Graco 3A4129A, ProMix® PD2K Proportioner Integrated for Automatic Spray Applications Owner's Manual

Installation
ProMix® PD2K Proportioner Integrated
for Automatic Spray Applications
3A4129A
EN
fast--setting
Electronic positive displacement proportioner integrated with air controls and electrostatics for fast
two--component materials. Automatic system with Advanced Display Module. For professional use only.
two
Important Safety Instructions
Read all warnings and instructions in this manual and in your
operation, repair, and associated component manuals. Save these
instructions.
See page 3 for model part numbers and
approvals information.
PROVEN QUALITY. LEADING TECHNOLOGY.
Contents
Related Manuals ................................................ 2
3
3
3
3
Fluid Supply ....................................................... 19
Fluid Requirements ...................................... 19
Single Color Connections ............................. 20
Color Change Connections........................... 20
Solvent Connections .................................... 20
Warnings ........................................................... 4
TSL™ Cup Kit .................................................... 21
Important Isocyanate (ISO) Information ................ 7
Light Tower Accessory........................................ 23
General Information ............................................ 9
Air Supply .......................................................... 24
Models...............................................................
Positive Displacement Proportioner...............
Integrated Air Control ...................................
Electrostatic Control .....................................
Configure Your System ....................................... 10
1. Select a Base Model ................................ 10
2. Select Hoses ........................................... 12
3. Select a Spray Gun .................................. 13
4. Select an Adapter Plate............................ 13
5. Select Non-Intrinsically-Safe Color and
Catalyst Change Kits ...................... 14
6. Select Instrinsically-Safe Remote Color
Change Kits ................................... 15
7. Select Pump Expansion Kits ..................... 16
8. Select Communication Options ................. 16
Install the Display Module.................................... 17
Location ............................................................. 18
Electrical Supply ................................................. 25
Electrical Requirements................................ 25
Electrical Connections .................................. 25
Grounding .......................................................... 29
Electrical Schematics.......................................... 32
Optional Cables and Modules.............................. 38
Dimensions ........................................................ 39
Proportioner Dimensions .............................. 39
Air Control Dimensions................................. 40
Electrostatic Dimensions .............................. 41
Technical Specifications...................................... 44
Related Manuals
Current manuals are available at www.graco.com.
Manual No.
Description
Manual No.
Description
332709
ProMix PD2K Proportioner for
Automatic Spray Applications,
Repair — Parts
334183
Modbus TCP Gateway Module,
Instructions — Parts
334494
332458
ProMix PD2K Proportioner for
Automatic Spray Applications,
Installation
ProMix PD2K CGM Installation
Kits, Instructions — Parts
3A3465
Integrated Air Control, Instructions
313516
Automatic AirPro Spray Guns,
Instructions — Parts
311052
Dosing Pumps, Instructions —
Parts
Automatic G40 Air-Assisted Spray
Guns, Instructions — Parts
332992
Color/Catalyst Dispense Valves,
Instructions — Parts
Pro Xpc Auto Electrostatic Air
Spray Gun, Instructions — Parts
333266
Color Change and Remote Mix
Manifold Kits, Instructions — Parts
Pro Xpc Auto Controller,
Instructions
313869
AirPro EFX Automatic Spray Gun,
Instructions — Parts
332564
332339
332454
333282
332456
2
ProMix PD2K Proportioner for
Automatic Spray Applications,
Operation
Pump Expansion Kits, Instructions
— Parts
3A4129A
Models
Models
Positive Displacement Proportioner
Part No.
Series
Maximum Air Working Pressure
Maximum Fluid Working Pressure
AC0500
A
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)
AC1000
A
100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
AC2000
A
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa, 103.4 bar)
0359
II 2 G
EX ia IIA T3
FM13 ATEX 0026
IECEx FMG 13.0011
Instrinsically safe
equipment for Class I,
Div 1, Group D, T3
Ta = 2°C to 50°C
Integrated Air Control
Part No.
Series
Maximum Air Working Pressure
26A010
A
100 psi (0.7 MPa, 7.0 bar)
Electrostatic Control
Controller
Description
Maximum Gun Voltage Output
24Y307
Pro Xpc Auto Controller, solventborne
100 kV
0102
3A4129A
II 3(2)G T6
PTB 15 ATEX 5013
EN 50050–1, EN 50176
3
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation
point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these
symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard
symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. 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.
4
3A4129A
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.
3A4129A
5
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 Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications 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.
6
3A4129A
Important Isocyanate (ISO) Information
Important Isocyanate (ISO) Information
Isocyanates (ISO) are catalysts used in two
component materials.
Self--ignition
Material Self
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.
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.
• 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 isocyanates.
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.
3A4129A
7
Important Isocyanate (ISO) Information
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
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
Partially cured ISO will reduce performance and
the life of all wetted parts.
Changing the material types used in your
equipment requires special attention to avoid
equipment damage and downtime.
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere.
Never store ISO in an open container.
• When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.
• 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 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 (color) side.
• Always lubricate threaded parts with an
appropriate lubricant when reassembling.
8
3A4129A
General Information
General Information
The PD2K Integrated System coordinates the
operation of three independent systems: a Positive
Displacement Proportioner (models AC0500,
AC1000, and AC2000), an Integrated Air Control
(model 26A010), and Electrostatics (model 24Y307).
See Related Manuals, page 2 for additional
information about each of the integrated systems.
• Reference numbers and letters in parentheses
in the text refer to numbers and letters in the
illustrations.
3A4129A
• Be sure all accessories are adequately sized and
pressure-rated to meet system requirements.
• To protect the screens from paints and solvents,
clear-plastic protective shields (10 per pack) are
available. Order Part No. 197902 for the Advanced
Display Module. Clean the screens with a dry cloth
if necessary.
• For PD2K installation, reference ProMix PD2K
CGM Installation Kits and PD2K Proportioner
Installation Automatic Systems manuals. See
Related Manuals, page 2 .
9
Configure Your System
Configure Your System
1. Select a Base Model
Choose a PD2K base model that meets your
application’s requirements. See Models, page 3 .
Base unit components are described in the following
table.
Base models include components A through F shown
in the Typical Installation drawing on the next page.
Base Model Component
Description
Fluid Pumps (A, B)
The base models include two side-by-side fluid pumps, one side for color and
the other side for catalyst. Install in the non-hazardous area.
NOTE: By convention, the A side is either color or resin, depending on your
needs, and the B side is always catalyst. Throughout this manual, references
to “color” may also be applicable to “resin”.
Solvent Flow Switch (C)
Confirms solvent flow to gun during purge. The base models include two
solvent flow switches; one for color, and one for catalyst.
Electrical Control Box (D)
The electrical control box includes a barrier board, intrinsically safe isolation
board, 24 Vdc and 48 Vdc power supplies, Enhanced Fluid Control Module,
and Pump Control Modules. The Gateway communication module is
installed in the electrical control box. It accepts 90–250 Vac line power and
converts that power to acceptable low voltage signals used by other system
components. Install the electrical control box in the non-hazardous area.
Advanced Display Module (E)
The Advanced Display Module (ADM) enables the user to set up, monitor, and
control the system. Install the ADM in the non-hazardous area.
CAN cable (F)
The CAN cable connects the Gateway communication module in the electrical
control box (D) to the IS remote mix control module (R).
Air Control Component
Description
Air Control Box (V)
The air control box requires its own air supply. Air control provides closed
loop pressure control for fan and atomizing air. Also contains gun trigger
output with three auxiliary solenoids for process control. Install the air
control box in a non-hazardous area. See Integrated Control Manual in
Related Manuals, page 2 .
Electrostatic Control Component
Description
Electrostatic Control Box
(Solventborne) (U)
Solventborne control allows a maximum of 100 kV and 150 μA. The
control box has built-in arc detection and can be controlled remotely
through discrete I/O or Graco CAN. See Pro Xpc Auto Controller Manual in
Related Manuals, page 2 .
10
3A4129A
Configure Your System
HAZARDOUS (CLASSIFIED) LOCATION
NON--HAZARDOUS LOCATION ONLY
NON
Figure 1 Typical Installation
Component
Description
★ Components A through F are included with the base unit.
A★
Material A (Color) Pump
B★
Material B (Catalyst) Pump
C★
Solvent Flow Switch
D★
Electrical Control Box
E★
Advanced Display Module
F★
CAN Communication Cable
Components G through K are included in optional color change kits.
G
Color Change Valves (accessory, non-hazardous area)
H
Color Change Module (accessory, non-hazardous area)
J
Catalyst Change Valves (accessory, non-hazardous area)
K
Catalyst Change Module (accessory, non-hazardous area)
Components L through S are accessories and must be ordered separately.
L
Fluid/Air Hose Bundle (accessory)
M
Remote Color Change Manifold (accessory, hazardous area)
N
Remote Mix Manifold (accessory, hazardous area)
P
Automatic Spray Gun (accessory)
R
IS Remote Mix Control Module (accessory, hazardous area)
S
Gun Fluid Hose Integrator (accessory)
T
Supply Line Drain Valves (accessory, required, not shown)
U
Electrostatic Control Box
V
Air Control Box
3A4129A
11
Configure Your System
2. Select Hoses
Hose Selection Tool
NOTE: Shaded areas may use hose sizes from either
of the two adjacent areas.
Use this chart to determine the proper size hoses
for your mix ratio and viscosity, then select hoses
for your application.
NOTE: Always use Graco hoses.
Recommended Hose Sizes (internal diameter) for A and B
20 - 50
18
3/8 ʺ A
1/8 ʺ B
16
14
3/8 ʺ A
1/4 ʺ B
12
10
Mix
Ratio
(X:1)
8
1/4 ʺ A
1/4 ʺ B
6
4
2
0
10:1
1/4 ʺ A
3/8 ʺ B
7.5:1
5:1
2.5:1
1:1
1:2.5
1:5
Equal Viscosities
Thick Color (A)
1:7.5
1:10
Thin Color (A)
Thin Catalyst (B)
Thick Catalyst (B)
Viscosity Ratio (Color [A] : Catalyst [B]
1/4 in. (6 mm) ID Hoses
Application
Material
Moisture-Lok
Catalyst
Nylon
Color
Nylon
Solvent
Nylon
Atomizing
Air
Nylon
12
Pressure
Maximum Fluid Working
Pressure
Length
15 ft
(4.6 m)
25 ft
(7.6 m)
50 ft
(15.2 m)
High and Low
2000 psi (13.8 MPa, 138 bar)
947078
24T134
24T135
Low
225 psi (1.6 MPa, 16 bar)
17C967
24T266
24T267
High
4100 psi (28.3 MPa, 283 bar)
238825
239107
239111
Low
225 psi (1.6 MPa, 16 bar)
17C967
24T266
24T267
High
4100 psi (28.3 MPa, 283 bar)
238825
239107
239111
Low
225 psi (1.6 MPa, 16 bar)
17C967
24T266
24T267
High
4100 psi (28.3 MPa, 283 bar)
238825
239107
239111
Low
225 psi (1.6 MPa, 16 bar)
17C967
24T194
24T195
3A4129A
Configure Your System
3. Select a Spray Gun
Spray Guns
Select an automatic spray gun from the following table.
Application
Gun
Model
Gun Manual
No.
Maximum
Fluid
Working
Pressure
Air Control
Electrostatic
Control SB
Recip
Mount
Robot Mount
AirPro®
Auto
313516
100 psi
(0.7 MPa, 7
bar)
26A123
24Y307
–
24Y515
AirPro
EFX™
313869
100 psi
(0.7 MPa, 7
bar)
26A123
24Y307
–
24Y515
Conventional
Air-Assisted
Spray
G40
311052
4000 psi
(28 MPa,
280 bar)
26A123
24Y307
–
24Y515
Electrostatic
Air Spray
Cable
Pro Xpc™
Auto
332992
100 psi
(0.7 MPa, 7
bar)
26A123
24Y307
24L044
24Y515
Conventional
Air Spray
Conventional
Air Spray
NOTE: XP Auto not supported by PD2K Integrated.
4. Select an Adapter Plate
Mount Adapter Plates
Select an adapter from the following table.
Robot Model
Manufacturer
3A4129A
Graco Adapter
Fanuc
Paint Mate 200iA / 200iA/5L
24Y768
Fanuc
P250 / P50
24Y769
Yaskawa Motoman
EXP1250
24Y128
Yaskawa Motoman
EXP2050
24Y634
Yaskawa Motoman
EXP2700/2800/2900
24Y650
ABB
IRB 540
24Y172
ABB
IRB 1400
24Y173
ABB
IRB 580/5400
24Y634
13
Configure Your System
Non--Intrinsically
Intrinsically--Safe Color and Catalyst Change Kits
5. Select Non
Using the following table, choose the non-IS color/catalyst change kits that meet your application’s requirements. The
kits include a manifold with valves and a control module for installation in the non-hazardous area. See Color Change
and Remote Mix Manifold manual in Related Manuals, page 2 for more information.
Table 1 . Low Pressure Color/Catalyst Change Kits
(300 psi [2.068 MPa, 20.68 bar])
Kit Part No.
Kit Description
Table 2 . High Pressure Color/Catalyst Change Kits
(1500 psi [10.34 MPa, 103.4 bar])
Kit Part No.
Non--Circulating Kits
Low Pressure Non
Kit Description
Non--Circulating Kits
High Pressure Non
24X316
1 color or 1 catalyst
change valve
24X318
1 color or 1 catalyst
change valve
24R915
2 color or 2 catalyst
change valves
24R959
2 color or 2 catalyst
change valves
24R916
4 color or 4 catalyst
change valves
24R960
4 color or 4 catalyst
change valves
24R917
6 color change valves
24R961
6 color change valves
24R918
8 color change valves
24R962
8 color change valves
Low Pressure Circulating Kits
24X317
1 color or 1 catalyst
change valve
24R919
2 color or 2 catalyst
change valves
24R920
4 color or 4 catalyst
change valves
24R921
6 color change valves
24R922
8 color change valves
14
High Pressure Acid
Acid--Compatible Non
Non-Circulating Kits
24T579
2 catalyst change valves
24T580
4 catalyst change valves
High Pressure Circulating Kits
24X319
1 color or 1 catalyst
change valve
24R963
2 color or 2 catalyst
change valves
24R964
4 color or 4 catalyst
change valves
24R965
6 color change valves
24R966
8 color change valves
3A4129A
Configure Your System
Instrinsically--Safe Remote Color Change Kits
6. Select Instrinsically
IS remote color change manifold kits include a manifold with valves and a control module, which may be installed in
the hazardous area. The remote color change manifold kit must have the same number of color valves and catalyst
valves as the color/catalyst change kit you selected in the previous step. The remote color change manifolds attach
to the robot arm or wall, allowing mixing to occur close to the point of spray. See Color Change and Remote Mix
Manifold manual in Related Manuals, page 2 for more information.
Non--Circulating Remote
Table 3 . Low Pressure, Non
Color Change Manifold Kits
(300 psi [2.068 MPa, 20.68 bar])
Number
of Color
+ Solvent
Valves
Number of Catalyst + Solvent Valves
1
24V157
2
24V158
24V331
4
24V159
24V332
6
24V160
8
High--Pressure, Non
Non--Circulating Remote
Table 5 . High
Color Change Manifold Kits
(1500 psi [10.34 MPa, 103.4 bar])
Number
of Color
+ Solvent
Valves
Number of Catalyst + Solvent Valves
1
24V359
2
24V360
24V381
24V343
4
24V361
24V382
24V396
24V333
24V344
6
24V362
24V383
24V397
24V161
24V334
24V345
8
24V363
24V384
24V398
12
24V162
24V335
24V346
12
24V364
24V385
24V399
13–18
24V163
13–18
24V365
13–24
24V164
13–24
24V366
13–30
24V165
13–30
24V367
1
2
4
Table 4 . Low Pressure, Circulating Remote Color
Change Manifold Kits
(300 psi [2.068 MPa, 20.68 bar])
Number
of Color
+ Solvent
Valves
Number of Catalyst + Solvent Valves
1
24V166
2
24V167
24V336
4
24V308
24V337
6
24V309
8
1
2
4
High--Pressure, Circulating Remote Color
Table 6 . High
Change Manifold Kits
(1500 psi [10.34 MPa, 103.4 bar])
Number
of Color
+ Solvent
Valves
Number of Catalyst + Solvent Valves
1
24V369
2
24V370
24V389
24V347
4
24V371
24V390
24V402
24V338
24V348
6
24V372
24V391
24V403
24V326
24V339
24V349
8
24V373
24V392
24V404
12
24V327
24V340
24V350
12
24V374
24V393
24V405
13–18
24V328
13–18
24V375
13–24
24V329
13–24
24V376
13–30
24V330
13–30
24V377
3A4129A
1
2
4
1
2
4
15
Configure Your System
7. Select Pump Expansion Kits
8. Select Communication Options
The following table lists available kits to add a third
or fourth pump to your system. Each kit includes
one pump, a pump control module, solenoid,
frame, mounting bracket, and cabling. See the
Pump Expansion Kit manual (332456) for further
information.
The following table lists available kits to support an
alternate PLC protocol. See the CGM Installation Kits
manual (334494) for further information.
Kit Part No.
Kit Part No.
Kit Description
26A126
CGM Kit (PLC protocols)
CGMEP0
EtherNet/IP-CGM
(alternate PLC protocol)
CGMDN0
Low pressure color 70cc
pump
DeviceNet-CGM
(alternate PLC protocol)
CGMPN0
Low pressure catalyst
35cc pump
PROFINET-CGM
(alternate PLC protocol)
24W462
Modbus TCP-CGM
Kit Description
Low Pressure Pumps (300 psi [2.068
MPa, 20.68 bar])
24R968
24R970
High Pressure Pumps (1500 psi [10.34
MPa, 103.4 bar])
24R969
High pressure color
70cc pump
24R971
High pressure catalyst
35cc pump
16
3A4129A
Install the Display Module
Install the Display Module
1. Use the screws (11) to mount the bracket (10) for
the Advanced Display Module (12) on the front of
the Electrical Control Box or on the wall.
NOTE: For a list of alternate cable lengths, see
Electrical Schematics, page 32. The total length of
all cable used in the system must not exceed 150
ft (45 m).
2. Snap the Advanced Display Module into the
bracket.
Figure 3 Advanced Display Module Connection Ports
Figure 2 Install Display Module
3. Connect one end of the 5 ft (1.5 m) CAN cable
(provided) to the CAN Cable Connection (MM)
on the Advanced Display Module. The other end
of the cable comes from the factory connected to
the Enhanced Fluid Control Module (EFCM).
3A4129A
Item
Description
JJ
Battery Cover
KK
Model Number
LL
USB Drive Interface
MM
CAN Cable Connection
NN
ADM Status LEDs
PP
Accessory Cable
Connection
RR
Token Access Cover
17
Location
Location
Mounting the Air Control Box:
Mounting the Electrostatic Control Box:
• Mount the integrated air control (V) in a
non-hazardous location.
• Mount the electrostatic control (U) in a
non-hazardous location.
• Ensure that the mounting surface and mounting
hardware are strong enough to support the weight
of the equipment, cables, hoses, and stress
caused during operation.
• Ensure that the mounting surface and mounting
hardware are strong enough to support the weight
of the equipment, cables, hoses, and stress
caused during operation.
• Secure the air control enclosure to mounting
location. See Mounting the Air Control Enclosure,
page 8, in the Integrated Air Control manual
(3A3465).
• Secure the electrostatic controller to mounting
location. See Mount the Controller, page 14, in the
Pro Xpc Auto Controller manual (333266).
• There must be sufficient space on all sides of the
equipment for installation, operator access, and
maintenance.
18
• There must be sufficient space on all sides of the
equipment for installation, operator access, and
maintenance.
3A4129A
Fluid Supply
Fluid Supply
Fluid Requirements
• To reduce the risk of equipment
overpressurization and rupture which can
cause injury, including skin injection, do not
exceed the pressure rating of the lowest rated
system component. See the identification
label for the maximum working pressure of the
equipment.
• To reduce the risk of injury, including skin
injection, you must install a shutoff valve
between each fluid supply line and the mix
manifold. Use the valves to shut off fluid during
maintenance and service.
Models are available to operate air spray (300 psi) or
air-assisted (1500 psi) systems with a capacity of up
to 800 cc/minute (depending on material viscosity).
• Fluid supply pressure tanks, feed pumps, or
circulating systems can be used to supply fluid to
the system.
• Materials can be transferred from their original
containers or from a central paint recirculating line.
3A4129A
• Install a 100 mesh (minimum) fluid filter in the fluid
supply line, with a drain valve.
• The supply line should be sized to avoid pressure
loss of greater than a few psi between the
circulation header and the proportioner fluid inlet
port.
NOTE: The fluid supply must be free of pressure
spikes, which are commonly caused by pump stroke
changeover. Read the supply pressure on the gauge
(P, see figure on next page). Supply capability for
each pump must be at least 2 times the maximum
operating flow rate. Supply pressure must be as
close as possible to the pressure setpoint:
• For low pressure systems, ± 100 psi (0.7 MPa, 7
bar) of setpoint.
NOTE: For low pressure systems, it is
recommended the supply pressure should be
maintained at 1/2 to 2/3 of the system operating
spray pressure.
• For high pressure systems, ± 300 psi (2.1 MPa,
21 bar) of setpoint.
If necessary, install pressure regulators or a surge
tank on the pump fluid inlet lines to reduce pulsation.
Contact your Graco distributor for additional
information.
19
Fluid Supply
Single Color Connections
Color Change Connections
NOTE: Check valves (J, L) are provided on the inlet
(K) and outlet (H) manifolds of each pump.
If you are installing the color change accessory kit,
make the fluid connections as described in manual
333282.
1. Connect the color supply line to the pump fluid
inlet fitting (S).
2. Connect the color outlet line to the pump fluid
outlet fitting (R).
3. Make the same connections on the catalyst side.
NOTE: For isocyanate catalyst materials, moisture
resistant hose is required to supply fluid to the system
and also as a fluid line between the pump and the
mix manifold.
Solvent Connections
1. Connect the solvent supply line for the color to
the inlet fitting (17) for solvent flow switch 1 (FS1).
2. Connect the solvent supply line for the catalyst
to the inlet fitting (17) for solvent flow switch 2
(FS2).
3. Connect the solvent outlet line for the color to
the solvent flow switch 1 (FS1) outlet fitting (74)
and then to the appropriate remote color change
valve.
4. Connect the solvent outlet line for the catalyst to
the solvent flow switch 2 (FS2) outlet fitting (74)
and then to the appropriate remote color change
valve.
Figure 4 Pump Inlet and Outlet Connections
20
Figure 5 Solvent Connections
3A4129A
TSL™ Cup Kit
TSL™ Cup Kit
The cup is used for either Throat Seal Liquid (TSL™)
or ISO oil. These liquids prevent exposure to air or
moisture with the color or catalyst at the pump throat
packings and dosing valves. The PD2K Proportioner
includes two TSL Cup Kits, one for each pump. The
cups supply TSL to the upper throat cartridge of the
color (70 cc) pump, to the upper and lower throat
cartridges of the catalyst (35 cc) pump, and to the
four pump dosing valves. When using isocyanate
catalysts, the cup attached to the catalyst side of the
PD2K Proportioner is used to supply ISO oil to the
upper and lower throat cartridges of the catalyst (35
cc) pump and the catalyst dosing valves.
2. Place the TSL cup (73) into the bracket (73a).
NOTE: TSL and ISO oil must be ordered separately.
For TSL, order Part No. 206995, one quart (0.95
liter). For ISO oil, order Part No. 217374, one pint
(0.48 liter).
1. Slide the kit mounting bracket onto any side of
the pump’s hex nut.
NOTE: Prior to mounting the cup, use a
permanent black marker to mark a horizontal line
on the front of the cup approximately half way
between the top and bottom of the cup. Mark a
second horizontal line approximately 1/4 in. (3
mm) above the first line. Shining a strong light
towards these lines will indicate fluid level by
casting a shadow that will be visible from inside
the TSL cup.
3A4129A
Figure 6 Install TSL Cup Kit
NOTE: The pump’s upper throat cartridge has
three ports (two are plugged). Move a plug (73d)
if necessary so the barbed fitting (73b) can be
put in the port closest to the TSL cup.
3. Check that the o-ring is in place on the barbed
fitting (73b). Apply low strength thread adhesive
and install the fitting in the upper throat cartridge
port. Be sure the other two ports are plugged
(73d).
21
TSL™ Cup Kit
4. Catalyst (35 cc) pumps: Repeat for the lower
throat cartridge.
5. If you are lubricating the dosing valves, remove
the plug (73d) and gasket from the valve port (X)
closest to the TSL cup.
NOTE: Choose the valve port in the upward
facing position. This will allow liquid to flow into
the valve while allowing air to rise out of the
valve.
Check that the o-ring is in place on the barbed
fitting (73b). Apply low strength thread adhesive
and install the fitting in the valve port (X).
NOTE: Do not confuse the valve port (X) with the
air port (W).
NOTE: If you are not lubricating the dosing
valves, remove the unused barbed fittings (73b)
from the bottom of the TSL cup (73). Apply low
strength thread adhesive and install the plugs
and gaskets supplied with the kit.
6. Cut the tubing (73c) to length as required.
Connect the TSL cup fittings to the fittings on the
pump and valves. TSL is gravity-fed from the
cup to the pump and valves; position the fittings
and tubing to prevent kinks and enable the TSL
to flow freely down to the valve and air to rise
up and out of the valve.
7. Fill the cup to the level of the lower black
horizontal line with either TSL or ISO oil, as
appropriate for the color and catalyst materials
being used.
NOTE: If TSL leaks from the rod guard of the
color (70 cc) pump, be sure the lower u-cup seal
is installed in the lower throat cartridge.
NOTE: The fluid levels in the TSL cups should be
checked daily. Fluid levels should remain static
for an extended period of time. Rising or falling
fluid levels in a TSL cup can be an indication of a
condition which needs immediate attention. Refer
to the troubleshooting steps in the repair manual for
guidance.
22
3A4129A
Light Tower Accessory
ISO Oil Fill Procedure
When using polyurethane coatings with isocyanate
catalysts in high-humidity environments, use of ISO
oil on the catalyst pump TSL cup is recommended
instead of TSL. The ISO oil will present a barrier
that will prevent catalyst hardening from contact with
moisture. When performing the first fill of a cup with
ISO oil, it will be necessary to bleed the air out of the
feed line.
NOTE: If not already present on the TSL cup, draw
the two horizontal lines at, and slightly above, the
vertical center of the front of the cup before filling.
Light Tower Accessory
To install Light Tower Kit 24K337, see manual
3A1906.
To bleed air:
1. Fill the catalyst pump TSL cup to the lower
horizontal line.
2. Remove one plug (73d) from the upper throat
cartridge and allow air in that area to flow until no
air is being expelled. Replace the plug.
3. Repeat step 2 at the lower throat cartridge.
4. Use absorbent rags to clean up excess ISO oil
that escaped from the plug holes.
5. Replenish the ISO oil level in the TSL cup to the
lower horizontal line.
3A4129A
23
Air Supply
Air Supply
Air Requirements
Air Connections
• Compressed air supply pressure: 85-100 psi
(0.6–0.7 MPa, 6.0-7.0 bar).
1. Tighten all system air and fluid line connections
as they may have loosened during shipment.
• Air hoses: use grounded hoses that are correctly
sized for your system.
2. Connect the main air supply line to the main air
inlet (136). This air line supplies the solenoids,
valves, and pumps. Do not use this line to supply
the gun’s atomizing air.
• Air regulator and bleed-type shutoff valve: include
in each air line to fluid supply equipment. Install
an additional shutoff valve upstream of all air line
accessories to isolate them for servicing.
3. Connect a separate, dedicated, clean air supply
line to the air inlet of the integrated air control.
Trapped air can cause a pump or dispense
valve to cycle unexpectedly, which could result
in serious injury from splashing or moving parts.
Use bleed-type shutoff valves.
To reduce the risk of fire and explosion if using
a Graco electrostatic gun, a shutoff valve must
be installed in the gun air line to shutoff the
atomizing and turbine air to the gun. Contact
your Graco distributor for information on air
shutoff valves for electrostatic applications.
• Air line filter: to filter oil and water out
of the air supply and help avoid paint
contamination and clogged solenoids. See
Technical Specifications, page 44, for air filtration
requirements.
Figure 7 Atomizing Air and Air Manifold Connections
Key
24
Connection
Description
AN
Air inlet
AC
Air cutoff output
(plugged)
EM
Exhaust muffler
SC
Solvent cutoff output
(plugged)
3A4129A
Electrical Supply
Electrical Supply
Electrical Connections
PD2K Connections
Improper wiring may cause electric shock or other
serious injury if work is not performed properly. All
electrical wiring must be completed by a qualified
electrician and comply with all local codes and
regulations.
See Electrical Schematics, page 32.
1. Verify that electrical power at the main panel is
shut off. Open the Control Box cover.
2. Thread the power supply wires from the electrical
cord through the strain relief (SR).
Electrical Requirements
3. Connect the wires (LP, NE, GR) securely to the
corresponding terminals of the terminal block
(TB), as shown.
PD2K
4. Follow instructions in Grounding, page 29.
Enclose all cables routed in the spray booth and high
traffic areas in conduit to prevent damage from paint,
solvent, and traffic.
5. Tighten the strain relief nut securely.
The unit operates with 90-250 VAC, 50/60 Hz input
power, with a maximum 7 A current draw. The
power supply circuit must be protected with a 15 A
maximum circuit breaker.
• A power supply cord compatible to your local
power configuration is not included. Wire gauge
size must be 8-14 AWG.
6. Close the Control Box. Restore power.
Wire Key
Wire
Description
LP
Line Power
NE
Neutral
GR
Ground
• The input power access port is 22.4 mm (0.88
in.) in diameter. A strain relief is provided which
accepts a cord diameter of 0.157-0.354 in. (4-9
mm). If another cord size is used, a user-supplied,
appropriate size strain relief must be installed.
Integrated Air Control
The unit operates with 24 VDC, with a maximum
current draw of 1 Amp. The unit is powered by a
Graco non-hazardous CAN cable.
Electrostatic Control
The unit operates with 90–250 VAC 50/60 Hz input,
with a maximum current draw of 1.2 Amps. Power
cord 24Y335 is provided with unit.
3A4129A
Figure 8 Control Box Electrical Connection
25
Electrical Supply
Air Control Connections
1. Connect the ground wire to the ground
connection (GC). Connect the other end to a true
earth ground. This connection is required for all
installations.
The air control module receives commands and
power through the CAN connections. The module is
wired in series with other system components.
1. Connect an unattached CAN cable from one of
the neighboring system components to either of
the CAN connections (K).
2. Connect a second CAN cable to the other CAN
connection. The other end of this cable will be
attached to the next component in series.
Electrostatic Control Connections
Figure 9 Electrostatic Control Ground Connection
(GC)
2. Connect the supplied controller input power cord
to the input power connection (D) and secure with
the connector screw. This connection is required
for all installations. The controller can operate
at 100–240 VAC (50–60 Hz). Connect the leads
to a power source according to local electrical
codes. Pin 3 on the input power connection is the
system interlock. Pin 3 must have line voltage
applied to satisfy the system interlock. When the
system interlock pin is connected to line voltage,
icon will appear on the controller.
the
Controller Input Power Connection
Pin No.
Controller
Power Cord
Function
Wire Marking
1
Neutral conductor power supply
1
2
Phase (100-240 VAC)
2
3
System Interlock ON/OFF
(100-240 VAC) = ON
Grounding PE
3
PE
Green/Yellow
3. Connect the 7-pin end of the gun power cable
to the gun power cable connection (F) on the
controller. Connect the 4–pin end of the gun
power cable to the spray gun. Follow instructions
in the gun manual. This connection is required
for all installations.
26
3A4129A
Electrical Supply
Pre-wired Gun Power Cable Connection
Controller
Connector (F)
Gun
Cable
Cable
Power Supply Connector
Electrical Schematic for this cable:
NOTE: Connector pins not shown are not connected to
a wire in the cable.
4. Connect the Discrete I/O cable to the Discrete
I/O cable connection (E) on the controller. The
Discrete I/O cable is required for any installation
that involves integration. Two discrete I/O
interlock connections are supplied and must be
satisfied.
Discrete I/O cable Connection
Controller
Pin No.
1
Function
Preset Select 1
Wire Color
White
2
Brown
3
Preset Select 2
Error Reset
4
5
Remote Enable/Disable
Electrostatics Enable
6
7
Safe-to-Move Output
Error Output
Gray
Pink
Blue
8
I/O Ground
Red
9
Current Setpoint Input
Black
10
Voltage Setpoint Input
Reserved Input
Purple
11
Cable
3A4129A
Green
Yellow
Gray/Pink
Red/Blue
12
I/O Ground
13
Actual Spraying Current Output
White/Green
14
15
Actual Spraying Voltage Output
Electrostatic Discharge
Brown/Green
White/Yellow
16
Analog Output External Power (24 VDC)
17
I/O Ground
White/Gray
18
19
SAFE POSITION Interlock Input
24VDC Interlock Input
Gray/Brown
Pink/Brown
and
Pink/White
Yellow/Brown
27
Electrical Supply
5. Connect the Graco CAN cables to the CAN
cable connections (H) on the controller. CAN
communication is required for remote operation
with Graco modules to allow remote configuration
and operation of the controller.
NOTE: CAN communication is Graco proprietary
and will not work with other types of CAN.
FieldBus Connections
If used, connect the ethernet cable to the CGM (8)
in the PD2K Electrical Control Box, as applicable.
Connect the other end of the cable to the FieldBus
device.
NOTE: Connect the CGM (8) to the FieldBus per
FieldBus standards. The Modbus TCP interface
operates at 100 MBit, full duplex. The interface is
auto polarity sensing and auto-crossover capable.
2. Remove the nut on fitting (FT), but leave the
cable through the nut.
3. Remove the fitting far enough to allow
disassembly of the fitting and to open the
grommet.
4. Route FieldBus cable (EC) through the fitting
hole in the Electrical Control Box and through
the fitting nut. Ensure that the ethernet cable is
inserted with enough length to allow for routing
within the box and for connection to the CGM.
5. Insert the FieldBus cable into the grommet hole
and insert the grommet into the fittling.
6. Insert the fitting through the Electrical Control
Box wall and install the nut. Tighten finger tight.
7. Attach a ferrite (3) near the end of the FieldBus
cable.
1. Locate fitting (FT) on the Electrical Control Box.
8. Attach the FieldBus cable to the CGM.
28
3A4129A
Grounding
Grounding
The following figure shows the general grounding for
a typical system. The following sections describe
grounding details for specific system components.
This equipment must be grounded to reduce the
risk of static sparking and electric shock. Electric
or static sparking can cause fumes to ignite or
explode. Improper grounding can cause electric
shock. Grounding provides an escape wire for the
electric current.
HAZARDOUS LOCATION
NON--HAZARDOUS LOCATION
NON
Figure 10 System Grounding
Key
1
Electrical Control Box ground screw
6
Non-Intrinsically Safe cable
2
Electrical Control Box ground wire
7
3
Color Change (H)/Catalyst Change
(K) Module ground wires
Remote Mix Control Module (R)
ground wire
8
Electrostatic (U) ground wire
4
Intrinsically Safe (IS) cable
9
Air Control (V) ground wire
5
True Earth Ground; check local code
for requirements
3A4129A
29
Grounding
PD2K Electrical Control Box
Integrated Air Control
The electrical control box has two ground points.
Both connections must be made.
Verify the ground wire is attached to the ground
screw (GS), and the screw is attached securely to
the air control (V) enclosure. Connect the other end
of ground wire to an earth ground.
• Connect the ground wire (Y) to the ground screw
(GT) on the Electrical Control Box (D). Connect the
clamp end to a true earth ground.
• The power supply must be grounded according to
local codes. Connect the power supply ground
wire (GR) to the terminal block (TB) in the Electrical
Control Box. See Electrical Connections, page 25.
Figure 11 Ground Terminal
30
Figure 12 Air Control Ground Screw (GS)
3A4129A
Grounding
Pro Xpc Auto Controller
Intrinsically safe color change modules located in the
hazardous area must be connected to a true earth
ground in the hazardous area.
Feed Pumps or Pressure Pots
When operating the electrostatic gun, any
ungrounded objects in the spray location (people,
containers, tools, etc.) can become electrically
charged. Improper grounding can result in static
sparking, which can cause a fire, explosion, or
electric shock. Ground all equipment, personnel,
object being sprayed, and conductive objects in or
close to the spray location. Follow the grounding
instructions below.
• Pro Xpc Auto Controller / Electrostatic Control
Box (U): Ground the Pro Xpc Auto Controller
(Electrostatic Control Box) (U) with a grounded
power cord and grounded socket. Also ground the
controller with the ground connection (GC) and
ground wire.
Connect a ground wire and clamp from a true earth
ground to the pumps or pots. See pump or pressure
pot manual.
Air and Fluid Hoses
Use grounded hoses only.
Spray Gun
Follow the grounding instructions in your gun manual.
• Non-Electrostatic: Ground the spray gun through
connection to a Graco-approved grounded fluid
supply hose.
• Electrostatic: Ground the spray gun through
connection to a Graco-approved grounded air
supply hose. Connect the air hose ground wire to
a true earth ground.
Object Being Sprayed
Follow local codes for objects being sprayed. Keep
the workpiece hangers clean and grounded at all
times.
Solvent Reservoir or Purge Station
Figure 13 Electrostatic Control Ground Connection
(GC)
• Object Being Sprayed: Follow local codes for
objects being sprayed. Keep the workpiece
hangers clean and grounded at all times.
Fluid Supply Container
Follow local code. Use only a conductive solvent
reservoir or purge station placed on a grounded
surface. Do not place the solvent reservoir or purge
station on a nonconductive surface, such as paper or
cardboard, which interrupts the grounding continuity.
Check Resistance
Follow local code.
Color Change Module
Connect a ground wire from the color change module
(H) to a true earth ground.
3A4129A
To ensure proper grounding and reduce risk of fire
and explosion, resistance between components
and true earth ground must be less than 1 ohm.
31
Electrical Schematics
Electrical Schematics
NOTE: The electrical schematic illustrates all
possible wiring expansions in an integrated PD2K
system. Some components shown are not included
with all systems.
NOTE: See Optional Cables and Modules, page 38 for
a list of cable options.
CABLE
16H078
MODBUS TCP
(24R910)
2
MAC SERIES 46
SOLENOID
(16P812)
PUMP V/P FOR
FLUID REG.
UP
DOWN
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
PUMP V/P FOR
FLUID REG.
MAC SERIES 46
SOLENOID
(16P812)
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
UP
DOWN
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
CATALYST CHANGE
MODULE 6
6
(24N935)
CATALYST CHANGE
MODULE 5
6
(24N935)
COLOR CHANGE
MODULE 4
6
(24N935)
COLOR CHANGE
MODULE 3
6
(24N935)
SWITCH (120278)
SOLVENTMETER (258718)
SAFETYINTERLOCK SWITCH
CABLE (16T659)
CABLE (16T659)
CABLE (16T659)
CABLE (16T659)
1
FLOW RATE ANALOG IN
3
ADVANCED
CABLE
DISPLAY MODULE
(121003)
(24E451)
4
SOLVENT
FLOW
INPUTS
CABLE (16V429)
LIGHT
TOWER
(15X472)
COLOR CHANGE MODULE 7
(24R219)
7
1
CABLE
(16T280)
SOLVENTCUTOFF (121324)
SWITCH (120278)
1 CABLE
(16V426)
FAN
(24P658)
ENCODERAND MOT
OR
(16P036, 16P037)
WIRE HARNESS
(24P684, 24P685)
BREAKOUT MODULE PUMP 3
(24N527)
FAN
(24P658)
BARRIER
BOARD
(248192)
FLOW RATE ANALOG IN
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
SPLITTER
(16P243)
SOLENOID (121324)
GFB
ACES
PRESSURE SW (121323) INTERF
GCA
MODULE
EFCM
(24N913)
FLOW RATE ANALOG IN
UP
DOWN
ENCODERAND MOT
OR
(16P036, 16P037)
WIRE HARNESS
(24P684, 24P685)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
CABLE
(15V206)
119159
119159
119159
119159
FLOW RATE ANALOG IN
PUMP V/P FOR
FLUID REG.
BREAKOUT MODULE PUMP 2
(24N527)
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
MAC SERIES 46
SOLENOID
(16P812)
MAC SERIES 46
SOLENOID
(16P812)
UP
DOWN
PUMP INLET
TRANSDUCER
(16P289, 16P290)
COLOR CHANGE MODULE 8
(24R219)
7
BOOTH CONTROL
(24M731)
BREAKOUT MODULE PUMP 4
(24N527)
FAN
(24P658)
ENCODERAND MOT
OR
(16P036, 16P037)
WIRE HARNESS
(24P684, 24P685)
BREAKOUT MODULE PUMP 1
(24N527)
FAN
(24P658)
ENCODERAND M
OTOR
PUMP V/P FOR
FLUID REG.
2
GUNTRIGGER INPUTS
16T072
CAN
IS BOARD
(24M485)
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
CABLE
(15V206)
CABLE
(16V426)
16W159
16W159
16W159
16W159
TERMINAL
BLOCKS WITH FUSES
POWER IN
PUMP INLET
TRANSDUCER
(16P289, 16P290)
2
3 CABLE
(121227)
TERMINAL
BLOCK
(114095)
(16P036, 16P037)
WIRE HARNESS
(24P684, 24P685)
CABLE
(15V206)
2
5
COLOR CHANGE
MODULE 2
6
(24N935)
3 CABLE
(121001)
48V-10APOWER SUPPL
Y
(16U820)
3
CABLE
(121227)
LINE FIL
TER
(16V446)
5
24V
POWER
SUPPLY
(16T660)
CABLE (15V206)
CABLE
16T658
INTEGRA
TION
GATEWAY
COLOR CHANGE
MODULE 1
6
(24N935)
POWER MODULE
(24R257)
2 CABLE
(15V206)
2 CABLE
(15V206)
065161, 065159
RELA
Y
2 POSITION
SWITCH
(16U725)
HAZARDOUS LOCATION
NON-HAZARDOUS LOCATION
Figure 14 Electrical Schematic, Sheet 1
32
3A4129A
Electrical Schematics
CONTINUED ON PAGE 3
CONTINUED ON PAGE 3
5
4
3
2
1
10
1
2
3
4
5
8
1
2
3
4
5
6
7
8
9
10
11
12
5
AWI
GATEWAY
(24R910)
12345
CAN IS BOARD
(NON IS)
(IS)
(121227)
1
2
3
4
5
P3
P4
INTEGRATION
GATEWAY
3
5
1
GCAMODULE
EFCM
(24N913)
3
5
12345
UNUSED
UNUSED
CABLE
(16T280)
GFBINTERFACE
(121324)
123
1
2
3
SOLVENT CUTOFF (121324)
PWR (RED)
SIG (WHITE)
COM (B
LACK)
SHIELD/GRN
SOLVENT
UNUSED
1
RED WIRE (065161)
2
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
METER
(258718)
GROUND BAR
4
25 PIN D-SUB CABLE
(16T659)
BLACK WIRE (065159)
24V
POWER
SUPPLY
(16T660)
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
3
2
12345
13 A1(+) A2(-)
1234
4
7
6
5
12345
12345
1234
8
12 34
12 34
5678
2
12345
3
1234
4
12345
7
6
5
12345
1234
12 34
PUMP 2
UP
8
12 34
5678
MANI
FOLD
LINE
FILTER
(16V446)
MAC SERIES 46
(16P812 QTY 2)
+-+-+-+-
PWR (RED)
SIG (WHITE)
COM(BLACK)
SHIELD/GRN
INLET TRANSDUCER
PUMP 2
(16P289 OR 16P290)
FAN PUMP 1
(24P658)
PWR (RED)
SIG (WHITE)
COM(BLACK)
SHIELD/GRN
+24VDC
COM
+24VDC
COM
SEE DETAILAOR B
PUMP 1
DOWN
PUMP 1
UP
ENCODER/MOTOR
AND
WIRE HARNESS
PUMP2
MANI
FOLD
MAC SERIES 46
(16P812 QTY 2)
F2
F1
F4
N
F3
+-+-+-+-
V/P FOR FLUID REG.
PUMP 1
SEE DET
AILAOR B
POWER MODULE
(24R257)
N04
OUTLET TRANSDUCER
PUMP 1
(16P289 OR 16P290)
+ -
CABLE
(16T658)
L
ENCODER/MO
TOR
AND
WIRE HARNESS
PUMP1
N03
2 POSITION
SWITCH
(16U725)
N04
INLET TRANSDUCER
PUMP 1
(16P289 OR 16P290)
GRND
48V-10A
POWERSUPPLY
(16U820)
N (BLUE)
L (BROWN)
N03
1
+48V
COM
+48V
COM
RELAY
14
N L
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
BREAKO
UT MODULE PUMP 2 (24N527)
+48V
COM
+48V
COM
BREAKOUT
MODULE PUMP
1 (24N527)
GRND (GRN/YEL)
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
+24VDC
COM
+24VDC
COM
UNUSED
BARRIER
BOARD
(248192)
+12VDC
COM
UNUSED
UNUSED
+12VDC
COM
+12VDC
COM
PUMP 2
DOWN
UNUSED
54 3 2 1
UNUSED
UNUSED
(121001)
3
(24M485)
12345
SPLITTER
(16P243)
1
2
3
4
5
V/P FOR FLUID REG.
PUMP 2
4
1
2
3
4
5
CABLE
OUTLET TRANSDUCER
PUMP 2
(16P289 OR 16P290)
2
P4
P3
16T072
12345
1
1
2
3
4
5
CABLE
4 25 PIN
D-SUB CABLE
(16T659)
3
CABLE
(15V206)
CABLE (16V429)
2
UNUSED
CABLE (121227)
FAN PUMP 2
(24P658)
UNUSED
UNUSED
G3000
METER
PUMP 1
(EITHER, 239716,
258718,16M510,
OR 16M519)
GRND
SCREW
TWISTEDPAIR CABLE (16W159)
G3000
METER
PUMP 2
(EITHER, 239716,
258718,16M510,
OR 16M519)
GRND
SCREW
TWISTEDPAIR CABLE (16W159)
L GRND N
123456789
12
10
PUMP ENCODER AND MOTOR
(16P037)
MOTOR
MOUNTING
SCREW
1 2 3 4 5 6 78 9
1011 12
DRAIN/FOIL
UNUSED
UNUSED
UNUSED
UNUSED
DRAIN/FOIL
1011 12
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
123456789
DRAIN/FOIL
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
DRAIN/FOIL
MOTOR
MOUNTING
SCREW
3
1234
WIRE HARNESS
(24P685)
123456789
UNUSED
UNUSED
12345
1234
WIRE HARNESS
(24P684)
L N GRND
UNUSED
UNUSED
12345
BREAKOUT
MODULE
(24N527)
2
3
UNUSED
2
UNUSED
UNUSED
UNUSED
BREAKOUT
MODULE
(24N527)
TERMINAL
BLOCK
(114095)
UNUSED
L N GRND
POWER IN
DETAILB, HIG
H PRESSURE
PUMPS (24M
707, 24M715)
DETAILA, LOW PRESSURE
PUMPS (24M706, 24M714)
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
CABLE
(16H078)
10
PUMP ENCODER AND MOTOR
(16P036)
Figure 15 Electrical Schematic, Sheet 2, Part 1
CONTINUED ON THE NEXT PAGE
3A4129A
33
Electrical Schematics
GUN TRIGGER INPUTS
SIG
COM
SIG
COM
SIG
COM
SIG
COM
SIG
COM
SIG
COM
7
1
2
3
4
5
6
7
8
9
10
11
12
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
SOLVENT FLOW SWITCH 2 (120278)
COM
SIG
SAFETY INTERLOCK SWITCH
COM
9
1
2
3
4
5
6
GCAMODULE
EFCM
(24N913)
3
4
LIGHT
TOWER
(15X472)
3
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)
4
7
6
5
12345
1234
12 34
8
12 34
5678
2
3
12345
1234
4
12345
5
12345
7
6
1234
12 34
8
12 34
5678
PWR (RED)
SIG (WHITE)
COM(BLACK)
SHIELD/GRN
+24VDC
COM
+24VDC
COM
PUMP 4
UP
MANIFOLD
MAC SERIES 46
(16P812 QTY 2)
MAC SERIES 46
(16P812 QTY 2)
MANIFOLD
PUMP 4
DOWN
V/P FOR FLUID REG.
PUMP 4
OUTLET TRANSDUCER
PUMP 4
(16P289 OR 16P290)
SEE DETAILAOR B
INLET TRANSDUCER
PUMP 4
(16P289 OR 16P290)
FAN PUMP 3
(24P658)
PWR (RED)
SIG (WHITE)
COM(BLACK)
SHIELD/GRN
+24VDC
COM
+24VDC
COM
PUMP 3
UP
ENCODER/MOTOR
AND
WIRE HARNESS
PUMP 4
PUMP 3
DOWN
V/P FOR FLUID REG.
PUMP 3
SEE DETAILAOR B
OUTLET TRANSDUCER
PUMP 3
(16P289 OR 16P290)
ENCODER/MOTOR
AND
WIRE HARNESS
PUMP 3
INLET TRANSDUCER
PUMP 3
(16P289 OR 16P290)
+48V
COM
+48V
COM
12345
BREAKOUT MODULE PUMP 4 (24N527)
+48V
COM
+48V
COM
3
1234
1
2
3
4
5
ADVANCED
DISPLAY MODULE
(24E451)
FAN PUMP 4
(24P658)
1
2
(121003)
1
2
3
4
5
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
12345
GFB PRESSURE SWITCH (121323)
SOLVENT FLOW SWITCH 1 (120278)
CABLE
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
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
119159
1
2
3
4
5
6
7
8
9
10
11
12
G3000
METER
PUMP 3
(EITHER, 239716,
258718,16M510,
OR 16M519)
GRND
SCREW
G3000
METER
PUMP 4
(EITHER, 239716,
258718,16M510,
OR 16M519)
GRND
SCREW
TWISTED PAIR CABLE (16W159)
TWISTED PAIR CABLE (16W159)
Figure 16 Electrical Schematic, Sheet 2, Part 2
CONTINUED ON THE NEXT PAGE
34
3A4129A
Electrical Schematics
FROMCAN IS BOARD (24M485) ON PAGE 2
FROMCAN IS BOARD (24M485) ON PAGE 2
2 CABLE(15V206)
12 34 5
COLOR
CHANGE
MODULE 1
(COLORS
1 THRU 8)
MANIFOLD
FLUSH
COLOR1
COLOR2
COLOR3
COLOR4
COLOR5
COLOR6
COLOR7
COLOR8
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J8
MANIFOLD
J9
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J16
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J10
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
J15
J14
DUMP
COLOR1
COLOR2
COLOR3
COLOR4
COLOR5
COLOR6
COLOR7
COLOR8
MANIFOLD
*FLUSH
COLOR9
COLOR10
COLOR11
COLOR12
COLOR13
COLOR14
COLOR15
COLOR16
12 34 5
COLOR
CHANGE
MODULE 2
(COLORS
9 THRU 16)
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3 J15
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J9
J8
6
J16
J14
MANIFOLD
MANIFOLD
J10
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
DUMP*
FLUSH
COLOR9
CATALYST 1
COLOR10
CATALYST 2
COLOR11
CATALYST 3
COLOR12
CATALYST 4
COLOR13
COLOR14
COLOR15
COLOR16
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
UNUSED
UNUSED
1
2
3
4
5
6
J15
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
J14
COLOR17
COLOR18
COLOR19
COLOR20
COLOR21
COLOR22
COLOR23
COLOR24
12 34 5
COLOR
CHANGE
MODULE 3
(COLORS
17 THRU 24)
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J8
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J15
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J14
J9
6
J9
COM
+12VDC
COM
+12VDC
COM
+12VDC
J16
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
UNUSED
UNUSED
J10
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
6
2
CABLE
(15V206)
2
CABLE
MANIFOLD
J8
MANIFOLD
6
5
4
3
2
1
DUMP
CATALYST 1
CATALYST 2
CATALYST 3
CATALYST 4
12 34 5
12 34 5
*FLUSH
CATALYST
CHANGE
MODULE 5
(CATALYST
1 THRU 4)
MANIFOLD
MANIFOLD
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
COM
+12VDC
COM
+12VDC
COM
+12VDC
J16 43
2
1
6
5
4
J10 3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
*FLUSH
DUMP*
COLOR17
COLOR25
COLOR18
COLOR26
COLOR19
COLOR27
COLOR20
COLOR28
COLOR21
COLOR29
COLOR22
COLOR30
COLOR23
COLOR24
54 3 2 1
(15V206)
2
CABLE
(15V206)
12 34 5
12 34 5
COLOR
CHANGE
MODULE 4
(COLORS
25 THRU 32)
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J8
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J15
+12VDC
COM
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
J14
J9
6
J16
J10
MANIFOLD
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
UNUSED
UNUSED
UNUSED
UNUSED
DUMP*
COLOR25
COLOR26
COLOR27
COLOR28
COLOR29
COLOR30
12 34 5
2
CABLE(15V206)
Figure 17 Electrical Schematic, Sheet 3
* May be unused in some configurations.
CONTINUED ON THE NEXT PAGE
3A4129A
35
Electrical Schematics
CATALYST
CHANG
E
MODULE 6
(CATALYST
3 THRU 4)
MANIFOLD
FLUSH
CATALYST 3
CATALYST 4
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J8
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
J15
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
MANIFOLD
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J16
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
J10
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J16
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
J10
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
J9
6
J14
DUMP
CATALYST 3
CATALYST 4
2
CABLE
(15V206)
12 34 5
MANIFOLD
FLUSH
CATALYST 1
CATALYST 2
54 3 2 1
CATALYST
CHANG
E
MODULE 5
(CATALYST
1 THRU 2)
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J8
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
J15
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
MANIFOLD
J9
6
J14
DUMP
CATALYST 1
CATALYST 2
(15V206)
2
CABLE
12 34 5
12 34 5
COLOR
CHANG
E
MODULE 4
(COLORS
25 THRU 32)
Figure 18 Electrical Schematic, Sheet 3, Alternate
Configuration for Catalyst Change Control
CONTINUED ON THE NEXT PAGE
36
3A4129A
Electrical Schematics
FROM CAN IS
BOARD (24M485)
ON PAGE 2
NON-HAZARDOUS LOCATION
HAZARDOUS LOCATION
MAN
IFOLD
COLOR FLUSH
COLOR 1
COLOR 2
COLOR 3
COLOR 4
COLOR 5
COLOR 6
COLOR 7
COLOR 8
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
12 34 5
COLOR
CHANGE
MODULE 7
(COLORS
33 THRU 40)
J8
MAN
IFOLD
J9
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J16
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
7
J15
J14
J10
CATALYST FLUSH
CATALYST 1
CATALYST 2
CATALYST 3
CATALYST 4
COLOR 9
COLOR 10
COLOR 11
COLOR 12
1
CABLE
(16V426)
12 34 5
MAN
IFOLD
COLOR 13
COLOR 14
COLOR 15
COLOR 16
COLOR 17
COLOR 18
COLOR 19
COLOR 20
COLOR 21
12 34 5
COLOR
CHANGE
MODULE 8
(COLORS
41 THRU 48)
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J8
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J15
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J14
MAN
IFOLD
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J9
7
J16
J10
COLOR 22
COLOR 23
COLOR 24
COLOR 25
COLOR 26
COLOR 27
COLOR 28
COLOR 29
COLOR 30
1
CABLE
(16V426)
54 3 2 1
5 4 3 21
BOOTH CONTROL
(24M731)
Figure 19 Electrical Schematic, Sheet 3, Hazardous
Location
3A4129A
37
Optional Cables and Modules
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 32.
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.
Length ft (m)
16V423
2.0 (0.6)
16V424
3.0 (1.0)
Alternates for Communication Module 24W462
Module Part No.
Module Part No.
CGMDN0*, DeviceNet
CGMPN0*, Profinet
CGMEP0*, Ethernet IP
* You must purchase CGM Installation Kit 17L710
for use with these kits.
16V425
6.0 (2.0)
16V426
10.0 (3.0)
16V427
15.0 (5.0)
16V428
25.0 (8.0)
Alternates for Color Change Modules
by Part Number (Factory Configuration), for
Non--Hazardous Locations Only
Non
Module Part No.
Description
16V429
50.0 (16.0)
24T557
2 color/2 catalyst
16V430
100.0 (32.0)
24T558
4 color/4 catalyst
24T559
6 color/6 catalyst
24T560
8 color/8 catalyst
M12 CAN Cables, for Non
Non--Hazardous
Locations Only
15U531
2.0 (0.6)
15U532
3.0 (1.0)
15V205
6.0 (2.0)
15V206
10.0 (3.0)
15V207
15.0 (5.0)
15V208
25.0 (8.0)
15U533
50.0 (16.0)
15V213
100.0 (32.0)
Non--Hazardous
CAN Cables, for Non
Locations Only
Cable Part No.
Length ft (m)
125306
1.0 (0.3)
Alternates for Color Change Modules
by Part Number (Factory Configuration), for
Hazardous Locations Only
Module Part No.
Description
24T571
24T572
2 color/2 catalyst
4 color/2 catalyst
24T573
6 color/2 catalyst
24T574
24T774
8 color/2 catalyst, 13–24
color
12 color/2 catalyst
24T775
4 color/4 catalyst
24T776
6 color/4 catalyst
24T777
8 color/4 catalyst
24T778
12 color/4 catalyst, 13–30
color
13–18 color
123422
1.3 (0.4)
121000
1.6 (0.5)
121227
121001
121002
2.0 (0.6)
3.0 (1.0)
5.0 (1.5)
121003
10.0 (3.0)
Gun Power Cables for Pro Xpc Auto Gun
Module Part No.
Description
120952
13.0 (4.0)
17H040
121201
20.0 (6.0)
121004
25.0 (8.0)
121228
50.0 (15.0)
24T779
17H041
17H042
Gun Power Cable; 11 m
(36 ft)
Gun Power Cable; 20 m
(65.6 ft)
Gun Power Cable; 30 m
(98.4 ft)
Non--Hazardous
25 Pin D-SUB Cables, for Non
Locations Only
16T659
2.5 (0.8)
16V659
6.0 (1.8)
38
3A4129A
Dimensions
Dimensions
Proportioner Dimensions
Figure 21
Figure 20
Figure 22
A
58.20
in.
(1478
mm)
3A4129A
B
with
ADM
without
ADM
14.5 in.
(368
mm)
11.12 in.
(282
mm)
C
D
E
F
G
H
J
22.0 in.
(559
mm)
19.26 in.
(489
mm)
2.0 in.
(51 mm)
18.0 in.
(457
mm)
17.26 in.
(438
mm)
0.52 in.
(13 mm)
Minimum
6in (152 mm)
from mounting
surface
39
Dimensions
Air Control Dimensions
Figure 23
40
3A4129A
Dimensions
Electrostatic Dimensions
Electrostatic Controller
3A4129A
41
Dimensions
Electrostatic Controller Flush Mount
5.71 in.
(15.0 cm)
3.30 in.
(8.4 cm)
7.65 in.
(19.4 cm)
M6 X 1 mm
6.26 in.
(15.9 cm)
42
3A4129A
Dimensions
Electrostatic Controller Wall Mount
Bracket 17H288
3A4129A
43
Technical Specifications
Technical Specifications
Positive Displacement
Proportioner
Metric
U.S.
Maximum fluid working
pressure:
AC0500 Spray Systems
Pumps sold separately; see selected pump manual maximum working pressure.
AC1000 Air Spray Systems
300 psi
2.1 MPa, 21 bar
AC2000 Air-Assisted
Spray Systems
1500 psi
10.5 MPa, 105 bar
100 psi
0.7 MPa, 7.0 bar
85–100 psi
0.6–0.7 MPa, 6.0–7.0 bar)
Maximum working air
pressure:
Air supply:
Air filter inlet size:
3/8 npt(f)
Air filtration for air logic
(user-supplied):
5 micron (minimum) filtration required; clean and dry air
Air filtration for atomizing
air (user-supplied):
30 micron (minimum) filtration required; clean and dry air
Mixing ratio range:
Fluids handled:
0.1:1 to 50:1, ±1%
One or two components:
• solvent and waterborne paints
• polyurethanes
• epoxies
• acid catalyzed varnishes
• moisture sensitive isocyanates
Viscosity range of fluid:
20–5000 centipoise
Fluid filtration
(user-supplied):
100 mesh minimum
Maximum fluid flow:
800 cc/minute (depending on material viscosity)
Fluid outlet size:
External power supply
requirements:
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
Operating temperature
range:
36 to 122°F
2 to 50°C
Storage temperature
range:
–4 to 158°F
–20 to 70°C
195 lb
88 kg
Weight of base model
(approximate):
Sound data:
Less than 75 dB(A)
Wetted parts:
17–4PH SST, 303 SST, 304 SST, Tungsten carbide (with nickel binder),
perfluoroelastomer; PTFE, PPS, UHMWPE
44
3A4129A
Technical Specifications
U.S.
Metric
Maximum Air Inlet Pressure
100 psi
7 bar
Inlet Hose
3/8 in.
9.5 mm
Atomizing Air
5/16 in.
8 mm
Integrated Air Control
Outlet Hoses
Fan Air
5/16 in.
8 mm
Paint Trigger
5/32 in.
4 mm
Auxiliary Air 1
5/32 in.
4 mm
Auxiliary Air 2
5/32 in.
4 mm
Auxiliary Air 3
5/32 in.
4 mm
Voltage
24 VDC
Current
1 Amp
Environmental Temperature
Range
Weight
Electrostatics
32 — 122° F
0 — 50° C
15 lbs.
6.8 kg
Metric
U.S.
Nominal Input Voltage
100–240 VAC
Frequency
50–60 Hz
Input Power
40 VA
Nominal Output Voltage (to the gun)
eff 10V
Nominal Output Current (to the gun)
max 1.2 A
Protection Type
Ambient Temperature Range
IP54
41°F - 104°F
5°C - 40°C
Width
6.8 in.
173 mm
Depth
4.8 in.
122 mm
Height
7.5 in.
191 mm
Weight
approx. 4.5 lbs.
approx. 2.0 kg
Dimensions
3A4129A
45
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its
name to be free from defects in material and workmanship on the date of sale to the original purchaser for
use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a
period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained
in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction,
damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper
maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall
Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied
by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an
authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco
will repair or replace free of charge any defective parts. The equipment will be returned to the original
purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material
or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of
parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY
OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The
buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for
lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be
available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT,
MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but
not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if
any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim
for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from
Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods
sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents,
notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly
hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la 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.
For patent information, see www.graco.com/patents.
To place an order, contact your Graco Distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
Original Instructions. This manual contains English. MM 3A4129
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
2016,, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Copyright 2016
www.graco.com
Revision A, January 2017

* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project