressure.

Check the system for internal and external leaks on all color manifolds and plumbing.

Check paint supply on the A side, increase paint supply pressure.

3A2800F 21

Troubleshooting

System Errors

Code

EB00

Type Description

Record

Stop Button

Pressed

EC00

EL00

EM00

EMIX

Record

Record

Record

Advisory

Setup

Value(s)

Changed

System

Power On

System

Power Off

Pump Off

ES00 Advisory

Factory

Defaults

WSN1 Alarm Config Error

Color

WSN2 Alarm Config Error

Catalyst

Problem

Record of a stop button press.

Record of changing setup variables.

Record of power cycle

(ON).

Record of power cycle

(OFF).

The pumps are not powered and are unable to move.

Cause

Indicates system stop key on ADM was pressed.

Indicates date and time when setup values were changed.

Indicates date and time when system was started.

Indicates date and time when system was turned off.

Pump power was turned off or an error occurred.

Solution n/a n/a n/a n/a

Start pumps by pressing pump start key on

Advanced Display module.

n/a Record of defaults being loaded.

A color defined for the system is not assigned to any gun.

*This only applies to systems with multiple guns.

A catalyst defined for the system has an invalid gun assignment.

*This only applies to systems with multiple guns.

One or more colors is missing a valid gun assignment.

One or more catalyst is missing a valid gun assignment.

Too many catalyst gun assignments exist.

Ensure all colors for all color pumps have a gun assigned to them on

Pump Screen 4.

Ensure all catalysts for all catalyst pumps have a gun assigned to them on

Pump Screen 4.

The total number of catalyst gun assignments for the system may not exceed four.

22 3A2800F

Troubleshooting

Communication Errors

NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable component number, which can vary. The unit’s display will show the applicable number as the last digit in the code. For example, the CAC# code listed in this table will be displayed as CAC1 if the affected component is color change board 1, CAC2 for board 2, and so on.

Code

CA0X

CAC#

CADX

Type

Alarm

Alarm

Alarm

Description

Comm. Error

ADM

Comm. Error

Color Change

#

Comm. Error

Fluid Module

Problem

System does not detect the Advanced Display

Module (ADM).

System does not detect the Color Change

Module #.

System does not see the Enhanced

Fluid Control Module

(EFCM).

Cause

This communication error indicates that the Network has lost communication with the Advanced Display

Module.

This communication error indicates that the network has lost communication with the Color Change

Module #.

This communication error indicates that the Network has lost communication with the EFCM.

Solution

Check CAN cable connecting ADM to the

EFCM.

Check CAN cable connections to the Color Change

Module # and any interconnected modules.

Check CAN cables connecting ADM to the

EFCM. Replace Cable or EFCM as necessary.

CAGX

CAG#

CDC#

CDDX

Alarm

Alarm

Alarm

Alarm

Comm. Error

Gateway

Comm. Error

Modbus

Gateway

Duplicate Color

Change #

Duplicate Fluid

Module

System does not detect a CGM that was registered as being connected at power up.

System does not detect a Modbus CGM that was registered as being connected at power up.

System detects two or more identical Color

Change Modules.

System sees two or more identical

Enhanced Fluid

Control Modules

EFCM).

The Modbus CGM address dial was changed while the system was powered up.

The Modbus CGM is not connected/failed.

More than one Color

Change Module with the same address is connected in the system .

More than one EFCM is connected in the system.

Unplug the Modbus

CGM from the CAN network and re-plug it back in so that it re-registers with the new address.

Check that the Modbus

CGM is properly connected to the CAN network and it's LEDs indicate it is powered.

Check the system and remove the extra color change module.

Check the system and remove the extra

EFCM.

3A2800F 23

Troubleshooting

USB Errors

Code

EAUX

EBUX

EQU0

EQU1

EQU2

EQU3

EQU4

EQU5

EVUX

MMUX

Type

Advisory USB Busy

Record

Advisory USB Idle

Record

Record

Record

Record

Record

Description

USB Drive

Removed

USB Sys.

Settings

Downloaded

USB Sys.

Settings

Uploaded

USB Custom

Lang.

Downloaded

USB Custom

Lang.

Uploaded

USB Logs

Downloaded

Problem

USB drive is inserted, download is in progress.

USB drive was removed while downloading or uploading.

USB download completed, drive may be removed.

Settings were downloaded to USB drive.

Settings were uploaded from USB drive.

Custom language was downloaded to USB drive.

Custom language was uploaded from USB drive.

Data logs were downloaded to USB drive.

Advisory USB Disabled USB drive has been inserted, downloading is disabled.

Advisory Maint. USB

Logs Full

USB memory is more than 90% full.

WSUX

WXUD

WXUU

Advisory USB Config.

Err.

Advisory USB Download

Err.

Advisory USB Upload

Err.

Cause

Indicates USB port is uploading or downloading data.

Downloading/uploading data on USB was interrupted by the USB device being removed.

Data transfer is completed to the USB device.

User installed USB device in ADM USB port.

User installed USB device in ADM USB port.

User installed USB device in ADM USB port.

User installed USB device in ADM USB port.

User installed USB device in ADM USB port.

Configuration of system is blocking data transfer.

Configuration parameter on system is enabled to generate this advisory.

A software update was not completed successfully.

USB configuration file does not match expected; checked on startup.

An error occurred while downloading to the

USB drive.

An error occurred while uploading from the

USB drive.

User installed incompatible USB device in ADM USB port.

User installed incompatible USB device in ADM USB port.

Solution

Wait for USB Idle.

Replace the USB device and begin process again.

Remove USB device from ADM.

n/a n/a n/a n/a n/a

Change configuration to enable USB download function.

Complete download to ensure no data is lost.

Reinstall software.

Repeat process with compatible USB device.

Repeat process with compatible USB device.

24 3A2800F

Troubleshooting

Miscellaneous Errors

NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable component number, which can vary. The unit’s display will show the applicable number as the last digit in the code. For example, the B9D# code listed in this table will be displayed as B9D1 if the affected component is pump

1, B9D2 for pump 2, and so on.

Code

B9A0

B9AX

B9B0

B9BX

B9D#

B9S0

B9SX

WX00

Type

Advisory Volume

Rollover A

Advisory Volume

Advisory Volume

Advisory Volume

Advisory Volume

Advisory Volume

Advisory Volume

Alarm

Description

Current

Rollover A

Lifetime

Rollover B

Current

Rollover B

Lifetime

Rollover Pump

#

Rollover

Solvent

Current

Rollover

Solvent

Lifetime

Software

Errors

Problem

Batch counter for material A rolled over.

Grand total counter for material A rolled over.

Batch counter for material B rolled over.

Grand total counter for material B rolled over.

Grand total counter for pump # rolled over.

Batch counter for solvent rolled over.

Grand total counter for solvent rolled over.

An unexpected software error has occurred.

Cause

The totalizer has reached maximum capable value and started over at zero.

The totalizer has reached maximum capable value and started over at zero.

The totalizer has reached maximum capable value and started over at zero.

The totalizer has reached maximum capable value and started over at zero.

The totalizer has reached maximum capable value and started over at zero.

The totalizer has reached maximum capable value and started over at zero.

The totalizer has reached maximum capable value and started over at zero.

Solution n/a n/a n/a n/a n/a n/a n/a

Call Graco technical support.

Calibration Errors

NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable component number, which can vary. The unit’s display will show the applicable number as the last digit in the code. For example, the ENT# code listed in this table will be displayed as ENT1 if the affected component is pump

1, ENT2 for pump 2, and so on.

Code

END#

ENS0

ENT#

Type

Record

Record

Record

Name

Calibration Pump #

Description

A calibration test was run on the pump.

Calibration Solvent Meter A calibration test was run on the solvent meter.

Calibration Stall Test Pump # A stall test was completed successfully on pump #.

3A2800F 25

Troubleshooting

Maintenance Errors

NOTE: In some error codes listed below, a # symbol is shown as the last digit. This symbol represents the applicable component number, which can vary. For example, the MAD# code listed in this table will be displayed as MAD1 if the affected component is pump 1, MAD2 for pump 2, and so on.

Because some components are assigned a 2–digit number, the last digit of the code is displayed as an alphanumeric character. The second table below correlates the alphanumeric digit to its component number. For example, code

MEDZ represents outlet valve 30.

Code

MAD#

MAT#

MEB#

MED#

MEF#

MEG#

MES#

MFF#

MFS0

MGH0

MGP0

Type

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Name Description

Maint. Outlet Pump # Maintenance is due on pump.

Maintenance stall test is due on pump.

Maint. Stall Test Pump

#

Maint. Valve Catalyst

(B) #

Maintenance is due on catalyst valve.

Maint. Valve Outlet #

Maint. Valve Inlet #

Maintenance is due on outlet valve.

Maintenance is due on inlet valve.

Maint. Valve Gun # Maintenance is due on gun valve.

Maint. Valve Solvent # Maintenance is due on solvent valve.

Maint. Meter Flow #

Maint. Meter Solvent

Maint. Filter Fluid

Maint. Filter Air

Maintenance is due on flow meter.

Maintenance stall test is due on solvent meter.

Maintenance is due on fluid filter.

Maintenance is due on air filter.

Alphanumeric Last Digits

D

E

B

C

F

7

8

9

A

3

4

5

6

Alphanumeric Digit

1

2

Component Number

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Alphanumeric Digit

G

H

J

K

L

M

N

P

R

T

U

V

W

Y

Z

Component Number

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

26 3A2800F

Troubleshooting

Booth Control Troubleshooting

Figure 9 Bottom View of Booth Control

D8

D9

D10

J11

Figure 8 Booth Control

Table 1 . Booth Control Diagnostics

Indicator Description

Mix Mode (green)

Diagnosis

LED is on when in Mix mode.

Purge Mode (green)

LED blinks when in Mix Fill mode. Also blinks is Mix Idle mode

(together with Standby LED).

LED is on when in Purge mode.

LED blinks when a purge is needed.

Pressure Change Mode (green) LED blinks when in Pressure Change mode.

Alarm (red)

Standby Mode (green)

Heartbeat (green)

Communication (yellow)

Power (green)

Connector

LED is on steady when any event has been acknowledged.

LED blinks when any event has not been acknowledged.

LED turns off after the event is cleared.

LED is on steady when in Standby mode.

LED blinks when in Color Change, Startup, Shutdown, Prime

Pump, Fill, Calibration, Maintenance, and during Pump

Pressure Check. Also blinks is Mix Idle mode (together with

Mix LED).

LED blinks during normal operation.

LED turns on when board is communication with isolation board in electronic control.

LED turns on when power is supplied to the board (connector

J11).

Power/CAN connector.

3A2800F 27

Troubleshooting

Power Barrier Board Troubleshooting

Figure 10 Power Barrier Board

Table 2 . Power Barrier Board Diagnostics

Component or

Indicator

D4

D5

F3

F4

J4

J5

Description

LED (green)

LED (green)

Fuse, 400 mA, 250 V

Fuse, 400 mA, 250 V

Connector

Connector

Diagnosis

IS Power

Power

If either F3 or F4 is blown, there is no power to the IS location. D4 is out.

24 Vdc power input

+12 Vdc intrinsically safe power output

28 3A2800F

Isolation Board Troubleshooting

Troubleshooting

Figure 11 Isolation Board

Table 3 . Isolation Board Diagnostics

Component or

Indicator

D6

D7

D8

D14

J1

J2

J3

J4

S1

Description

LED (yellow)

LED (green)

LED (green)

LED (yellow)

Connector

Connector

Connector

Connector

Pushbutton Switch

S2 Pushbutton Switch

Diagnosis

IS Communication

IS Power

Non-IS Power

Non-IS Communication

Non-IS, Optional Gateway

Non-IS, Optional Color Change Module

Intrinsically Safe, Barrier Board

Intrinsically Safe, Optional Color Change Module

For Non IS connectors. If switch S1 is off, yellow LED (D14) is steady on. Push switch to turn switch on.

For Intrinsically Safe connectors. If switch S2 is off, yellow LED (D6) is steady on. Push switch to turn switch on.

3A2800F 29

Troubleshooting

Enhanced Fluid Control Module Troubleshooting

Figure 12 Enhanced Fluid Control Module

Table 4 . Enhanced Fluid Control Module Diagnostics

Connector or

Indicator

1

6

7

4

5

2

3

8

9

10

CPLD (D37)

POW (D19)

CAN (D69)

ERR (D38)

Description

25 pin connector

25 pin connector

25 pin connector

25 pin connector

12 pin connector

12 pin connector

12 pin connector

5 pin connector

5 pin connector

5 pin connector

LED (orange)

LED (green)

LED (yellow)

LED (red)

Diagnosis

Pump 1 Module

Pump 2 Module

Pump 3 Module (accessory)

Pump 4 Module (accessory)

Multiple purpose I/O

Multiple purpose I/O

Multiple purpose I/O

24 Vdc Power/CAN (Communication Barrier)

Advanced Display Module

24 Vdc Input

Heartbeat

Power

Communication.

Blinks an error code. If the LED is on steady, the system is down. Cycle power.

30 3A2800F

Pump Module Troubleshooting

Troubleshooting

Figure 13 Pump Module

Component or

Indicator

3

4

5

Table 5 . Pump Module Diagnostics

Description

1

2

10

11

24V

48V

8

9

6

7

25 pin connector

5 pin connector

5 pin connector

5 pin connector

5 pin connector

4 pin connector

8 pin connector

4 pin connector

LED (red)

LED (red)

LED (red)

LED (green)

LED (green)

Diagnosis

Input from EFCM

Pump connection

Encoder connection

Pump Inlet Transducer

Pump Outlet Transducer

Dual Panel System: Motor Power Control

Dose Valve Solenoids

48 Vdc Input Power and fan connection

Pump Up Valve Output

Pump Down Valve Output

Not used

24 Vdc power supplied

48 Vdc power supplied

3A2800F 31

Troubleshooting

Advanced Display Module Troubleshooting

J1

J2

J3

J7

Figure 14 Advanced Display Module

Table 6 . Advanced Display Module Diagnostics

Connector or

Indicator

D1

Description

LED (yellow/green)

D6 LED (red/yellow/green)

8 pin connector

8 pin connector

5 pin connector

5 pin connector

Diagnosis

Green: USB inserted

Yellow: USB communication

Green: Power

Yellow: Communication

Red: Error

Token port

USB port

Light tower (accessory)

CAN power/communication port

32 3A2800F

Electrical Schematics

Electrical Schematics

Standard Models (MC1000, MC2000,

MC3000, MC4000)

NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix PD2K system; models

MC1000, MC2000, and MC4000. Some components shown are not included with all systems.

NOTE: See

Optional Cables and Modules, page 45

for a list of cable options.

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)

2 POSITION

SWITCH

(16U725)

CABLE

16T658

LINE FILTER

(16V446)

CABLE

16H078

TERMINAL BLOCK

(114095)

24V

POWER

SUPPLY

(16T660)

POWER IN

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)

RELAY

POWER MODULE

(24R257)

48V-10A POWER SUPPLY

(16U820)

TERMINAL BLOCKS WITH FUSES

065161, 065159

INTEGRATION

GATEWAY

5

CABLE (121227)

16T072

CAN

IS BOARD

(24M485)

CABLE (121227)

AWI

GATEWAY

(24R910)

5

CABLE (121001)

SPLITTER

(16P243)

CABLE (16T280)

BARRIER

BOARD

(248192)

4

CABLE (16T659)

CABLE (16T659)

CABLE (16T659)

CABLE (16T659)

FAN

(24P658)

ENCODER AND MOTOR

(16P036, 16P037)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

PUMP V/P FOR

FLUID REG.

FAN

(24P658)

ENCODER AND MOTOR

(16P036, 16P037)

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 15 Electrical Schematic, Sheet 1

2 CABLE

(15V206)

2

CABLE

(15V206)

MODULE 1 (24N935)

2

CABLE

(15V206)

MODULE 2 (24N935)

GCA

MODULE

EFCM

(24N913)

MODULE 3 (24N935) MODULE 4 (24N935) MODULE 5 (24N935) MODULE 6 (24N935)

2

CABLE

(15V206)

2

CABLE

(15V206)

GUN TRIGGER INPUTS

119159

119159

119159

119159

SOLENOID (121324)

PRESSURE SW (121323)

GFB

INTERFACES

SOLVENT CUTOFF (121324)

SWITCH (120278)

SWITCH (120278)

SOLVENT

FLOW

INPUTS

SOLVENT METER (258718)

SAFETY INTERLOCK SWITCH

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)

3A2800F 33

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

Electrical Schematics

SPLITTER

(16P243)

5 4 3 2 1

3

CABLE (121227)

1 2 3 4 5

2

4

1 2 3 4 5

CABLE (15V206)

16T072

1 2 3 4 5

CAN IS BOARD

(NON IS)

(IS)

(24M485)

3

1 2 3 4 5

1

UNUSED

CONTINUED ON PAGE 3

CABLE (16T280)

1 2 3

UNUSED UNUSED

BARRIER

BOARD

(248192)

CONTINUED ON PAGE 3

P3 P4

AWI

GATEWAY

(24R910)

5

CABLE

(121227)

3

P3

GFB INTERFACE

(121324)

SOLVENT CUTOFF (121324)

PWR (RED)

SIG (WHITE)

SOLVENT

METER

(258718)

COM (BLACK)

SHIELD/GRN

P4

INTEGRATION

GATEWAY

5

UNUSED

UNUSED

+24VDC

UNUSED

+24VDC

+24VDC

10

UNUSED

CABLE

(121001)

3

UNUSED

8

GCA MODULE

EFCM

(24N913)

8

9

6

7

4

5

2

3

10

11

12

5

1 2 3 4 5 6 7 8 9

1

10 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

UNUSED UNUSED UNUSED

RED WIRE (065161)

BLACK WIRE (065159)

GROUND BAR

4

25 PIN D-SUB CABLE

(16T659)

24V

POWER

SUPPLY

(16T660)

GRND (GRN/YEL)

1 2 3 4 5 6 7 8

BREAKOUT MODULE PUMP 1 (24N527)

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

1

24 25

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

BREAKOUT MODULE PUMP 2 (24N527)

9 10 11 12 13

1

14 15 16 17 18 19 20 21 22 23 24 25

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

13 A1(+) A2(-)

RELAY

14

N L GRND

48V-10A

POWER SUPPLY

+ -

+ - + - + - + -

+ - + - + - + -

DETAIL A, LOW PRESSURE PUMPS

(24M706, 24M714, 24T799)

2

1 2 3 4 5

BREAKOUT MODULE

(24N527)

3

1 2 3 4

WIRE HARNESS

(24P684) DRAIN/FOIL

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

DETAIL B, HIGH PRESSURE PUMPS

(24M707, 24M715, 24T800)

2

1 2 3 4 5

BREAKOUT MODULE

(24N527)

3

1 2 3 4

WIRE HARNESS

(24P685) DRAIN/FOIL

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 2

SEE DETAIL A OR B

TRANSDUCER PUMP TRANSDUCER PUMP

TWISTED PAIR CABLE (16W159)

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

+48V COM +48V COM

MOTOR

GROUND

SCREW

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 16 Electrical Schematic, Sheet 2, Part 1

CONTINUED ON THE NEXT PAGE

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)

10

34 3A2800F

Electrical Schematics

1 2 3 4 5 6 7 8 9

3

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

6

8

7

6

5

4

3

2

1

10

11

12

GUN TRIGGER INPUTS

SIG

COM

SIG

COM

SIG

COM

SIG

COM

SIG

COM GFB PRESSURE SWITCH (121323)

SOLVENT FLOW SWITCH 1 (120278)

GCA MODULE

EFCM

(24N913)

1 2 3 4 5 6 7 8 9

9

10

4

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

7

9

10

8

7

6

5

4

3

2

1

3

4

1

2

5

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

SIG

COM

SIG

COM

SOLVENT FLOW SWITCH 2 (120278)

SAFETY INTERLOCK SWITCH

CABLE

(121003)

3

3

4

2

1

5

ADVANCED

DISPLAY MODULE

(24E451)

3

4

1

2

5

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 17 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)

3A2800F 35

Electrical Schematics

FROM CAN IS BOARD (24M485)

2

CABLE (15V206)

FLUSH

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

MANIFOLD

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

*FLUSH

COLOR 9

COLOR 10

COLOR 11

COLOR 12

COLOR 13

COLOR 14

COLOR 15

COLOR 16

MANIFOLD

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

3

4

1

2

5

6

J8

1 2 3 4 5

COLOR

CHANGE

MODULE 1

(COLORS

1 THRU 8)

J9

6

3

4

1

2

5

6

J15 J16 4

3

6

5

2

1

4

3

6

5

2

1

3

4

1

2

5

6

J14 J10

1 2 3 4 5

4

3

6

5

2

1

3

4

1

2

5

6

J8

1 2 3 4 5

COLOR

CHANGE

MODULE 2

(COLORS

9 THRU 16)

J9

6

3

4

1

2

5

6

J15 J16

4

3

6

5

2

1

4

3

6

5

2

1

3

4

1

2

5

6

J14 J10

1 2 3 4 5

4

3

6

5

2

1

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

MANIFOLD

DUMP

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

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

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

3

4

1

2

5

6

1 2 3 4 5

COLOR

CHANGE

MODULE 3

(COLORS

17 THRU 24)

J8

3

4

1

2

5

6

J15

6

J9

J16 4

3

6

5

2

1

4

3

6

5

2

1

3

4

1

2

5

6

J14

5 4 3 2

J10

4

3

6

5

2

1

1

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

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

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

3

4

1

2

5

6

J8

CATALYST

CHANGE

MODULE 5

(CATALYST

1 THRU 4)

J9

6

4

3

6

5

2

1

3

4

1

2

5

6

J15 J16 4

3

6

5

2

1

3

4

1

2

5

6

J14 J10

1 2 3 4 5

4

3

6

5

2

1

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

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

+24VDC

COM

+24VDC

COM

+12VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

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

4

3

6

5

2

1

3

4

1

2

5

6

J15 J16 4

3

6

5

2

1

3

4

1

2

5

6

J14 J10

1 2 3 4 5

4

3

6

5

2

1

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

UNUSED

UNUSED

UNUSED

UNUSED

MANIFOLD

DUMP*

COLOR 25

COLOR 26

COLOR 27

COLOR 28

COLOR 29

COLOR 30

2

CABLE (15V206)

Figure 18 Electrical Schematic, Sheet 3

* May be unused in some configurations.

CONTINUED ON THE NEXT PAGE

36 3A2800F

FLUSH

CATALYST 3

CATALYST 4

MANIFOLD

+24VDC

COM

+24VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

4

5

6

1

2

J8

CATALYST

CHANGE

MODULE 6

(CATALYST

3 THRU 4)

J9

6

4

5

6

1

2

J15 J16

4

5

6

1

2

J14 J10

1 2 3 4 5

4

3

6

5

4

3

6

5

4

3

6

5 +24VDC

COM

COM

+24VDC

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

MANIFOLD

DUMP

CATALYST 3

CATALYST 4

Electrical Schematics

FLUSH

CATALYST 1

CATALYST 2

MANIFOLD

COM

+24VDC

+24VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

3

4

1

2

J8

5 4 3 2 1

CATALYST

CHANGE

MODULE 5

(CATALYST

1 THRU 2)

J9

6

2

1

5

4

3

4

1

2

J15 J16

2

1

5

4

3

4

1

2

J14 J10

2

1

5

4

1 2 3 4 5

1 2 3 4 5

COLOR

CHANGE

MODULE 4

(COLORS

25 THRU 32)

COM

+24VDC

+24VDC

+24VDC

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

MANIFOLD

DUMP

CATALYST 1

CATALYST 2

ALTERNATE CONFIGURATION

FOR CATALYST CHANGE CONTROL

Figure 19 Electrical Schematic, Sheet 3, Alternate

Configuration for Catalyst Change Control

CONTINUED ON THE NEXT PAGE

3A2800F 37

Electrical Schematics

FROM CAN IS BOARD (24M485)

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

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

3

4

1

2

5

6

1 2 3 4 5

COLOR

CHANGE

MODULE 7

(COLORS

33 THRU 40)

J8 J9

4

3

6

5

2

1

7

3

4

1

2

5

6

J15 J16

4

3

6

5

2

1

3

4

1

2

J14 J10

4

3

6

5

2

1

1 2 3 4 5

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

+12VDC

COM

+12VDC

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

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

3

4

1

2

5

6

1 2 3 4 5

COLOR

CHANGE

MODULE 8

(COLORS

41 THRU 48)

J8 J9

7

4

5

6

1

2

J15 J16

3

2

5

4

1

3

2

1

6

5

3

4

1

2

5

6

J14

5 4 3 2

J10

1

4

3

6

5

Figure 20 Electrical Schematic, Sheet 3, Hazardous

Location

5 4 3 2 1

BOOTH CONTROL

(24M731)

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

MANIFOLD

COLOR 22

COLOR 23

COLOR 24

COLOR 25

COLOR 26

COLOR 27

COLOR 28

COLOR 29

COLOR 30

38 3A2800F

Electrical Schematics

Dual Panel Models (MC1002,

MC2002, MC4002)

NOTE:The electrical schematic illustrates all possible wiring expansions in a ProMix PD2K system; models

MC1002, MC2002, and MC4002. Some components shown are not included with all systems.

NOTE: See

Optional Cables and Modules, page 45

for a list of cable options.

POWER MODULE

(26A189)

2 POSITION

SWITCH

(16U725)

CABLE

16T658

LINE FILTER

(16V446)

CABLE

16H078

TERMINAL BLOCK

(114095)

POWER IN

24V

POWER

SUPPLY

(16T660)

48V-10A POWER SUPPLY

(16U820)

RELAY 1 RELAY 2

TERMINAL BLOCK WITH FUSES

FAN

(24P658)

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

CABLE 126232

OR 17N315

SOLENOID (16P812)

UP

DOWN

SOLVENT

METER 1

(258718)

FAN

(24P658)

ENCODER AND MOTOR

(16P036, 16P037)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

CABLE 126232

OR 17N315

SOLENOID (16P812)

UP

DOWN

SOLVENT

METER 2

(258718)

SPLITTER

(16P243)

INTEGRATION

GATEWAY

5

CABLE (121227)

16T072

CAN

IS BOARD

(24M485)

17L058

CABLE (16T280)

BARRIER

BOARD

(248192)

CABLE (121227)

AWI

GATEWAY

(24R910)

5

CABLE (121001)

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 21 Electrical Schematic, Sheet 1

4

CABLE (16T659)

1 CABLE (16V429)

2 CABLE

(15V206)

2

CABLE

(15V206)

MODULE 1 (24N935)

2

CABLE

(15V206)

MODULE 2 (24N935)

GCA

MODULE

EFCM

(24N913)

MODULE 3 (24N935) MODULE 4 (24N935) MODULE 5 (24N935) MODULE 6 (24N935)

2

CABLE

(15V206)

2

CABLE

(15V206)

CABLE

15V819

AIR FLOW SW. 1 (119159)

AIR FLOW SW. 2 (119159)

GFB PRESS. SW. 1 (121323)

GFB PRESS. SW. 2 (121323)

GFB VALVE 1 (121324)

GFB VALVE 2 (121324)

AIR

CONTROL

MODULE

(26A231)

SOLVENT CUTOFF VALVE (121324)

SOLVENT CUTOFF VALVE (121324)

SWITCH (120278)

SWITCH (120278)

SWITCH (120278)

SWITCH (120278)

SOLVENT

FLOW

INPUTS

SAFETY INTERLOCK SWITCH

CABLE

(121003)

3

ADVANCED DISPLAY MODULE

(24E451)

LIGHT

TOWER

(15X472)

COLOR CHANGE

MODULE 7

(24R219)

7

1

CABLE

(16V426)

BOOTH CONTROL

(24M731)

WITH SHUNT

(17M540)

COLOR CHANGE

MODULE 8

(24R219)

7

1

CABLE

(16V426)

BOOTH

CONTROL

(24M731)

HAZARDOUS LOCATION

NON-HAZARDOUS LOCATION

3A2800F 39

Electrical Schematics

SPLITTER

(16P243)

5 4 3 2 1

UNUSED UNUSED UNUSED

24V

POWER

SUPPLY

(16T660)

3

CABLE (121227)

3

4

1

2

5

3

4

1

2

5

CABLE (15V206)

16T072

1 2 3 4 5

2

4

1 2 3 4 5

CAN IS BOARD

1 2 3 4 5

1

(NON IS)

(IS)

(24M485)

3

1 2 3 4 5

SPLITTER (17L058)

CABLE (16T280)

UNUSED UNUSED

UNUSED

J4

1 2 3

J5

BARRIER

BOARD

(248192)

P3 P4

AWI

GATEWAY

(24R910)

5

CABLE

(121227)

3

UNUSED

UNUSED

P3 P4

INTEGRATION

GATEWAY

5

UNUSED

CABLE

(121001)

3

10

1

2

8

SOLVENT CUTOFF VALVE 1 (121324)

SOLVENT CUTOFF VALVE 2 (121324)

GFB OUTPUT VALVE 1

GFB OUTPUT VALVE 2

GREEN/BLACK

ORANGE/BLACK

BLUE/BLACK

RED/WHITE

SAFETY INTERLOCK SWITCH

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

UNUSED

SIG

COM

UNUSED

1

2

6

7

4

5

8

9

10

12

5

4

25 PIN D-SUB

CABLE (16T659)

GROUND

BAR

BREAKOUT MODULE PUMP 1 (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

1 2 3 4

7

5 6 7 8

8

1 2 3 4

1

GCA MODULE

2

EFCM

(24N913)

3 4

BREAKOUT MODULE PUMP 2 (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

1 2 3 4

7

5 6 7 8

7

7

8

5

6

3

4

2

1

9

10

11

12

6

7

8

5

6

3

4

2

1

9

10

11

12

9 3

5

8

1 2 3 4

L (BROWN) N (BLUE)

N03 N03

2 POSITION

SWITCH

(16U725)

N04 N04

CABLE

(16T658)

L N

LINE

FILTER

(16V446)

L GND N

CABLE

(16H078)

L N GND

TERMINAL

BLOCK

(114095)

L N GND

GRND (GRN/YEL)

N L GRND

48V-10A

POWER SUPPLY

(16U280)

- - + +

15

18

RELAY

2

A1

A2

15

18

RELAY

1

A1

A2

+ - + - + - + -

4 3 2 1

DETAIL A, LOW PRESSURE PUMPS

(24M706, 24M714, 24T799)

2

1 2 3 4 5

BREAKOUT MODULE

(24N527)

3

1 2 3 4

WIRE HARNESS

(24P684) DRAIN/FOIL

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 1

SEE DETAIL A OR B

BROWN (UNUSED)

DRAIN (UNUSED)

BLUE

BLACK

BROWN (UNUSED)

DRAIN (UNUSED)

BLUE

BLACK

+24VDC COM +24VDC COM

CABLE (126232 OR 17N315)

PUMP 1

MANIFOLD

SOLVENT

METER 1

(258718)

MAC SERIES 46 (16P812 QTY

GND

SCREW

TWISTED PAIR CABLE (16W159)

DETAIL B, HIGH PRESSURE PUMPS

(24M707, 24M715, 24T800)

2

1 2 3 4 5

BREAKOUT MODULE

(24N527)

3

1 2 3 4

WIRE HARNESS

(24P685) DRAIN/FOIL

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 2

SEE DETAIL A OR B

CABLE (126232 OR 17N315)

TWISTED PAIR CABLE (16W159)

+24VDC COM +24VDC COM

PUMP 2

MANIFOLD

SOLVENT

METER 2

(258718)

MAC SERIES 46 (16P812 QTY

GND

SCREW

MOTOR

GROUND

SCREW

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 22 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

40 3A2800F

Electrical Schematics

2

3

1

4

5

4

3

5

2

1

10

8

8

7

6

5

4

3

2

1

9

10

11

12

5

1

GCA MODULE

EFCM

(24N913)

2 3 4

6

8

7

6

5

4

3

2

1

10

11

12

SIG

COM

SIG

COM

SIG

COM

SIG

COM

SIG

COM

SIG

COM

BLACK

WHITE

RED

GREEN

AIR FLOW SWITCH 1

AIR FLOW SWITCH 2

SOLVENT FLOW SW. 1 (120278) LEFT BRKT

SOLVENT FLOW SW. 2 (120278) LEFT BRKT

SOLVENT FLOW SW. 3 (120278) RIGHT BRKT

SOLVENT FLOW SW. 4 (120278) RIGHT BRKT

7

8

7

6

5

4

3

2

1

10

9

11

12

9

4

3

5

2

1

PLC DISCRETE 4-20mA INPUT 1

PLC DISCRETE 4-20mA COMMON 1

PLC DISCRETE 4-20mA COMMON 2

UNUSED

UNUSED

UNUSED

UNUSED

SIG

COM

SIG

COM

ORANGE

BLUE

WHITE/BLACK

RED/BLACK

CABLE

(121003)

3

4

3

5

2

1

ADVANCED

DISPLAY MODULE

(24E451)

GFB INPUT PRESSURE SWITCH 1

GFB INPUT PRESSURE SWITCH 2

4

3

5

2

1

LIGHT

TOWER

(15X472)

CABLE

15V819

AIR CONTROL MODULE (26A231)

BLACK

WHITE

RED

GREEN

ORANGE

BLUE

WHITE/BLACK

RED/BLACK

GREEN/BLACK

ORANGE/BLACK

BLUE/BLACK

RED/WHITE

9

10

7

8

11

12

TERMINAL

BLOCKS

1

2

5

6

3

4

+ SIG

- COM

+ SIG

- COM

+ SIG

- COM

+ SIG

- COM

+ 24VDC

- COM

+ 24VDC

- COM

RED

BLACK

RED

BLACK

AIR FLOW SWITCH 1

119159

AIR FLOW SWITCH 2

119159

GFB INPUT PRESSURE SWITCH 1

121323

GFB INPUT PRESSURE SWITCH 2

121323

GFB OUTPUT VALVE 1

121324

GFB OUTPUT VALVE 2

121324

2

1 2 3 4 5

25 PIN D-SUB

CABLE (16T659)

4

3

1 2 3 4

1

4

1 2 3 4 5

BREAKOUT MODULE PUMP 3 (24N527)

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

2

1 2 3 4 5

3

1 2 3 4

1

BREAKOUT MODULE PUMP 4 (24N527)

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

AND

WIRE HARNESS

PUMP 4

SEE DETAIL A OR B

+24VDC COM +24VDC COM

PUMP 3

MANIFOLD

G3000

METER

PUMP 3

(EITHER, 239716,

258718,16M510,

OR 16M519)

MAC SERIES 46 (16P812 QTY

GND

SCREW

+24VDC COM +24VDC COM

PUMP 4

MANIFOLD

G3000

METER

PUMP 4

(EITHER, 239716,

258718,16M510,

OR 16M519)

MAC SERIES 46 (16P812 QTY

GND

SCREW

TWISTED PAIR CABLE (16W159)

TWISTED PAIR CABLE (16W159)

Figure 23 Electrical Schematic, Sheet 2, Part 2

CONTINUED ON THE NEXT PAGE

3A2800F 41

Electrical Schematics

FROM CAN IS BOARD (24M485)

2

CABLE (15V206)

FLUSH

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

MANIFOLD

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

*FLUSH

COLOR 9

COLOR 10

COLOR 11

COLOR 12

COLOR 13

COLOR 14

COLOR 15

COLOR 16

MANIFOLD

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

3

4

1

2

5

6

J8

1 2 3 4 5

COLOR

CHANGE

MODULE 1

(COLORS

1 THRU 8)

J9

6

3

4

1

2

5

6

J15 J16

4

3

6

5

2

1

4

3

6

5

2

1

3

4

1

2

5

6

J14 J10

1 2 3 4 5

4

3

6

5

2

1

3

4

1

2

5

6

J8

1 2 3 4 5

COLOR

CHANGE

MODULE 2

(COLORS

9 THRU 16)

J9

6

3

4

1

2

5

6

J15 J16

4

3

6

5

2

1

4

3

6

5

2

1

3

4

1

2

5

6

J14 J10

1 2 3 4 5

4

3

6

5

2

1

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

MANIFOLD

DUMP

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

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

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

3

4

1

2

5

6

1 2 3 4 5

COLOR

CHANGE

MODULE 3

(COLORS

17 THRU 24)

J8

3

4

1

2

5

6

J15

6

J9

J16 4

3

6

5

2

1

4

3

6

5

2

1

3

4

1

2

5

6

J14

5 4 3 2

J10

4

3

6

5

2

1

1

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

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

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

3

4

1

2

5

6

CATALYST

CHANGE

MODULE 5

(CATALYST

1 THRU 4)

J8 J9

6

4

3

6

5

2

1

3

4

1

2

5

6

J15 J16 4

3

6

5

2

1

3

4

1

2

5

6

J14 J10

1 2 3 4 5

4

3

6

5

2

1

COM

+24VDC

COM

+24VDC

COM

+12VDC

COM

+24VDC

COM

+24VDC

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

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

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

4

3

6

5

2

1

4

3

6

5

2

1

3

4

1

2

5

6

J14 J10

1 2 3 4 5

4

3

6

5

2

1

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

UNUSED

UNUSED

UNUSED

UNUSED

MANIFOLD

DUMP*

COLOR 25

COLOR 26

COLOR 27

COLOR 28

COLOR 29

COLOR 30

Figure 24 Electrical Schematic, Sheet 3, Part 1

* May be unused in some configurations.

CONTINUED ON THE NEXT PAGE

2

CABLE (15V206)

42 3A2800F

Electrical Schematics

FROM CAN IS BOARD (24M485)

1 CABLE (16V429)

NON-HAZARDOUS LOCATION

HAZARDOUS LOCATION

COLOR FLUSH

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

MANIFOLD

BLACK

RED

BLACK

BLACK

RED

BLACK

RED

BLACK

RED

BLACK

+12VDC

COM

+12VDC

COM

+12VDC

COM

BLACK

RED

BLACK

BLACK

3

4

1

2

1 2 3 4 5

COLOR

CHANGE

MODULE 7

(COLORS

33 THRU 40)

J8 J9 3

1

5

4

7

3

4

1

2

5

6

J15 J16

3

1

5

4

4

6

2

3

J14 J10

4

3

6

5

2

1

5 4 3 2 1

COM

+12VDC

COM

+12VDC

COM

+12VDC

BLACK

RED

BLACK

RED

BLACK

RED

MANIFOLD

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

BLACK

RED

BLACK

RED

BLACK

RED

CATALYST FLUSH

CATALYST 1

CATALYST 2

CATALYST 3

CATALYST 4

COLOR 9

COLOR 10

COLOR 11

COLOR 12

5 4 3 2 1

BOOTH CONTROL

(24M731)

WITH SHUNT

(17M540)

1 2 3 4 5

J1

COLOR 13

COLOR 14

COLOR 15

COLOR 16

COLOR 17

COLOR 18

COLOR 19

COLOR 20

COLOR 21

MANIFOLD

BLACK

RED

BLACK

BLACK

RED

BLACK

RED

BLACK

RED

BLACK

+12VDC

COM

+12VDC

COM

+12VDC

COM

RED

BLACK

RED

BLACK

RED

BLACK

+12VDC

COM

+12VDC

COM

+12VDC

COM

3

4

1

2

5

6

1 2 3 4 5

COLOR

CHANGE

MODULE 8

(COLORS

41 THRU 48)

J8 J9

7

3

4

1

2

5

6

J15 J16

3

1

5

4

3

1

5

4

4

6

2

3 J14

5 4 3 2

J10

1

4

3

6

5

2

1

5 4 3 2 1

BOOTH CONTROL

(24M731)

COM

+12VDC

COM

+12VDC

COM

+12VDC

BLACK

RED

BLACK

RED

BLACK

RED

+12VDC

COM

+12VDC

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

BLACK

RED

BLACK

RED

BLACK

RED

MANIFOLD

COLOR 22

COLOR 23

COLOR 24

COLOR 25

COLOR 26

COLOR 27

COLOR 28

COLOR 29

COLOR 30

Figure 25 Electrical Schematic, Sheet 3, Part 2

CONTINUED ON THE NEXT PAGE

3A2800F 43

Electrical Schematics

FLUSH

CATALYST 3

CATALYST 4

MANIFOLD

COM

+24VDC

COM

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

3

4

1

2

CATALYST

CHANGE

MODULE 6

(CATALYST

3 THRU 4)

J8 J9

6

4

6

2

3 J15 J16

3

4

1

2

5

6

J14 J10

1 2 3 4 5

3

1

5

4

2

1

4

3

3

1

5

4 COM

+24VDC

COM

+24VDC

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

MANIFOLD

DUMP

CATALYST 3

CATALYST 4

FLUSH

CATALYST 1

CATALYST 2

MANIFOLD

+24VDC

COM

+24VDC

COM

+24VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

5

6

2

3

3

4

1

2

5 4 3 2

CATALYST

CHANGE

MODULE 5

(CATALYST

1 THRU 2)

1

J8 J9 4

3

6

5

2

1

6

J15 J16

3

1

5

4

4

6

2

3 J14 J10

1 2 3 4 5

4

3

6

5

2

1

1 2 3 4 5

COLOR

CHANGE

MODULE 4

(COLORS

25 THRU 32)

+24VDC

COM

+24VDC

+24VDC

MANIFOLD

DUMP

CATALYST 1

CATALYST 2

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

ALTERNATE CONFIGURATION

FOR CATALYST CHANGE CONTROL

IN NON-HAZARDOUS LOCATION

Figure 26 Electrical Schematic, Sheet 4, Alternate

Configuration for Catalyst Change Control

44 3A2800F

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 33

.

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

15V205

M12 CAN Cables, for Non-Hazardous

Locations Only

2.0 (0.6)

3.0 (1.0)

15V206

15V207

6.0 (2.0)

10.0 (3.0)

15.0 (5.0)

15V208

15U533

15V213

25.0 (8.0)

50.0 (16.0)

100.0 (32.0)

CAN Cables, for Non-Hazardous

Locations Only

Cable Part No.

125306

Length ft (m)

1.0 (0.3)

123422

121000

121227

121001

1.3 (0.4)

1.6 (0.5)

2.0 (0.6)

3.0 (1.0)

121002

121003

120952

121201

121004

121228

5.0 (1.5)

10.0 (3.0)

13.0 (4.0)

20.0 (6.0)

25.0 (8.0)

50.0 (15.0)

25 Pin D-SUB Cables, for Non-Hazardous

Locations Only

16T659

16V659

2.5 (0.8)

6.0 (1.8)

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

Non-Hazardous Locations Only

Module Part No.

Description

24T557 2 color/2 catalyst

24T558

24T559

24T560

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, 13–24 color

24T774

24T775

24T776

24T777

24T778

24T779

12 color/2 catalyst

4 color/4 catalyst

6 color/4 catalyst

8 color/4 catalyst

12 color/4 catalyst, 13–30 color

13–18 color

3A2800F 45

Electrical Schematics

Communications Options (for PLC and AWI)

1. If you are upgrading to an automatic system: a. 24T803, Automatic Upgrade Kit

2. If you are upgrading to an automatic system that requires a different PLC protocol than Modbus

TCP: a. CGMEP0, Ethernet IP

CGMDN0, DeviceNet

CGMPN0, ProfiNet

3. If you are upgrading to an automatic system AND

AWI: a. 24W829, CGM Kit for PD2K b. 24W462, Modbus TCP

4. If your application requires ONLY AWI: a. 15V337, AWI Module b. 24T805, AWI Kit

46 3A2800F

Repair

Before Servicing

Servicing the electrical control box exposes you to high voltage. To avoid electric shock;

• Turn off power at the main circuit breaker before opening the enclosure.

• All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations.

• Do not substitute or modify system components as this may impair intrinsic safety.

NOTICE

To avoid damaging the circuit boards when servicing the control box, 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.

Repair

1. Flush the system as explained in your

PD2K Operation Manual if service time may exceed pot life time. Follow the

Pressure Relief Procedure, page 48

before servicing fluid components.

2. Close the main air shutoff valve on the air supply line.

3. Shut off the power switch (P) at the electrical control box.

4. If servicing the electrical control box, shut off power at the main circuit breaker before opening the enclosure.

Figure 27 Control Box Power Switch

3A2800F 47

Repair

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the

Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

Without Color Change

NOTE: The following procedure relieves all fluid and air pressure in the system.

1. Turn off the supply pumps. Open the drain valve on the supply line fluid filter to relieve pressure in the supply line.

NOTE: If your system does not include a drain valve on the supply line, set the mix manifold to SPRAY and press . Cycle the A and B dosing pumps a couple of times to drain the pumps.

2. Press Standby relieve pressure.

. Trigger the gun to

3. Set the mix manifold to FLUSH. Flush the mix manifold and gun. See Flush Mixed Material in the PD2K Operation Manual.

4. Shut off the solvent supply pump. To relieve pressure, press Purge and trigger the gun. Press Standby when pressure is relieved, to avoid getting a Purge

Incomplete alarm.

5. Dual Panel Systems: Repeat for Mix Unit #2.

NOTE: If pressure remains in the solvent line between the solvent supply pump and the solvent valve, VERY SLOWLY loosen a fitting to relieve pressure gradually.

With Color Change

NOTE: The following procedure relieves all fluid and air pressure in the system.

1. Turn off the supply pumps. Open the drain valve on the supply line fluid filter to relieve pressure in the supply lines. Do this for each color.

NOTE: If your system does not include a drain valve on the supply line, set the mix manifold to

SPRAY and press . Cycle the A and

B dosing pumps a couple of times to drain the pumps. Repeat for each color.

2. If you are using a high pressure gun, engage the trigger lock. Remove the spray tip and clean it separately.

3. If using an electrostatic gun, shut off the electrostatics before flushing the gun.

To help prevent fire and explosion, shut off electrostatics before flushing.

4. Set the mix manifold to SPRAY. Trigger the gun to relieve pressure. Repeat for each color.

5. Press Purge . Repeat for each color.

Hold the gun trigger open after the solvent valve shuts off to relieve all pressure.

6. Set the system to Recipe 0 to flush the system from the pumps to the gun. When flushing is complete the system will go to Standby.

7. Shut off the solvent supply pump. To relieve pressure, press Purge and trigger the gun. Press Standby when pressure is relieved, to avoid getting a Purge

Incomplete alarm.

8. Dual Panel Systems: Repeat for Mix Unit #2.

NOTE: If pressure remains in the solvent line between the solvent supply pump and the solvent valve, VERY SLOWLY loosen a fitting to relieve pressure gradually.

48 3A2800F

Repair

Repairing the Advanced Display Module (ADM)

To replace the Advanced Display Module, disconnect the cable from the module and remove the module from the bracket. Install the new module on the bracket and attach the cable.

3. Insert and press token (T) firmly into slot.

NOTE: There is no preferred orientation of the token.

Figure 28 Replace the Advanced Display Module

Install Key Token or Upgrade Token

1. Shut off the PD2K power switch.

2. Remove the token access panel.

Figure 30 Insert Token

4. Turn the power switch back on. The red indicator light (L) will flash until the new firmware is completely loaded.

5. Remove the token (T).

6. Replace the token access panel.

Replace the Battery

A lithium battery maintains the ADM clock when the power is not connected.

Sparking can occur when changing the battery. To reduce the risk of fire and explosion, replace the battery only in a non-hazardous location, away from flammable fluid or fumes.

1. Turn off the PD2K power switch.

2. Remove the rear access panel.

Figure 29 Remove Token Access Panel

3A2800F

Figure 31 Remove Battery Panel

3. Remove the old battery and replace with a new

CR2032 battery.

4. Replace the rear access panel.

5. Turn the power switch on.

6. Dispose of the old battery according to your federal, state, and local waste regulations.

49

Repair

Servicing the Control Box

Replacing the Isolation Board

NOTICE

To avoid damaging the circuit boards when servicing the control box, 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. Follow the steps in

Before Servicing, page 47

.

2. Loosen the screws (124) and remove the enclosure cover (117).

3. Note the position of the isolation board cables. See the following table and

Electrical Schematics, page 33 . Disconnect the

cables from the isolation board (111). Remove the brackets (110).

Isolation Board

Connector

J1 (non-intrinsically safe)

J2 (non-intrinsically safe)

J3 (intrinsically safe)

J4 (intrinsically safe)

Cable Destination

EFCM

Optional Color

Change Module

Barrier Board

Booth Control

4. Remove the screws (128) holding the isolation board (111) to the barrier cover (107). Remove the isolation board.

5. Install the new isolation board, using the screws

(128).

6. Install the brackets (110). Reconnect the cables to the positions as noted above.

7. Turn on power at the main circuit breaker.

8. Turn on the control box power switch. Check that the two green LEDs (D7, D8) and two yellow

LEDs (D6, D14) are on.

9. Reinstall the cover (117) and tighten the screws

(124).

Figure 32 Replacing the Isolation Board

Figure 33 Detail of Isolation Board Cable

Connections

50 3A2800F

Repair

Replacing the Barrier Board

NOTICE

To avoid damaging the circuit boards when servicing the control box, 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. Follow the steps in

Before Servicing, page 47

.

2. Loosen the screws (124) and remove the enclosure cover (117).

3. Loosen the screws (125) and remove the barrier cover (107), leaving the isolation board (111) attached to the cover.

4. Note the position of the barrier board input and output cables. See

Electrical Schematics, page 33 . Disconnect the

cables from the barrier board (106).

5. Remove the two screws (108), and the three screws (109), spacers (105), and lockwashers

(104). Remove the barrier board (106).

6. Install the new barrier board, using the screws, spacers, and lockwashers.

7. Reconnect the cables to the barrier board, as noted above.

8. Install the barrier cover (107) and isolation board

(111).

9. Turn on power at the main circuit breaker.

10. Turn on the control box power switch. Check that the system is operating.

NOTE: The two green LEDs (D4, D5) on the barrier board will light if the board has power.

11. Reinstall the cover (117) and tighten the screws

(124).

Figure 34 Replacing the Barrier Board

Replacing the Barrier Board Fuses

NOTICE

To avoid damaging the circuit boards when servicing the control box, 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. Follow steps 1–4 under

Replacing the Barrier Board, page 51

.

2. Remove the fuse (F3 or F4) from its fuseholder.

3. Snap the new fuse into the fuseholder.

4. Follow steps 7–11 under

Replacing the Barrier Board, page 51

.

3A2800F 51

Repair

Replacing the EFCM Control Module

NOTICE

To avoid damaging the circuit boards when servicing the control box, 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. Follow the steps in

Before Servicing, page 47

.

2. Loosen the screws (124) and remove the enclosure cover (117, not shown).

3. Note the position of the EFCM input and output cables. See

Electrical Schematics, page 33 .

Disconnect the cables from the EFCM (139).

4. Loosen the screws (142) holding the EFCM to the enclosure. Remove the module.

5. Install the new EFCM, using the screws (142).

6. Reconnect the cables to the positions as noted above.

7. Turn on power at the main circuit breaker.

8. Load the software. See

Install Key Token or Upgrade Token, page 49

.

9. Turn on the control box power switch. Check that the green is on, the orange and yellow LEDs are blinking, and the red LED is off.

10. Reinstall the cover (117) and tighten the screws

(124).

Figure 35 Replacing the EFCM Control Module

52 3A2800F

Replacing the 24 VDC Power Supply

NOTICE

To avoid damaging the circuit boards when servicing the control box, 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. Follow the steps in

Before Servicing, page 47

.

2. Loosen the screws (124) and remove the enclosure cover (117, not shown).

3. Note the position of the power supply input and output wires. See

Electrical Schematics, page 33 .

Disconnect the wires from the power supply

(120).

4. Remove the screws (129) holding the power supply to the side of the enclosure. Remove the power supply.

5. Install the new power supply, using the screws

(129).

6. Reconnect the wires to the positions as noted above.

7. Reinstall the cover (117) and tighten the screws

(124).

8. Turn on power at the main circuit breaker.

Repair

9. Turn on the control box power switch.

NOTE: The green LED on the barrier board (106), the green power LED on the EFCM module (139), and the 24V green LED on each of the pump control modules (132) will light when operating.

Figure 36 Replacing the 24 Vdc Power Supply

3A2800F 53

Repair

Replacing the 48 VDC Pump Power Supply

NOTICE

To avoid damaging the circuit boards when servicing the control box, 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. Follow the steps in

Before Servicing, page 47

.

2. Loosen the screws (124) and remove the enclosure cover (117).

3. Note the position of the power supply input and output wires. See

Electrical Schematics, page 33 .

Disconnect the wires from the power supply

(103).

4. Remove the screws (128) holding the power supply din rail to the enclosure. Remove the entire assembly, mounted to the din rail.

5. Install the new power supply assembly, using the screws (128).

6. Reconnect the wires to the positions as noted above.

7. Reinstall the cover (117) and tighten the screws

(124).

8. Turn on power at the main circuit breaker.

9. Turn on the control box power switch. Press to turn pump power on.

NOTE: The 48V green LED on each of the pump control modules (132) will light when operating.

Figure 37 Replacing the 48 Vdc Power Supply

54 3A2800F

Replacing a Pump Control Module

NOTICE

To avoid damaging the circuit boards when servicing the control box, 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. Follow the steps in

Before Servicing, page 47

.

2. Loosen the screws (124) and remove the enclosure cover (117).

3. Note the position of the pump control module input and output cables. See

Electrical Schematics, page 33 . Disconnect the

cables from the pump control module (132).

4. Remove the screws (143) holding the pump control module to the enclosure. Remove the pump control module.

5. Install the new pump control module, using the screws (143).

6. Reconnect the cables to the positions as noted above.

7. Turn on power at the main circuit breaker.

8. Turn on the control box power switch. Check that the 48V green LED and the 24V green LED on each of the pump control modules (132) are on.

Repair

9. Reinstall the cover (117) and tighten the screws

(124).

Figure 38 Replacing a Pump Control Module

3A2800F 55

Repair

Replacing the Line Filter

NOTICE

To avoid damaging the circuit boards when servicing the control box, 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. Follow the steps in

Before Servicing, page 47

.

2. Loosen the screws (124) and remove the enclosure cover (117).

3. Note the position of the line filter input and output wires. See

Electrical Schematics, page 33 .

Disconnect the wires from the line filter (115).

4. Remove the screws (142) holding the line filter to the enclosure. Remove the line filter.

5. Install the new line filter, using the screws (142).

6. Reconnect the wires to the positions as noted above.

7. Reinstall the cover (117) and tighten the screws

(124).

8. Turn on power at the main circuit breaker.

Figure 39 Replacing the Line Filter

56 3A2800F

Replacing the Power Switch

NOTICE

To avoid damaging the circuit boards when servicing the control box, 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. Follow the steps in

Before Servicing, page 47

.

2. Loosen the screws (124) and remove the enclosure cover (117).

3. Note the position of the power switch input and output wires. See

Electrical Schematics, page 33 .

Disconnect the wires from the power switch

(112).

4. Remove the switch terminal blocks, unscrew the retaining nut, and remove the switch.

5. Install the new switch.

6. Reconnect the wires to the positions as noted above.

Repair

7. Reinstall the cover (117) and tighten the screws

(124).

8. Turn on power at the main circuit breaker.

Figure 40 Replacing the Power Switch

3A2800F 57

Repair

Replacing the Air Flow Switch

NOTICE

To avoid damaging the circuit boards when servicing the control box, 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. Follow the steps in

Before Servicing, page 47

.

2. Loosen the screws (124) and remove the enclosure cover (117).

3. Disconnect the air flow switch wires from J6 pins 1–2 on the EFCM. See

Electrical Schematics, page 33 .

4. Disconnect the air lines.

5. Remove the air flow switch (159) and attaching hardware from the side of the control box.

6. Install a new air flow switch. Connect the wires to J6 pins 1–2. Reconnect the air lines.

7. Reinstall the cover (117) and tighten the screws

(124).

8. Turn on power at the main circuit breaker.

9. Turn on the control box power switch.

Figure 41 Replacing the Air Flow Switch

58 3A2800F

Servicing the Fluid Section

Removing a Pump

1. Follow the steps in

Before Servicing, page 47

.

2. Remove the screws (56) holding the cover (8) to the front of the unit.

3. Disconnect the cable from the pump driver (101).

4. Disconnect the air lines from the dosing valves

(V).

5. Disconnect the fluid inlet and outlet lines from the pump manifolds (IN, OUT).

6. Remove the screws (15) and pump bracket (7).

7. Loosen the jam nuts holding the pump to the mounting bracket (4). Remove the pump.

8. See manual 332339 to repair the pump.

Repair

Installing a Pump

1. Slide the pump into the mounting bracket (4).

Tighten the jam nuts to secure.

2. Install the pump bracket (7) and screws (15).

3. Connect the fluid inlet and outlet lines to the pump manifolds (IN, OUT).

4. Connect the air lines to the dosing valves (V).

5. Connect the cable to the pump driver (101).

6. Install the cover (8) to the front of the unit with the screws (56).

7. Open the main air shutoff valve on the air supply line.

8. Restore power to the unit. Turn on the power switch at the electrical control box.

Figure 42 Installing a Pump

3A2800F 59

Repair

Replacing a Solenoid

NOTICE

To avoid damaging the circuit boards when servicing the control box, 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. Follow the steps in

Before Servicing, page 47

.

2. Remove the screws (56) holding the cover (8) to the front of the unit.

3. Loosen the screws (124) and remove the enclosure cover (117).

4. Disconnect the 2 solenoid wires from

J1 on the pump control module. See

Electrical Schematics, page 33 .

5. Remove 2 screws (303) and the solenoid (305).

6. Install the new solenoid (305) with the screws

(303).

7. Connect the 2 solenoid wires to J1 on the pump control module. See

Electrical Schematics, page 33 .

8. Replace the covers (8, 117).

Figure 43 Solenoid Replacement

60 3A2800F

Replacing a Fan

NOTICE

To avoid damaging the circuit boards when servicing the control box, 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.

Repair

1. Follow the steps in

Before Servicing, page 47 .

2. Remove the screws (56) holding the cover (8) to the front of the unit.

3. Loosen the screws (124) and remove the enclosure cover (117).

4. Disconnect the 2 fan wires from the pump control module. See

Electrical Schematics, page 33 .

5. Remove the 4 screws, nuts, and washers.

6. Install the new fan and attaching hardware.

7. Connect the 2 fan wires to the pump control module. See

Electrical Schematics, page 33 .

8. Replace the covers (8, 117).

Figure 44 Replacing a Fan

3A2800F 61

Repair

Replacing the Solvent Flow Switch

1. Follow the steps in

Before Servicing, page 47

.

2. Remove the screws (56) holding the cover (8) to the front of the unit.

3. Disconnect the solvent flow switch wires from J6 pins 11–12 on the EFCM. See

Electrical Schematics, page 33 .*

4. Disconnect the solvent lines.

5. Unscrew the adapter (45) from the solvent flow switch (19).

6. Unscrew the solvent flow switch from the elbow

(18).

7. Remove the solvent flow switch (159).

8. Screw the new solvent flow switch onto the elbow

(18).

9. Screw the adapter (45) into the solvent flow switch (19).

10. Connect the wires to J6 pins 11–12. Reconnect the solvent lines.*

11. Install the cover (8) to the front of the unit with the screws (56).

12. Open the main air shutoff valve on the air supply line.

13. Restore power to the unit. Turn on the power switch (P) at the electrical control box.

* If your system has mix-at-wall, and two solvent switches; the second solvent flow switch wires are connected to J7 pins 9–10.

Table 7 Dual Panel Systems Solvent Flow Switches

Solvent Flow Switch 1:

Mix Unit #1

Solvent Flow Switch 2:

Mix Unit #1 w/ mix-at-wall

Solvent Flow Switch 3:

Mix Unit #2

Solvent Flow Switch 4:

Mix Unit #2 w/ mix-at-wall

EFCM Connector J6

Pins 5–6

EFCM Connector J6

Pins 7–8

EFCM Connector J6

Pins 9–10

EFCM Connector J6

Pins 11–12

Replacing the Solvent Valve

1. Follow the steps in

Before Servicing, page 47 .

2. Disconnect the air lines from the solvent valve

(25).

3. Disconnect the solvent inlet and outlet lines.

4. Unscrew the solvent valve (25) from the adapter

(21).

5. Remove the seat (23) and o-rings (22, 24).

6. See manual 312782 to repair the valve.

7. Reassemble in the reverse order.

Figure 45 Solvent Valve and Solvent Flow Switch

62 3A2800F

Parts

Parts

Proportioner Parts (Standard Models)

Part No. MC1000 Low Pressure Proportioner

Part No. MC2000 High Pressure Proportioner

Part No. MC3000 Acid Low Pressure Proportioner

Part No. MC4000 Acid High Pressure Proportioner

3A2800F 63

Parts

3

4

5

Part No. MC1000 Low Pressure Proportioner

Part No. MC2000 High Pressure Proportioner

Part No. MC3000 Acid Low Pressure Proportioner

Part No. MC4000 Acid High Pressure Proportioner

Ref Part

1 — — —

2 — — —

6

7

8

9

— — —

— — —

24T790

24T791

24T788

24T789

24T819

24T818

— — —

24T771

24T770

10 277853

11 — — —

Description

FRAME

CONTROL BOX, electrical; see

Control Box Parts

(Standard Models),

page 69

PANEL, fluid 1

BRACKET, mounting 2

PUMP, 70 cc, A side, low pressure; for

Model MC1000; see manual 332339

PUMP, 70 cc, A side, high pressure; for

Models MC2000 and

MC4000; see manual

332339

PUMP, 35 cc, B side, low pressure; for

Model MC1000 and

MC3000; see manual

332339

PUMP, 35 cc, B side, high pressure; for

Model MC2000; see manual 332339

PUMP, 35 cc, B side, high pressure; for

Model MC4000 Acid; see manual 332339

PUMP, 35 cc, B side, low pressure: for

Model MC3000 Acid; see manual 332339.

BRACKET, mounting, pump

COVER; includes (2) of item 56

KIT, fan

1

1

1

1

1

1

2

1

2

BRACKET, mounting 2

SCREW, machine, pan head; M5 x 0.8;

10 mm

2

Qty

1

1

Ref Part

12 24U602

12a 16X039

12b 26A312

13 24M731

14 24T772

15 C19798

16 16U655

17 104641

18 111763

19 24T787

21 15T717

22 111457

23 15T725

27

28

29

24 15Y627

25 15X303

— — —

— — —

— — —

Description

MODULE, display, advanced; includes item 12a

TOKEN; latest version of software for the Advanced

Display Module; not shown

KIT, membrane repair

MODULE, booth control

MANIFOLD, solenoid; see

Solenoid Manifold

Parts, page 75

SCREW, cap, socket head; 1/4–20 x 3/8 in.

(10 mm)

BRACKET, mounting, valve

FITTING, bulkhead

ELBOW; 1/4 npt

(mbe)

SWITCH, solvent flow; 1/4 npt(f) ports

ADAPTER, solvent valve

O-RING; ptfe

RETAINER, seat, solvent valve

O-RING; ptfe

VALVE, solvent; see manual 312782

GUSSET

LEG, floor stand

1

1

1

2

8

1

1

1

4

2

PLUG, tube, square 6

1

1

1

1

1

1

Qty

1

64 3A2800F

Ref Part

30 — — —

31 — — —

32 — — —

33

34

— — —

— — —

35

36

43

— — —

— — —

— — —

— — —

44 155541

45 15F741

50 115287

51 — — —

52

53

— — —

— — —

Description

WASHER; 3/8

SCREW, cap, hex head; 3/8–16 x 2.75

in. (70 mm)

SCREW, cap, hex head; 3/8–16 x 7/8 in.

(22 mm)

NUT, lock; 3/8–16

SCREW, cap, hex head; 3/8–16 x 3 in.

(76 mm)

WASHER, lock; 3/8

NUT, hex; 3/8–16

WIRE HARNESS; for

Model MC1000 (not shown)

WIRE HARNESS; for

Model MC2000 (not shown)

SWIVEL, 90°; 1/4 npt(m) x 1/4 npsm(f)

FITTING, adapter;

1/4 npt(m) x 1/4 npt(f)

FITTING, Y-tube; for

1/4 in. (6 mm) OD tubing

TUBE, polyethylene;

1/4 in. (6 mm) OD x

3 ft

TUBE, nylon; 5/32 in.

(4 mm) OD x 3.5 ft

TUBE, nylon, green; for control air to turn valves on; 5/32 in. (4 mm) OD x 20 ft (cut to length required)

10

8

8

2

Qty

40

4

10

8

2

A/R

A/R

A/R

1

1

1

Parts

Ref Part

54

55

56

69

70 16V429

73

— — —

223547

— — —

— — —

24T302

73a — — —

73b 24U617

73c — — —

73d — — —

73e — — —

74 166421

Description

TUBE, nylon, red; for control air to turn valves off; 5/32 in. (4 mm) OD x 20 ft (cut to length required)

GROUND WIRE

SCREW, cap, socket head; 1/4–20 x 3/4 in.

(19 mm)

GROMMET, cable

CABLE, CAN, intrinsically safe, 5 pin; for booth control; fbe; 50 ft (15 m)

KIT, cup, TSL; includes items

73a-73e

BRACKET

KIT, barbed fittings; includes o-rings; package of 12

TUBE, polyurethane;

1/4 in. (6 mm) OD;

10 ft (3.05 m); cut to fit

PLUG, screw; 10–32; to replace unused item 73b at TSL cup; not shown

GASKET; for item

73d; not shown

NIPPLE, pipe; 1/4 npt

Qty

A/R

1

2

1

1

2

1

1

1

4

4

1

Items marked — — — are not available separately.

3A2800F 65

Parts

Proportioner Parts (Dual Panel Models)

Part No. MC1002 Low Pressure Proportioner

Part No. MC2002 High Pressure Proportioner

Part No. MC4002 Acid High Pressure Proportioner

66 3A2800F

Parts

Part No. MC1002 Low Pressure Proportioner

Part No. MC2002 High Pressure Proportioner

Part No. MC4002 Acid High Pressure Proportioner

Ref

201

202

203

204

205

206

207

208

209

210

211

Part

— — —

— — —

— — —

— — —

24T790

24T791

24T788

24T789

24T819

— — —

24T771

24T770

277853

— — —

Description

FRAME

CONTROL BOX, electrical; see

Control Box Parts

(Standard Models),

page 69

PANEL, fluid

BRACKET, mounting

PUMP, 70 cc, A side, low pressure; for Model MC1000; see manual 332339

PUMP, 70 cc, A side, high pressure; for Models MC2000 and MC4000; see manual 332339

PUMP, 35 cc, B side, low pressure; for Model MC1000; see manual 332339

PUMP, 35 cc, B side, high pressure; for Model MC2000; see manual 332339

PUMP, 35 cc, B side, high pressure; for Model MC4000

Acid; see manual

332339

BRACKET, mounting, pump

COVER; includes

(2) of item 56

KIT, fan

BRACKET, mounting

SCREW, machine, pan head; M5 x 0.8;

10 mm

Qty

1

1

1

2

1

1

1

1

2

1

2

2

2

Ref

212

212a

Part

24U602

16X039

212b 26A312

213 24M731

214 24T772

215 C19798

216

217

218

219

221

222

223

224

225

227

228

229

16U655

104641

111763

24T787

15T717

111457

15T725

15Y627

15X303

— — —

— — —

— — —

Description

ELBOW; 1/4 npt

(mbe)

SWITCH, solvent flow; 1/4 npt(f) ports

ADAPTER, solvent valve

O-RING; ptfe

Qty

MODULE, display, advanced; includes item 12a

TOKEN; latest version of software for the Advanced

Display Module; not shown

KIT, membrane repair

MODULE, booth control

MANIFOLD, solenoid; see

Solenoid Manifold

Parts, page 75

1

1

1

1

2

SCREW, cap, socket head; 1/4–20 x 3/8 in. (10 mm)

BRACKET,

8

1 mounting, valve

FITTING, bulkhead 1

1

1

1

1

1 RETAINER, seat, solvent valve

O-RING; ptfe

VALVE, solvent; see manual 312782

GUSSET

LEG, floor stand

1

1

4

2

PLUG, tube, square 6

3A2800F 67

Parts

Ref

230

231

Part

— — —

— — —

232 — — —

233

234

— — —

— — —

235

236

243

— — —

— — —

— — —

— — —

244

245

155541

15F741

250 115287

— — — 251

252

253

— — —

— — —

Description

WASHER; 3/8

SCREW, cap, hex head; 3/8–16 x 2.75

in. (70 mm)

SCREW, cap, hex head; 3/8–16 x 7/8 in. (22 mm)

NUT, lock; 3/8–16

10

10

SCREW, cap, hex head; 3/8–16 x 3 in.

8

(76 mm)

WASHER, lock; 3/8 8

Qty

40

4

NUT, hex; 3/8–16

WIRE HARNESS; for Model MC1000

(not shown)

WIRE HARNESS; for Model MC2000

(not shown)

SWIVEL, 90°; 1/4 npt(m) x 1/4 npsm(f)

FITTING, adapter;

1/4 npt(m) x 1/4 npt(f)

FITTING, Y-tube; for 1/4 in. (6 mm)

OD tubing

TUBE, polyethylene; 1/4 in. (6 mm)

OD x 3 ft

TUBE, nylon; 5/32 in. (4 mm) OD x 3.5

ft

TUBE, nylon, green; for control air to turn valves on; 5/32 in. (4 mm) OD x

20 ft (cut to length required)

8

2

2

1

1

1

A/R

A/R

A/R

Ref

254

255

256

269

270

273

273a

273c

273d

273e

274

Part

— — —

223547

— — —

— — —

16V429

24T302

— — —

273b 24U617

— — —

— — —

— — —

166421

Description

TUBE, nylon, red; for control air to turn valves off; 5/32 in. (4 mm) OD x

20 ft (cut to length required)

GROUND WIRE

SCREW, cap, socket head; 1/4–20 x 3/4 in. (19 mm)

GROMMET, cable

CABLE, CAN, intrinsically safe,

5 pin; for booth control; fbe; 50 ft

(15 m)

KIT, cup, TSL; includes items

73a-73e

BRACKET

KIT, barbed fittings; includes o-rings; package of 12

TUBE, polyurethane; 1/4 in. (6 mm) OD; 10 ft

(3.05 m); cut to fit

PLUG, screw;

10–32; to replace unused item 73b at

TSL cup; not shown

GASKET; for item

73d; not shown

NIPPLE, pipe; 1/4 npt

Qty

A/R

1

2

1

1

2

1

1

1

4

4

1

Items marked — — — are not available separately.

68 3A2800F

Control Box Parts (Standard Models)

Electrical Control Box

Parts

3A2800F 69

Parts

Electrical Control Box (continued)

Ref

101

104

105

Part Description

— — — ENCLOSURE

— — — PANEL, back 102

103 24T769 POWER SUPPLY; 48

Vdc; 10 A; 480 W

— — — WASHER, lock; no. 6

— — — SPACER, standoff

106

106a 15D979 FUSE; 400 mA, quick acting

107

255786 BOARD, barrier; includes item 106a

108

109

— — — COVER, barrier

— — — SCREW, machine, pan head; 6–32 x 1.5 in. (38 mm)

— — — SCREW, machine, pan head; 6–32 x 0.375 in.

(10 mm)

3

3

3

1

2

1

2

1

1

Qty

1

113

114

115

116

117

118

119

120

Ref

110

111

112

Part Description

— — — BRACKET, board

24M485 BOARD, isolation, IS

16U725 SWITCH, selector, 2 position

— — — DUCT, wire

— — — COVER, duct

16V446 FILTER , line; 10A

— — — BLOCK, terminal

— — — COVER, enclosure

— — — GROMMET

— — — LIGHT

16T660 POWER SUPPLY; 24

Vdc, 4 A, 96 W

2

4

1

1

1

1

2

1

1

1

Qty

2

70 3A2800F

Parts

Ref

121

122

123

124

125

126

127

128

129

130

131

132

133

134

135

136

137

138

139

140

141

Part Description

— — — CONNECTOR, bar, ground

— — — SCREW, ground; M5 x

— — — NUT, hex, flange head;

1/4–20

— — — SCREW, flanged, hex head; 1/4–20 x 0.75 in.

— — — SCREW, machine, pan head; 10–24 x 0.375 in.

(10 mm)

— — — SCREW, machine, pan head; 10–32 x 0.75 in.

(19 mm)

— — — FITTING, connector; 1/8 npt(m) x 1/4 in. (6 mm)

— — — SCREW, machine, pan head; 8–32 x 0.25 in. (6

4

2

3

1

8

— — — SCREW, machine, binding head; 6–32 x

0.25 in. (6 mm)

121003 CABLE, CAN; fbe; 3.0

— — — SCREW, cap, socket head; 8–32 x 0.625 in.

(16 mm)

4

1

1

24N527 MODULE, control, pump 2

16P243 CABLE, splitter

— — — MUFFLER

1

1

121324 VALVE, solenoid; 3–way 1

— — — ELBOW, swivel; 1/8 1 npt(m) x 5/32 in. (4 mm)

OD tube

— — — PLUG, pipe; 1/8 npt(m) 3

— — — STRAIN RELIEF, cord 4

24T773 MODULE, control, enhanced fluid

— — — SCREW, machine, pan head; 1/4–20 x 0.5 in.

1

2

2

3

4

Qty

1

Ref

142

Part Description

— — — SCREW, machine, pan head; 10–32 x 0.25 in.

(6 mm)

Qty

10

143 — — — SCREW, machine, pan head; 10–32 x 1.5 in.

8

(38 mm)

144▲ 172953 LABEL, ground symbol 1

145 — — — CLAMP; for 3/8 in. (10 mm) OD cable

147▲ 15W598 LABEL, warning

148 — — — HARNESS, CAN

150

151

152

153 isolation, power (not shown)

16T072 ADAPTER, CAN cable,

IS to non-IS

121227 CABLE, CAN; fbe; 0.6

m

— — — HARNESS, 3–wire

— — — HARNESS, 2–wire

4

1

1

1

1

1

1

2 154

155

16T659 CABLE, D-SUB, 25 pin,

— — — SCREW, self sealing

159 15T632 KIT, air flow switch; includes items

159a-159c

159a 104641 FITTING, bulkhead

2

1

1

159b 111763 ELBOW; 1/4 npt (mbe) 1

159c 113029 NIPPLE; 1/4 npt 1

163 16V429 CABLE, CAN, I.S.; fbe;

50 ft. 15.25 m)

1

168▲ 16U600 LABEL, isolation board 1

169 — — — NUT, hex, self-locking; 4

170 — — — SCREW, machine, pan head; 8–32 x 0.312 in.

(8 mm)

173▲ 15W776 LABEL, warning

4

1

Items marked — — — are not available separately.

▲ Replacement Danger and Warning labels, tags, and cards are available at no cost.

3A2800F 71

Parts

Control Box Parts (Dual Panel Models)

Electrical Control Box

72 3A2800F

Parts

Electrical Control Box (continued)

Ref

401

402

403

Part

— — —

— — —

Description

ENCLOSURE

PANEL, back

24T769 POWER SUPPLY; 48

— — —

Vdc; 10 A; 480 W

WASHER, lock; no. 6

— — — SPACER, standoff

404

405

406 255786 BOARD, barrier; includes item 106a

406a 15D979 FUSE; 400 mA, quick acting

407 — — — COVER, barrier

408 — — —

409 — — —

SCREW, machine, pan head; 6–32 x 1.5 in. (38 mm)

SCREW, machine, pan head; 6–32 x 0.375 in.

(10 mm)

3

3

3

1

2

1

2

1

1

Qty

1

413

414

415

416

417

418

419

420

Ref

410

411

412

Part

— — —

Description

BRACKET, board

24M485 BOARD, isolation, IS

16U725 SWITCH, selector, 2 position

— — — DUCT, wire

— — — COVER, duct

16V446 FILTER , line; 10A

— — — BLOCK, terminal

— — — COVER, enclosure

— — — GROMMET

— — — LIGHT

16T660 POWER SUPPLY; 24

Vdc, 4 A, 96 W

2

4

1

1

1

1

2

1

Qty

2

1

1

3A2800F 73

Parts

Ref

421

422

423

424

425

426

427

428

429

430

431

432

433

434

435

436

437

438

439

440

441

Part

— — —

— — —

— — —

— — —

— — —

— — —

Description

CONNECTOR, bar, ground

SCREW, ground; M5 x

0.8

NUT, hex, flange head;

1/4–20

SCREW, flanged, hex head; 1/4–20 x 0.75 in.

(19 mm)

SCREW, machine, pan head; 10–24 x 0.375 in.

(10 mm)

SCREW, machine, pan head; 10–32 x 0.75 in.

(19 mm)

FITTING, connector; 1/8

Qty

1

3

4

4

2

3

— — —

— — —

— — — npt(m) x 1/4 in. (6 mm)

OD tube

SCREW, machine, pan head; 8–32 x 0.25 in. (6 mm)

SCREW, machine, binding head; 6–32 x

0.25 in. (6 mm)

1

8

4

121003 CABLE, CAN; fbe; 3.0 m 1

— — — MANIFOLD, air 1

24N527 MODULE, control, pump 2

16P243

— — —

CABLE, splitter

MUFFLER

1

1

121324 VALVE, solenoid; 3–way 1

— — —

— — —

ELBOW, swivel; 1/8 npt(m) x 5/32 in. (4 mm)

1

OD tube

PLUG, pipe; 1/8 npt(m) 3

— — — STRAIN RELIEF, cord 4

24T773 MODULE, control,

— — —

— — — enhanced fluid

SCREW, machine, pan head; 1/4–20 x 0.5 in.

(13 mm)

SCREW, cap, socket head; 8–32 x 0.625 in.

(16 mm)

1

2

2

Ref

442

443

Part

— — —

— — —

Description

SCREW, machine, pan head; 10–32 x 0.25 in.

(6 mm)

SCREW, machine, pan head; 10–32 x 1.5 in.

(38 mm)

Qty

10

8

444▲ 172953 LABEL, ground symbol 1

445 — — — 4 CLAMP; for 3/8 in. (10 mm) OD cable

447▲ 15W598 LABEL, warning

448 — — —

450

HARNESS, CAN isolation, power (not shown)

16T072 ADAPTER, CAN cable,

451

452

453

1

1

IS to non-IS

121227 CABLE, CAN; fbe; 0.6 m 1

— — — HARNESS, 3–wire

1

1

— — — HARNESS, 2–wire 1

454

455

459

16T659 CABLE, D-SUB, 25 pin,

— — —

2.5 ft

SCREW, self sealing

15T632 KIT, air flow switch; includes items

159a-159c

459a 104641 FITTING, bulkhead

2

2

1

1

459b 111763 ELBOW; 1/4 npt (mbe) 1

459c 113029 NIPPLE; 1/4 npt 1

463 16V429 CABLE, CAN, I.S.; fbe;

50 ft. 15.25 m)

1

468▲ 16U600 LABEL, isolation board 1

469 — — — 4

470 — — —

NUT, hex, self-locking;

1/4–20

SCREW, machine, pan head; 8–32 x 0.312 in.

(8 mm)

473▲ 15W776 LABEL, warning

4

1

Items marked — — — are not available separately.

▲ Replacement Danger and Warning labels, tags, and cards are available at no cost.

74 3A2800F

Solenoid Manifold Parts

Part No. 24T772 Solenoid Manifold

Parts

Ref Part

301 — — —

302 — — —

303 — — —

304 115671

305 16P812

307 114151

308 114263

309 C06061

Description

PLATE

MANIFOLD

SCREW, cap, socket head; 1/4–20 x 0.375

in. (10 mm)

CONNECTOR; 1/8 npt(m) x 1/4 in. (6 mm) OD tube

VALVE, solenoid

FITTING, elbow, swivel; 1/8 npt(m) x

5/32 in. (4 mm) OD tube

FITTING, straight;

1/8 npt(m) x 5/32 in.

(4 mm) OD tube

MUFFLER

Qty

1

1

4

1

2

4

4

2

Items marked — — — are not available separately.

3A2800F 75

Technical Data

Technical Data

Positive Displacement

Proportioner

Maximum fluid working pressure:

MC0500 and MC0502

Systems with

Low-Pressure Pumps

MC0500 and MC0502

Systems with

High-Pressure Pumps

MC1000, MC1002, and

MC3000 Air Spray System

MC2000, MC2002,

MC4000, and MC4002

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:

Viscosity range of fluid:

Fluid filtration

(user-supplied):

Maximum fluid flow:

Fluid outlet size:

External power supply requirements:

U.S.

300 psi

1500 psi

300 psi

1500 psi

100 psi

85–100 psi

3/8 npt(f)

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

Metric

2.1 MPa, 21 bar

10.5 MPa, 105 bar

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

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:

–4 to 158°F

195 lb

Less than 75 dB(A)

–20 to 70°C

88 kg

76 3A2800F

Metric

Technical Data

Positive Displacement

Proportioner

Wetted parts:

MC0500 and MC0502

MC1000, MC1002,

MC2000, and MC2002

MC4000, MC3000, and

MC4002

U.S.

Pumps sold separately; see selected pump manual for wetted parts information.

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

316 SST, 17–4PH SST, PEEK, perfluoroelastomer; PTFE, PPS, UHMWPE

3A2800F 77

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 period of twelve months from the date of sale, repair or replace any part of the equipment determined by 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, by Graco.

purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material parts, labor, and transportation.

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.

not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS 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 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 3A2800

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

Revision F, September 2017

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