Graco 332457J, ProMix PD2K Electronic Proportioner Owner's Manual

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Graco 332457J, ProMix PD2K Electronic Proportioner Owner's Manual | Manualzz

Installation

ProMix® PD2K Electronic Proportioner

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

Important Safety Instructions

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

PROVEN QUALITY. LEADING TECHNOLOGY.

2

Contents

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

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

Warnings ........................................................... 6

Important Isocyanate (ISO) Information................ 9

Important Acid Catalyst Information ..................... 11

Acid Catalyst Conditions............................... 11

Moisture Sensitivity of Acid Catalysts ............ 11

System Control Drawing 16P577 ......................... 12

Configuring Your System .................................... 14

1. Select a Base Model ................................ 14

2. Select Hoses ........................................... 19

3. Select Mixing Option ................................ 21

4. Select a Spray Gun .................................. 22

5. Select Color and Catalyst Change

Kits ................................................ 23

6. Select Pump Expansion Kits ..................... 24

7. Select Communication Options ................. 24

General Information ............................................ 25

Location............................................................. 25

Install the Display Module.................................... 26

Install the Booth Control ...................................... 27

Air Supply .......................................................... 28

Fluid Supply ....................................................... 30

Fluid Requirements ...................................... 30

Single Color Connections ............................. 31

Color Change Connections........................... 31

Solvent Connections .................................... 31

TSL Cup Kit........................................................ 32

Solvent Meter Accessory..................................... 35

Light Tower Accessory........................................ 35

Electrostatic Air Hose Quick Disconnect Kit

24S004................................................. 35

Electrical Supply................................................. 36

Electrical Requirements................................ 36

Electrical Connections.................................. 36

Grounding .......................................................... 37

Electrical Schematics.......................................... 40

Standard Models (MC1000, MC2000,

MC3000, MC4000) ......................... 40

Dual Panel Models (MC1002, MC2002,

MC4002)........................................ 46

Optional Cables and Modules ....................... 52

Dimensions ........................................................ 53

Technical Data ................................................... 54

Related Manuals

Manual No.

3A2800

332562

3A4186

3A2801

332339

332454

332455

332456

334512

3A4497

Description

PD2K Proportioner Repair-Parts Manual, Manual Systems

PD2K Proportioner Operation Manual, Manual Systems

PD2K Dual Panel Proportioner Opertion Manual, Manual Systems

Mix Manifold Instructions-Parts Manual

Pump Repair-Parts Manual

Color Change Valve Repair-Parts Manual

Color Change Kits Instructions-Parts Manual

3rd and 4th Pump Kits Instructions-Parts Manual

PD1K Pump Expansion Kits Instructions-Parts Manual

Air Control Box Kit Instructions Manual

332457J

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

M4002

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 Models 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.

332457J 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 Models MC2000, MC2002, MC4000, &

MC4002 (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

.7

7

II 2 G

Ex ia IIA T3 Gb

FM13 ATEX 0026

IECEx FMG 13.0011

MPa

100 bar PSI

GRACO INC.

P.O. Box 1441

Minneapolis, MN

55440 U.S.A.

Continued on the next page.

4 332457J

www.graco.com/patents

12 VDC FM16US0241

FM16CA0129

II 2 G

Ex ia IIA T3 Gb

FM13 ATEX 0026

IECEx FMG 13.0011

Figure 6 Booth Control Identification Label

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

332457J 5

6

Warnings

Warnings

The following warnings are for the setup, use, grounding, maintenance and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these

Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. 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.

332457J

332457J

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.

7

8

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.

332457J

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.

332457J 9

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

Partially cured ISO will reduce performance and the life of all wetted parts.

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

Never store ISO in an open container.

• Keep the ISO pump wet cup or reservoir (if installed) filled with appropriate lubricant. The lubricant creates a barrier between the ISO and the atmosphere.

• Use only moisture-proof hoses compatible with

ISO.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

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

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

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.

10 332457J

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.

332457J 11

System Control Drawing 16P577

System Control Drawing 16P577

Do not substitute or modify system components as this may impair intrinsic safety. For installation, maintenance, or operation instructions, read instruction manuals. Do not install equipment approved only for non-hazardous location in a hazardous location. See the identification label for the intrinsic safety rating for your model.

NOTES FOR SYSTEM CONTROL DRAWING 16P577 (FM13ATEX0026 SYSTEM ASSEMBLY

CERTIFICATE)

Alternate M12 CAN Cables, for Hazardous Locations

Cable Part No.

Length ft (m)

16V423

16V424

2.0 (0.6)

3.0 (1.0)

16V425

16V426

6.0 (2.0)

10.0 (3.0)

16V427

16V428

16V429

16V430

15.0 (5.0)

25.0 (8.0)

50.0 (16.0)

100.0 (32.0)

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

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

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

500 Vrms.

Do not operate system with power barrier cover removed.

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

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

Appendix F.

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

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

12 332457J

NON-HAZARDOUS LOCATION ONLY

NON-HAZARDOUS LOCATION ONLY

POWER IN

250 VAC MAXIMUM SUPPLY VOLTAGE

PROMIX PD2K

ELECTRICAL ENCLOSURE

(24M672)

POWER

BARRIER

(248192)

5

FM13ATEX0026

IECEx FMG 13.0011

COMMUNICATION

BARRIER

(24M485)

ASSOCIATED APPARATUS

J4

OR

J3

SPLITTER 17L058

System Control Drawing 16P577

HAZARDOUS (CLASSIFIED) LOCATION

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

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

Ta = 2°C to 50°C

HAZARDOUS (CLASSIFED) LOCATION

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

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

Ta = 2 C TO 50 C

BOOTH CONTROL

(24M731)

FM13ATEX0026

IECEx FMG 13.0011

INTRINSIC SAFE APPARATUS

CABLE (16V429)

CABLE (16V429)

COLOR CHANGE MODULE

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

(24V406, 24V407, 24V408)

(24V409, 24V410, 24V411)

FM13ATEX0026

IECEx FMG 13.0011

INTRINSIC SAFE APPARATUS

CABLE (16V426)

COLOR CHANGE MODULE

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

(24V406, 24V407, 24V408)

(24V409, 24V410, 24V411)

FM13ATEX0026

IECEx FMG 13.0011

INTRINSIC SAFE APPARATUS

CABLE (16V426)

BOOTH CONTROL

(24M731)

FM13ATEX0026

IECEx FMG 13.0011

INTRINSIC SAFE APPARATUS

Figure 8 System Control Drawing 16P577

332457J 13

Con fi guring Your System

Configuring Your System

1. Select a Base Model

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

Models, page 3 .

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

Component

Fluid Pumps (A, B)

Solvent Valve (C)

Booth Control (D)

Electrical Control Box (E)

Advanced Display Module (F)

If using a mix-at-wall configuration, see Figure 10, page 14.

Description

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

Dispenses solvent to the gun during purge.

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

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

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

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

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

14 332457J

HAZARDOUS (CLASSIFIED) LOCATION

Con fi guring Your System

NON-HAZARDOUS LOCATION ONLY

Figure 9 Typical Installation

P

R

S

C★

D★

E★

F★

Component Description

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

A★

B★

Material A (Color) Pump

Material B (Catalyst) Pump

Solvent Valve

Booth Control

Electrical Control Box

Advanced Display Module

H

J

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

G Color Change Valves (accessory)

Color Change Module (accessory)

Catalyst Change Valves (accessory)

K Catalyst Change Module (accessory)

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

L Fluid/Air Hose Bundle (accessory)

M

N

Mix Manifold (accessory)

Air Spray Gun (accessory)

Gun Air Hose (accessory)

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

Gun Fluid Hose (accessory)

332457J 15

Con fi guring Your System

HAZARDOUS (CLASSIFIED) LOCATION NON-HAZARDOUS LOCATION ONLY

Figure 10 Typical Installation with Remote Mix

Manifold

S

T

U

P

R

M

N

Component Description

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

A★ Material A (Color) Pump

B★

C★

D★

E★

Material B (Catalyst) Pump

Solvent Flow Switch

Electrical Control Box

Advanced Display Module

G

H

F★ CAN Communication Cable

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

Color Change Valves (accessory, non-hazardous area)

Color Change Module (accessory, non-hazardous area)

J

K

Catalyst Change Valves (accessory, non-hazardous area)

Catalyst Change Module (accessory, non-hazardous area)

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

L Fluid/Air Hose Bundle (accessory)

Remote Color Change Manifold (accessory, hazardous area)

Remote Mix Manifold (accessory, hazardous area)

Air Spray Gun (accessory)

IS Remote Mix Control Module (accessory, hazardous area)

Gun Fluid Hose (accessory)

Supply Line Drain Valves (accessory, required, not shown)

Gun Air Hose (accessory)

16 332457J

HAZARDOUS (CLASSIFIED) LOCATION

Con fi guring Your System

NON-HAZARDOUS LOCATION ONLY

Figure 11 Typical Dual Panel Installation (MC1002,

MC2002, MC4002)

J

K

G

H

Component Description

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

A★

B★

Material A (Color) Pump

Material B (Catalyst) Pump

C★

D★

Solvent Valve

Booth Control

E★ Electrical Control Box

F★ Advanced Display Module

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

Color Change Valves (accessory)

Color Change Module (accessory)

Catalyst Change Valves (accessory)

Catalyst Change Module (accessory)

332457J 17

Con fi guring Your System

S

T

N

P

Component Description

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

L

M

Fluid/Air Hose Bundle (accessory) — see PD2K Installation Manual

(332457) for acid-compatible hose bundles

Mix Manifold (accessory) — see Mix Manifold Instruction-Parts Manual

(3A2801) for acid-compatible mix manifolds

Air Spray Gun (accessory)

R

Gun Air Hose (accessory)

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

Gun Fluid Hose (accessory)

Air Control Module (accessory) — see Air Control Module Kit Manual

(3A4497)

18 332457J

Con fi guring Your System

2. Select Hoses

Hose Selection Tool

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

NOTE: Always use Graco hoses.

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

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

Recommended Hose Sizes (internal diameter) for A and B

20 - 50

18

16

14

12

10

3/8ʺ A

1/8ʺ B

3/8ʺ A

1/4ʺ B

Mix

Ratio

(X:1) 1/4ʺ A

1/4ʺ B

8

6

4

2

0

10:1

Thick Resin (A)

Thin Catalyst (B)

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

Equal Viscosities

1:2.5

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

1:5 1:7.5

1/4ʺ A

3/8ʺ B

1:10

Thin Resin (A)

Thick Catalyst (B)

332457J 19

Con fi guring Your System

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

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

Application

Low Pressure

Conventional Air

Spray

Low Pressure

Electrostatic Air

Spray*

Hose Bundle

Part No.

Length

25 ft

(7.6 m)

50 ft

(15.2 m)

25 ft

(7.6 m)

50 ft

(15.2 m)

Material and Description Maximum

Fluid Working

Pressure

High Pressure

Conventional

High Pressure

Electrostatic

24T140

24T141

24T138

24T139

24T247

25A524**

24T245

25A522**

25 ft

(7.6 m)

50 ft

(15.2 m)

25 ft

(7.6 m)

50 ft

(15.2 m)

Nylon (A side and Solvent, both are white/translucent, solvent is marked with a band of black tape), Moisture Guard (B side, red), Air Hose

Nylon (A side and Solvent, both are white/translucent, solvent is marked with a band of black tape), Moisture Guard

(B side; red), Grounded Air Hose with left-hand thread

Nylon (A side and Solvent, both are blue, solvent is marked with a band of black tape), Moisture Guard (B side, red), Air

Hose

Nylon (A side and Solvent, both are blue, solvent is marked with a band of black tape), Moisture Guard (B side, red),

Grounded Air Hose with left-hand thread

225 psi (1.6

MPa, 16 bar)

225 psi (1.6

MPa, 16 bar)

2000 psi (13.8

MPa, 138 bar)

2000 psi (13.8

MPa, 138 bar)

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

Electrostatic Air Hose Quick Disconnect Kit 24S004, page 35 .

** Has PTFE and SST catalyst hose for acid applications.

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

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

hose in your hose bundle. Always use Graco hoses.

Application

Low Pressure Air

Spray

Hose Part

No.

24T763

24T764

Length

25 ft (7.6 m)

50 ft (15.2 m)

Material

Nylon

Maximum Fluid Working Pressure

200 psi (1.4 MPa, 13.8 bar)

Fluid Whip Hoses

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

Application

Low Pressure

High Pressure

Hose Part

No.

24N641

24N305

24N641

24N348

Hose I.D.

0.125 in.

(3 mm)

0.25 in.

(6 mm)

0.125 in.

(3 mm)

0.25 in.

(6 mm)

Length

6 ft (1.8 m)

6 ft (1.8 m)

6 ft (1.8 m)

6 ft (1.8 m)

Material

Nylon

Nylon

Nylon

PTFE

Maximum Fluid Working

Pressure

3200 psi (22 MPa, 220 bar)

225 psi (1.6 MPa, 16 bar)

3200 psi (22 MPa, 220 bar)

3000 psi (20.7 MPa, 207 bar)

20 332457J

Con fi guring Your System

3. Select Mixing Option

The system will use either a Mix at Belt Manifold or a

Wall Mounted Mix Manifold.

3a. Mix At Belt Using Mix Manifold

The following mix manifold kits are available. The mix manifolds attach to the painter’s belt, allowing

Mix Manifold

24R991

24R992

24T273

Description

Low pressure mix manifold

High pressure mix manifold

High pressure mix manifold, for acid-compatible materials mixing to occur at the point of spray. See manual

3A2801 for further information.

Maximum Fluid Working Pressure

300 psi (2.1 MPa, 21 bar)

1500 psi (10.5 MPa, 105 bar)

1500 psi (10.5 MPa, 105 bar)

3b. Mix At Wall Using IS Remote Color Change Kits

NOTE: This configuration will require installation of a second solvent flow switch kit (24T787), sold separately.

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 total for the system, whether or not a color/catalyst change kit is used. The remote color change manifolds attach to the wall, allowing mixing to occur close to the point of spray. See color change kit manual 333282 for further information.

Table 1 . Low Pressure, Non-Circulating Remote

Color Change Manifold Kits (300 psi [2.068 MPa,

20.68 bar])

2

4

Number of Color

+ Solvent

Valves

1

6

8

12

13–18

Number of Catalyst + Solvent Valves

1

24V157

24V158

24V159

24V160

24V161

24V162

24V163

2

24V331

24V332

24V333

24V334

24V335

4

24V343

24V344

24V345

24V346

Number of Color

+ Solvent

Valves

13–24

13–30

Number of Catalyst + Solvent Valves

1 2 4

24V164

24V165

Table 2 . Low Pressure, Circulating Remote Color

Change Manifold Kits (300 psi [2.068 MPa, 20.68

bar])

Number of Color

+ Solvent

Valves

1

2

4

6

8

12

13–18

13–24

13–30

Number of Catalyst + Solvent Valves

1 2 4

24V166

24V167

24V308

24V309

24V326

24V327

24V328

24V329

24V330

24V336

24V337

24V338

24V339

24V340

24V347

24V348

24V349

24V350

332457J 21

Con fi guring Your System

Number of Color

+ Solvent

Valves

4

6

8

Table 3 . High-Pressure, Non-Circulating Remote

Color Change Manifold Kits (1500 psi [10.34 MPa,

103.4 bar])

1

2

12

13–18

13–24

13–30

Number of Catalyst + Solvent Valves

1 2 4

24V359

24V360

24V361

24V362

24V363

24V364

24V365

24V366

24V367

24V381

24V382

24V383

24V384

24V385

24V396

24V397

24V398

24V399

Table 4 . High-Pressure, Circulating Remote Color

Change Manifold Kits (1500 psi [10.34 MPa, 103.4

bar])

Number of Color

+ Solvent

Valves

4

6

8

1

2

12

13–18

13–24

13–30

Number of Catalyst + Solvent Valves

1 2 4

24V369

24V370

24V371

24V372

24V373

24V374

24V375

24V376

24V377

24V389

24V390

24V391

24V392

24V393

24V402

24V403

24V404

24V405

4. Select a Spray Gun

Spray Guns

Select a spray gun from the following table.

Application Gun Model

Conventional Air Spray

Electrostatic Air Spray

Conventional

Air-Assisted Spray

Electrostatic Air-Assisted

Spray

AirPro

Pro Xp

G15

Pro Xp AA

Gun Manual No.

312414

3A2494

3A0149

3A2495

Maximum Fluid Working

Pressure

300 psi (2.1 MPa, 21 bar)

100 psi (0.7 MPa, 7 bar)

1500 psi (10.5 MPa, 105 bar)

3000 psi (21 MPa, 210 bar)

22 332457J

Con fi guring Your System

5. Select Color and Catalyst Change Kits

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

Table 5 . Low Pressure Color/Catalyst Change Kits

(300 psi [2.068 MPa, 20.68 bar])

Kit Part No.

Kit Description

Low Pressure Non-Circulating Kits

24X316

24R915

1 color or 1 catalyst change valve

2 color or 2 catalyst change valves

24R916

24R917

24R918

24X317

4 color or 4 catalyst change valves

6 color change valves

8 color change valves

Low Pressure Circulating Kits

1 color or 1 catalyst change valve

24R919

24R920

24R921

24R922

2 color or 2 catalyst change valves

4 color or 4 catalyst change valves

6 color change valves

8 color change valves

Table 6 . High Pressure Color/Catalyst Change Kits

(1500 psi [10.34 MPa, 103.4 bar])

Kit Part No.

Kit Description

High Pressure Non-Circulating Kits

24X318

24R959

1 color or 1 catalyst change valve

2 color or 2 catalyst change valves

24R960

24T579

24T580

24X319

4 color or 4 catalyst change valves

24R961

24R962

6 color change valves

8 color change valves

High Pressure Acid-Compatible Non-

Circulating Kits

2 catalyst change valves

4 catalyst change valves

High Pressure Circulating Kits

1 color or 1 catalyst change valve

24R963

24R964

24R965

24R966

2 color or 2 catalyst change valves

4 color or 4 catalyst change valves

6 color change valves

8 color change valves

332457J 23

Con fi guring Your System

6. Select Pump Expansion Kits

NOTE: These are not required for Acid systems which only use a single catalyst, or Dual Panel systems which already include four pumps.

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

Kit Part No.

Kit Description

Low Pressure Pumps (300 psi [2.068

MPa, 20.68 bar])

24R968

24R970

Low pressure resin 70cc pump

Low pressure catalyst

35cc pump

High Pressure Pumps (1500 psi [10.34

MPa, 103.4 bar])

24R969

24R971

High pressure resin

70cc pump

High pressure catalyst

35cc pump

26A048 High pressure catalyst

35cc acid compatible

7. Select Communication Options

Use the following table to choose the appropriate kit(s) to meet your system requirements.

Kit Part No.

24T805

15V337

Kit Description

AWI Kit for PD2K

AWI Module

24 332457J

General Information

General Information

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

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

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

Display Module and Part No. 15M483 for the

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

Location

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

Mounting the PD2K Base Unit:

• Mount the PD2K in a non-hazardous location.

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

• Do not mount to a wall.

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

Dimensions, page 53

.

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

Mounting the Booth Control:

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

Install the Booth Control, page 27

.

332457J 25

Install the Display Module

Install the Display Module

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

2. Snap the Advanced Display Module into the bracket.

Figure 12 Install Display Module

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

(provided) to the Advanced Display Module

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

Module (EFCM).

NOTE: For a list of alternate cable lengths, see

Electrical Schematics, page 40

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

P

R

M

N

K

L

Item

J

Figure 13 Advanced Display Module Connection

Ports

Description

Battery Cover

Model Number

USB Drive Interface

CAN Cable Connection

ADM Status LEDs

Accessory Cable Connection

Token Access Cover

26 332457J

Install the Booth Control

Install the Booth Control

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

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

2. Snap the Booth Control into the bracket.

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

m) intrinsically safe CAN cable (163).

NOTE: For a list of alternate cable lengths, see

Electrical Schematics, page 40 . The total length

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

Figure 14 Ground the Booth Control Bracket

Figure 15 Install the Booth Control

332457J 27

Air Supply

Air Supply

Air Requirements

• Compressed air supply pressure: 85-100 psi

(0.6–0.7 MPa, 6.0-7.0 bar).

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

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

Use bleed-type shutoff valves.

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

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

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

Technical Data, page 54

for air filtration requirements.

28 332457J

Air Supply

Air Connections

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

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

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

This air supplies gun atomizing air. The air flow switch detects air flow to the gun and signals the controller when the gun is being triggered.

NOTE: For Dual Panel systems, the guns’ atomizing air is connected at the Air Control

Module (see manual 3A4497).

NOTE: If you are using a Graco hose bundle, connect the 4 ft (1.2 m) end of the air hose to the atomizing air outlet (159c) and the 7 ft (2.1m) end of the air hose to the gun. If there is more than one gun (for example, a separate gun for each color), the atomizing air outlet (159c) must be branched to each gun. For ease of maintenance, install a ball valve at all air line tees.

Figure 17 Air Manifold Connections

Key

C

M

Connection

A

S

Description

Air inlet

GFB/Air cutoff output (plugged)

Exhaust muffler

Solvent cutoff output

Figure 16 Connect Atomizing Air

332457J 29

Fluid Supply

Fluid Supply

Fluid Requirements

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

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

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

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

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

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

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

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

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

NOTE: For low pressure systems, it is recommended the supply pressure be maintained between 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.

30 332457J

Single Color Connections

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

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

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

3. Make the same connections on the catalyst side.

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

Color Change Connections

Fluid Supply

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

332455.

Solvent Connections

1. Connect the solvent supply line to the cutoff valve inlet fitting (FI).

2. Connect the solvent outlet line to the solvent flow switch outlet fitting (FO).

3. For Dual Panel Systems: Repeat previous steps for second solvent cutoff valve for Mix Unit #2.

Figure 18 Pump Inlet and Outlet Connections

332457J 31

TSL Cup Kit

TSL Cup Kit

The cup is used for either Throat Seal Liquid (TSL) or ISO oil. These liquids prevent exposure of air or moisture with the resin 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.

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.

2. Place the TSL cup (73) into the bracket (73a).

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 provide a shadow that will be visible from inside the TSL cup.

Figure 19 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).

32 332457J

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 (V) 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 (V).

NOTE: Do not confuse the valve port (V) 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 resin 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.

332457J 33

TSL Cup Kit

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.

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.

34 332457J

Solvent Meter Accessory

To install Solvent Meter Kit 280555, see manual

308778.

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

Light Tower Accessory

To install Light Tower Kit 24K337, see manual

3A1906.

Solvent Meter Accessory

Electrostatic Air Hose

Quick Disconnect Kit

24S004

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

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

Install the kit as follows.

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

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

3. Screw the 24U059 Electrostatic Air Whip Hose

(WH) onto the male end of the adapter fitting

(QF).

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

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

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

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

Figure 20 Electrostatic Air Hose Quick Disconnect Kit

332457J 35

Electrical Supply

Electrical Supply

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

Electrical Requirements

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

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

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

• The input power access port is 22.4 mm (0.88

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

Electrical Connections

See

Electrical Schematics, page 40 .

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

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

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

4. Tighten the strain relief nut securely.

5. Close the Control Box. Restore power.

6. Follow instructions in

Grounding, page 37 .

Wire Key

N

G

Wire

L

Description

Line Power

Neutral

Ground

36

Figure 21 Control Box Electrical Connection

332457J

Grounding

Grounding

This equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current.

Electrical Control Box

The electrical control box has two ground points.

Both connections must be made.

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

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

Electrical Connections, page 36 .

Booth Control

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

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

Install the Booth Control, page 27 .

Color Change Module

Connect a ground wire from the color change module to a true earth ground.

Intrinsically safe color change modules located in the hazardous area must be connected to a true earth ground in the hazardous area.

Feed Pumps or Pressure Pots

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

Air and Fluid Hoses

Use grounded hoses only.

Spray Gun

Follow the grounding instructions in your gun manual.

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

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

Figure 22 Ground Screw and Power Switch

Fluid Supply Container

Follow local code.

332457J 37

Grounding

HAZARDOUS LOCATION NON-HAZARDOUS LOCATION

Figure 23 System Grounding

Key

3

4

1

2

Electrical Control Box ground screw

Electrical Control Box ground wire

Color Change Module (CC) ground wires

Intrinsically Safe (IS) cable

5

6

7

True Earth Ground; check local code for requirements

Non-Intrinsically Safe cable

Booth Control (BC) mounting bracket ground wire

38 332457J

Grounding

Object Being Sprayed

Follow local code.

All Solvent Pails Used When Purging

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

Check Resistance

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

332457J 39

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

FLOW SENSOR

(120278)

OR G3000 METER

(239716, 258718

16M510, 16M519)

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 52

for a list of cable options.

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)

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

SPLITTER

(16P243)

065161, 065159

INTEGRATION

GATEWAY

5

CABLE (121227)

16T072

CAN

IS BOARD

(24M485)

CABLE (121227)

AWI

GATEWAY

(24R910)

5

CABLE (121001)

CABLE (16T280)

BARRIER

BOARD

(248192)

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)

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 24 Electrical Schematic, Sheet 1

4

CABLE (16T659)

CABLE (16T659)

CABLE (16T659)

CABLE (16T659)

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)

40 332457J

Electrical Schematics

SPLITTER

(16P243)

5 4 3 2 1

UNUSED UNUSED UNUSED

CONTINUED ON PAGE 3 CONTINUED ON PAGE 3

1 2 3 4 5

2

4

1 2 3 4 5

CABLE (15V206)

16T072

1 2 3 4 5

CAN IS BOARD

(NON IS)

(IS)

(24M485)

3

1 2 3 4 5

1

UNUSED

CABLE (16T280)

1 2 3

UNUSED UNUSED

BARRIER

BOARD

(248192)

3

CABLE (121227)

2

3 P3 P4

AWI

GATEWAY

(24R910)

5

CABLE

(121227)

3

2

3 P3

SOLVENT CUTOFF (121324)

PWR (RED)

SIG (WHITE)

COM (BLACK)

SHIELD/GRN SOLVENT

METER

(258718)

P4

INTEGRATION

GATEWAY

5

UNUSED

UNUSED

10

UNUSED

CABLE

(121001)

3

+24VDC

COM

UNUSED

UNUSED

+24VDC

COM

+24VDC

COM

UNUSED

8

GCA MODULE

EFCM

(24N913)

1

2

6

7

4

5

8

9

10

12

5

1 2 3 4 5 6 7 8 9 10

1

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

2

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

RED WIRE (065161)

BLACK WIRE (065159)

GROUND BAR

4

25 PIN D-SUB CABLE

(16T659)

24V

POWER

SUPPLY

(16T660)

L (BROWN) N (BLUE)

N03 N03

2 POSITION

SWITCH

(16U725)

N04 N04

CABLE

(16T658)

L N

LINE

FILTER

(16V446)

L GRND N

CABLE

(16H078)

L N GRND

TERMINAL

BLOCK

(114095)

L N GRND

GRND (GRN/YEL)

13 A1(+) A2(-)

RELAY

14

N L GRND

48V-10A

POWER SUPPLY

+ -

+ - + - + - + -

+ - + - + - + -

DETAIL A, LOW PRESSURE PUMPS

(24M706, 24M714, 24T799)

2

1 2 3 4 5

BREAKOUT MODULE

(24N527)

3

1 2 3 4

WIRE HARNESS

(24P684) DRAIN/FOIL

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 24 25

1

2

1 2 3 4 5

3

1 2 3 4

4

1 2 3 4 5

5

1 2 3 4 5

6

1 2 3 4 1 2 3 4

7

5 6 7 8

8

1 2 3 4

1 2 3 4 5 6 7 8

BREAKOUT MODULE PUMP 2 (24N527)

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

1

2

1 2 3 4 5

3

1 2 3 4

4

1 2 3 4 5

5

1 2 3 4 5

6

1 2 3 4 1 2 3 4

7

5 6 7 8

8

1 2 3 4

+48V COM +48V COM

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 1

SEE DETAIL A OR B

TRANSDUCER PUMP TRANSDUCER PUMP

TWISTED PAIR CABLE (16W159)

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

1 UP

MANIFOLD

MAC SERIES 46 (16P812 QTY

G3000

METER

PUMP 1

(EITHER, 239716,

258718,16M510,

OR 16M519)

GRND

SCREW

+48V COM +48V COM

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 2

SEE DETAIL A OR B

TRANSDUCER PUMP TRANSDUCER PUMP

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

2 UP

MANIFOLD

MAC SERIES 46 (16P812 QTY

G3000

METER

PUMP 2

(EITHER, 239716,

258718,16M510,

OR 16M519)

GRND

SCREW

TWISTED PAIR CABLE (16W159)

DETAIL B, HIGH PRESSURE PUMPS

(24M707, 24M715, 24T800)

2

1 2 3 4 5

BREAKOUT MODULE

(24N527)

3

1 2 3 4

WIRE HARNESS

(24P685) DRAIN/FOIL

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 25 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

332457J 41

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

7

8

5

6

3

4

2

1

10

9

11

12

GUN TRIGGER INPUTS

SIG

COM

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

4

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

9

7

7

8

5

6

3

4

2

1

9

10

11

12

3

5

1

2

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)

4

5

1

2 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 26 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

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 4

SEE DETAIL A OR B

TRANSDUCER PUMP TRANSDUCER PUMP

TWISTED PAIR CABLE (16W159)

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

+48V COM +48V COM

42 332457J

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

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

*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 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

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

4

3

6

5

2

1

1 2 3 4 5

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 27 Electrical Schematic, Sheet 3

* May be unused in some configurations.

CONTINUED ON THE NEXT PAGE

332457J 43

Electrical Schematics

FLUSH

CATALYST 3

CATALYST 4

MANIFOLD

COM

+24VDC

COM

+24VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

5

6

2

3 J8

CATALYST

CHANGE

MODULE 6

(CATALYST

3 THRU 4)

J9

6

5

6

2

3 J15 J16

3

2

5

4

1

3

2

5

4

1

5

6

2

3 J14 J10

1 2 3 4 5

3

2

5

4

1

COM

+24VDC

+24VDC

+24VDC

UNUSED

UNUSED

UNUSED

UNUSED

MANIFOLD

DUMP

CATALYST 3

CATALYST 4

UNUSED

UNUSED

UNUSED

UNUSED

FLUSH

CATALYST 1

CATALYST 2

MANIFOLD

+24VDC

COM

+24VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

4

5

6

1

2

J8

5 4 3 2

CATALYST

CHANGE

MODULE 5

(CATALYST

1 THRU 2)

1

J9 4

3

6

5

6

4

5

6

1

2

J15 J16 4

3

6

5

4

5

6

1

2

J14

1 2 3 4 5

J10

4

3

6

5

+24VDC

COM

COM

+24VDC

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

MANIFOLD

DUMP

CATALYST 1

CATALYST 2

1 2 3 4 5

COLOR

CHANGE

MODULE 4

(COLORS

25 THRU 32)

ALTERNATE CONFIGURATION

FOR CATALYST CHANGE CONTROL

Figure 28 Electrical Schematic, Sheet 3, Alternate

Configuration for Catalyst Change Control

CONTINUED ON THE NEXT PAGE

44 332457J

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

COM

+12VDC

COM

+12VDC

COM

COM

+12VDC

COM

+12VDC

COM

COM

+12VDC

COM

3

4

1

2

5

6

4

5

6

1

2

1 2 3 4 5

COLOR

CHANGE

MODULE 7

(COLORS

33 THRU 40)

J8 J9

4

3

6

5

2

1

7

J15 J16

3

2

5

4

1

3

4

1

2

5

6

J14 J10

4

3

6

5

2

1

1 2 3 4 5

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+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

+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 8

(COLORS

41 THRU 48)

J8 J9

7

3

4

1

2

5

6

J15 J16

4

3

6

5

2

1

4

3

6

5

4

5

6

1

2

J14

5 4 3 2

J10

1

4

3

6

5

2

1

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

+12VDC

COM

+12VDC

COM

+12VDC

MANIFOLD

COLOR 22

COLOR 23

COLOR 24

COLOR 25

COLOR 26

COLOR 27

COLOR 28

COLOR 29

COLOR 30

5 4 3 2 1

BOOTH CONTROL

(24M731)

Figure 29 Electrical Schematic, Sheet 3, Hazardous

Location

332457J 45

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 52

for a list of cable options.

POWER MODULE

(26A189)

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 1

(258718)

2 POSITION

SWITCH

(16U725)

CABLE

16T658

LINE FILTER

(16V446)

CABLE

16H078

TERMINAL BLOCK

(114095)

POWER IN

24V

POWER

SUPPLY

(16T660)

RELAY 1 RELAY 2

TERMINAL BLOCK WITH FUSES

FAN

(24P658)

ENCODER AND MOTOR

(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 2

(258718)

48V-10A POWER SUPPLY

(16U820)

SPLITTER

(16P243)

INTEGRATION

GATEWAY

5

CAN

IS BOARD

(24M485)

17L058

CABLE (16T280)

CABLE (121227)

16T072

BARRIER

BOARD

(248192)

CABLE (121227)

AWI

GATEWAY

(24R910)

5

CABLE (121001)

2

CABLE

(15V206)

2 CABLE

(15V206)

MODULE 1 (24N935)

2

CABLE

(15V206)

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

2

CABLE

(15V206)

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

2

CABLE

(15V206)

MODULE 6 (24N935)

GCA

MODULE

EFCM

(24N913)

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)

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 30 Electrical Schematic, Sheet 1

4

CABLE (16T659)

1

CABLE (16V429)

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

46 332457J

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

4

5

CABLE

(121227)

3

UNUSED

UNUSED

P3 P4

INTEGRATION

GATEWAY

5

UNUSED

CABLE

(121001)

3

3

1

10

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

8

9

6

7

4

5

2

3

10

11

12

5

4

25 PIN D-SUB

CABLE (16T659)

GROUND

BAR

1

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

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

6

7

8

5

6

3

4

2

1

9

10

11

12

7

7

8

5

6

3

4

2

1

9

10

11

12

9

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

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 1

SEE DETAIL A OR B

BROWN (UNUSED)

DRAIN (UNUSED)

BLUE

BLACK

BROWN (UNUSED)

DRAIN (UNUSED)

BLUE

BLACK

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

CABLE (126232 OR 17N315)

PUMP 1

MANIFOLD

SOLVENT

METER 1

(258718)

MAC SERIES 46 (16P812 QTY

GND

SCREW

TWISTED PAIR CABLE (16W159)

+24VDC COM +24VDC 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

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 31 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

332457J 47

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

9

10

11

12

SIG

COM

SIG

COM

SIG

COM

SIG

COM

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

11

12

9

4

3

5

2

1

PLC DISCRETE 4-20mA INPUT 1

PLC DISCRETE 4-20mA COMMON 1

PLC DISCRETE 4-20mA INPUT 2

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

TERMINAL

BLOCKS

7

8

5

6

3

4

2

1

9

10

11

12

+ 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

4

1 2 3 4 5

BREAKOUT MODULE PUMP 4 (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

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 3

SEE DETAIL A OR B

ENCODER/MOTOR

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

Figure 32 Electrical Schematic, Sheet 2, Part 2

CONTINUED ON THE NEXT PAGE

TWISTED PAIR CABLE (16W159)

TWISTED PAIR CABLE (16W159)

48 332457J

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

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

*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 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

+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

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

Figure 33 Electrical Schematic, Sheet 3, Part 1

* May be unused in some configurations.

CONTINUED ON THE NEXT PAGE

2

CABLE (15V206)

332457J 49

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

RED

BLACK

RED

BLACK

RED

BLACK

+12VDC

COM

+12VDC

COM

+12VDC

COM

BLACK

RED

BLACK

BLACK

RED

BLACK

4

6

2

3

4

6

2

3

1 2 3 4 5

COLOR

CHANGE

MODULE 7

(COLORS

33 THRU 40)

J8 J9

4

3

6

5

2

1

7

J15 J16

4

3

6

5

2

1

3

4

1

2

5

6

J14

5 4 3 2 1

J10 3

1

5

4

+12VDC

COM

+12VDC

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

BLACK

RED

BLACK

RED

BLACK

RED

COM BLACK

COM BLACK

+12VDC

+12VDC

RED

RED

MANIFOLD

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

RED

BLACK

RED

BLACK

RED

BLACK

+12VDC

COM

+12VDC

COM

+12VDC

COM

RED

BLACK

RED

BLACK

RED

BLACK

+12VDC

COM

+12VDC

COM

+12VDC

COM

BLACK

RED

BLACK

4

6

1

2

4

6

2

3

1 2 3 4 5

COLOR

CHANGE

MODULE 8

(COLORS

41 THRU 48)

J8 J9

7

J15 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

1

3

1

5

4

5 4 3 2 1

BOOTH CONTROL

(24M731)

+12VDC

COM

+12VDC

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

BLACK

RED

BLACK

RED

BLACK

RED

+12VDC

COM

+12VDC

MANIFOLD

COLOR 22

COLOR 23

COLOR 24

COLOR 25

COLOR 26

COLOR 27

COLOR 28

COLOR 29

COLOR 30

Figure 34 Electrical Schematic, Sheet 3, Part 2

CONTINUED ON THE NEXT PAGE

50 332457J

Electrical Schematics

FLUSH

CATALYST 3

CATALYST 4

MANIFOLD

+24VDC

COM

+24VDC

COM

+24VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

5

6

2

3

CATALYST

CHANGE

MODULE 6

(CATALYST

3 THRU 4)

J8 J9

6

4

6

1

2

J15 J16

3

1

5

4

4

3

6

5

5

6

2

3 J14 J10

4

3

6

5

2

1

1 2 3 4 5

+24VDC

COM

+24VDC

+24VDC

MANIFOLD

DUMP

CATALYST 3

CATALYST 4

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

FLUSH

CATALYST 1

CATALYST 2

MANIFOLD

COM

+24VDC

COM

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

4

6

1

2

5

6

3

4

5 4 3 2

CATALYST

CHANGE

MODULE 5

(CATALYST

1 THRU 2)

1

J8 J9

2

1

5

4

6

J15 J16 4

3

6

5

2

1

3

4

1

2

J14 J10

3

1

5

4

1 2 3 4 5

1 2 3 4 5

COLOR

CHANGE

MODULE 4

(COLORS

25 THRU 32)

COM

+24VDC

COM

+24VDC

COM

+24VDC

UNUSED

UNUSED

UNUSED

UNUSED

MANIFOLD

DUMP

CATALYST 1

CATALYST 2

UNUSED

UNUSED

UNUSED

UNUSED

ALTERNATE CONFIGURATION

FOR CATALYST CHANGE CONTROL

IN NON-HAZARDOUS LOCATION

Figure 35 Electrical Schematic, Sheet 4, Alternate

Configuration for Catalyst Change Control

332457J 51

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 40

.

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

16V424

2.0 (0.6)

3.0 (1.0)

16V425

16V426

16V427

16V428

16V429

16V430

6.0 (2.0)

10.0 (3.0)

15.0 (5.0)

25.0 (8.0)

50.0 (16.0)

100.0 (32.0)

15U531

15U532

15V205

15V206

15V207

15V208

15U533

15V213

M12 CAN Cables, for Non-Hazardous

Locations Only

2.0 (0.6)

3.0 (1.0)

6.0 (2.0)

10.0 (3.0)

15.0 (5.0)

25.0 (8.0)

50.0 (16.0)

100.0 (32.0)

CAN Cables, for Non-Hazardous

Locations Only

Cable Part No.

Length ft (m)

125306

123422

1.0 (0.3)

1.3 (0.4)

121000

121227

121001

121002

1.6 (0.5)

2.0 (0.6)

3.0 (1.0)

5.0 (1.5)

121003

120952

121201

121004

121228

10.0 (3.0)

13.0 (4.0)

20.0 (6.0)

25.0 (8.0)

50.0 (15.0)

16T659

25 Pin D-SUB Cables, for Non-Hazardous

Locations Only

2.5 (0.8)

16V659 6.0 (1.8)

Alternates for Communication Module 24R910, for Non-Hazardous Locations Only

Module Part No.

Module Part No.

CGMDN0*, DeviceNet

CGMEP0*, Ethernet IP

CGMPN0*, Profinet

* You must purchase Map Token Kit 17C087 for use with these kits.

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

24T571

Hazardous Locations Only

2 color/2 catalyst

24T572 4 color/2 catalyst

24T573

24T574

24T774

24T775

24T776

24T777

24T778

24T779

6 color/2 catalyst

8 color/2 catalyst, 13–24 color

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

52 332457J

Dimensions

Dimensions

Figure 36

Figure 37

A

65.3 in.

(1659 mm)

B with ADM without

ADM

14.5 in.

(368 mm)

11.12 in.

(282 mm)

C

22.5 in.

(572 mm)

D

Figure 38

19.26 in.

(489 mm)

E

2.25 in.

(57 mm)

F G H

18.0 in.

(457 mm)

17.26 in.

(438 mm)

0.52 in.

(13 mm)

332457J 53

Technical Data

Technical Data

Positive Displacement

Proportioner

Maximum fluid working pressure:

MC1000, MC1002, and

MC3000 Air Spray

Systems

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

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

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

54 332457J

Technical Data

Positive Displacement

Proportioner

U.S.

Metric

Wetted parts:

MC0500 and MC0502 Pumps sold separately; see selected pump manual for wetted parts information.

MC1000, MC1002,

MC2000, and MC2002

17–4PH, 303, 304 SST, Tungsten carbide (with nickel binder),

MC3000, MC4000, and MC4002 perfluoroelastomer; PTFE, PPS, UHMWPE

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

332457J 55

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use.

With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, free of charge any defective parts. The equipment will be returned to the original purchaser transportation made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of these warranties.

supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

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

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

Graco Information

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

To place an order, contact your Graco Distributor or call to identify the nearest distributor.

Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

For patent information, see www.graco.com/patents.

Original Instructions. This manual contains English. MM 332457

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

Copyright 2013, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revision J, September 2017

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