Graco 332458G, ProMix® PD2K Proportioner for Automatic Spray Applications Owner's Manual

Installation
ProMix® PD2K Proportioner for
Automatic Spray Applications
332458G
EN
fast--setting two
two--component materials. Automatic
Electronic positive displacement proportioner for fast
system with Advanced Display Module. For professional use only.
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
Models............................................................... 3
Warnings ........................................................... 6
Important Isocyanate (ISO) Information ................ 9
Important Acid Catalyst Information ..................... 11
System Control Drawing 16P577 ......................... 12
Configure Your System ....................................... 14
1. Select a Base Model ................................ 14
2. Select Hoses ........................................... 17
3. Select Remote Mix Manifold ..................... 18
4. Select a Spray Gun .................................. 18
5. Select Color and Catalyst Change
Control Module Kits ........................ 19
6. Select Color and Catalyst Change
Manifold Kits .................................. 19
7. Select Pump Expansion Kits ..................... 21
8. Select Communication Options ................. 21
9. Accessory Tool Kit ................................... 21
Single Color Connections ............................. 26
Color Change Connections........................... 26
Solvent Connections .................................... 26
Dual Panel Solvent Connections ................... 27
TSL Cup Kit........................................................ 28
Alternate TSL Plumbing for
Highly-Reactive/Moisture-Sensitive
ISO Catalyst PD2K Pumps .............. 30
Solvent Meter Accessory..................................... 32
Light Tower Accessory........................................ 32
Electrical Supply ................................................. 33
Electrical Requirements................................ 33
Electrical Connections .................................. 33
Grounding .......................................................... 35
General Information ............................................ 22
Electrical Schematics.......................................... 37
Standard Models (AC1000, AC2000,
AC3000, AC4000) .......................... 37
Dual Panel Models (AC1002, AC2002,
AC3002, AC4002) .......................... 43
Location ............................................................. 22
Optional Cables and Modules.............................. 49
Install the Display Module.................................... 23
Dimensions ........................................................ 50
Air Supply .......................................................... 24
Technical Data ................................................... 51
Fluid Supply ....................................................... 25
Fluid Requirements ...................................... 25
Related Manuals
Current manuals are available at www.graco.com.
Manual No.
Description
Manual No.
Description
332455
332709
PD2K Proportioner Repair-Parts
Manual, Automatic Systems
Color Change Kits InstructionsParts Manual
333282
Color Change and Remote Mix
Manifold Kits Instructions-Parts
Manual
332456
3rd and 4th Pump Kits
Instructions-Parts Manual
334494
ProMix PD2K CGM Installation Kits
Instructions-Parts Manual
332564
PD2K Proportioner Operation
Manual, Automatic Systems
3A4486
PD2K Dual Panel Proportioner
Manual, Automatic Systems
332339
Pump Repair-Parts Manual
332454
Color/Catalyst Dispense Valves
Instructions-Parts Manual
2
332458G
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
AC0500
AC0502
A
100 psi (0.7 MPa, 7.0 bar)
With low–pressure pumps:
300 psi (2.068 MPa,
20.68 bar)
Location of PD2K and
Electrical Control Box
(ECB) Labels
With high–pressure pumps:
1500 psi (10.34 MPa,
103.4 bar)
AC1000
AC1002
A
100 psi (0.7 MPa, 7.0 bar)
300 psi (2.068 MPa,
20.68 bar)
A
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa,
103.4 bar)
AC3000
AC3002
Acid-based
Material
AC2000
AC2002
AC4000
AC4002
Acid-based
Material
0359
II 2 G
®
ProMix PD2K / PD1K
Electronic Proportioner
II 2 G
Ex ia IIA T3
FM13 ATEX 0026
IECEx FMG 13.0011
FM16US0241
FM16CA0129
Intrinsically safe
equipment for Class I,
Div 1, Group D, T3
Ta = 2°C to 50°C
.7
7
100
MPa
bar
PSI
MAX FLUID WPR
2.068 20.68
MPa
bar
300
PSI
MAX TEMP 50°C (122°F)
Figure 1 Model AC1000, AC1002, AC3000, and
AC3002 (Low Pressure) Identification Label
332458G
Artwork No. 294021 Rev. F
MAX AIR WPR
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.
MFG. YR.
SERIES
SERIAL
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
Continued on the next page.
3
®
POWER REQUIREMENTS
ProMix PD2K / PD1K
PART NO. SERIES NO. MFG. YR.
90-250 ~
AMPS 7 AMPS MAX
Intrinsically safe connections
for Class I, Div 1, Group D
50/60 Hz
Ta = 2°C to 50°C
VOLTS
GRACO INC.
P.O. Box 1441
Install per 16P577
Minneapolis, MN FM16US0241
55440 U.S.A.
FM16CA0129 Um: 250 V
II (2) G
[Ex ia] IIA Gb
FM13 ATEX 0026
IECEx FMG 13.0011
Artwork No. 294024 Rev. D
Models
Figure 2 24M672 and 26A188 Control Box
Identification Label
®
ProMix PD2K / PD1K
Electronic Proportioner
II 2 G
Ex ia IIA T3
FM13 ATEX 0026
IECEx FMG 13.0011
FM16US0241
FM16CA0129
Intrinsically safe
equipment for Class I,
Div 1, Group D, T3
Ta = 2°C to 50°C
.7
7
100
MPa
bar
PSI
MAX FLUID WPR
10.34 103.4 1500
MPa
bar
PSI
MAX TEMP 50°C (122°F)
Artwork No. 294022 Rev. F
MAX AIR WPR
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
MFG. YR.
SERIAL
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
Figure 3 Model AC2000, AC2002, AC4000, and
AC4002 (High Pressure) Identification Label
®
ProMix PD2K / PD1K
Electronic Proportioner
II 2 G
Ex ia IIA T3
FM13 ATEX 0026
IECEx FMG 13.0011
FM16US0241
FM16CA0129
Intrinsically safe
equipment for Class I,
Div 1, Group D, T3
Ta = 2°C to 50°C
MAX AIR WPR
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
7
100
MPa
bar
PSI
POWER REQUIREMENTS
VOLTS
AMPS
90-250 ~
7 AMPS MAX
50/60 Hz
Um: 250 V
MAX TEMP 50°C (122°F)
Artwork No. 294280 Rev. E
Read Instruction Manual
.7
Warning: Substitution of components
may impair intrinsic safety.
PART NO.
MFG. YR.
SERIES
SERIAL
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
Figure 4 Model AC0500 and AC0502 Identification
Label
Figure 5 Non-Intrinsically Safe Color Change Control (Accessory) Identification Label
4
332458G
Models
ProMix® PD2K / PD1K COLOR CHANGE CONTROL
PART NO.
SERIES
MAX AIR WPR
SERIAL MFG. YR.
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
II 2 G
Ex ia IIA T3 Gb
FM13 ATEX 0026
IECEx FMG 13.0011
.7
7
MPa
bar
100
PSI
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
Figure 6 Intrinsically Safe Color Change Control
(Accessory) Identification Label
Figure 7 Pump Expansion Kit (Accessory) Identification Label
PART NO.
DATE / SERIES
RECOGNIZED
COMPONENT
SERIAL NO.
4003764
Conforms to
UL STD 508
Certified to CAN/CSA
STD C22.2 No. 14
Artwork No.
Pending 293656 Rev. D
12-30 VDC
4 AMP MAX
Type 1 ENCL
U.S. Patent
Figure 8 CGM Identification Label
332458G
5
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.
6
332458G
Warnings
WARNING
INTRINSIC SAFETY
Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe
equipment will create a hazardous condition and can cause fire, explosion, or electric shock. Follow
local regulations and the following safety requirements.
• Be sure your installation complies with national, state, and local codes for the installation of
electrical apparatus in a Class I, Group D, Division 1 (North America) or Class I, Zones 1 and 2
(Europe) Hazardous Location, including all of the local safety fire codes (for example, NFPA 33,
NEC 500 and 516, OSHA 1910.107, etc.).
• To help prevent fire and explosion:
• Do not install equipment approved only for a non-hazardous location in a hazardous location.
See model ID label for the intrinsic safety rating of your model.
• Do not substitute system components as this may impair intrinsic safety.
• Equipment that comes in contact with the intrinsically safe terminals must be rated for Intrinsic
Safety. This includes DC voltage meters, ohmmeters, cables, and connections. Remove the unit
from the hazardous area when troubleshooting.
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like
just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
•
•
•
•
•
•
Do not spray without tip guard and trigger guard installed.
Engage trigger lock when not spraying.
Do not point gun at anyone or at any part of the body.
Do not put your hand over the spray tip.
Do not stop or deflect leaks with your hand, body, glove, or rag.
Follow the Pressure Relief Procedure when you stop spraying/dispensing and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure and disconnect all power sources.
TOXIC FLUID OR FUMES
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read 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.
332458G
7
Warnings
WARNING
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.
8
332458G
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
Keep Components A and B Separate
• 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.
Cross-contamination can result in cured
material in fluid lines which could cause serious
injury or damage equipment. To prevent
cross-contamination:
• 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.
• Never use solvent on one side if it has been
contaminated from the other side.
• Never interchange component A and component
B wetted parts.
• 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.
332458G
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.
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.
• Always lubricate threaded parts with an
appropriate lubricant when reassembling.
10
332458G
Important Acid Catalyst Information
Important Acid Catalyst Information
Only the PD2K Proportioner acid catalyst models are 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.
332458G
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
2.0 (0.6)
16V424
3.0 (1.0)
16V425
6.0 (2.0)
16V426
10.0 (3.0)
16V427
15.0 (5.0)
16V428
25.0 (8.0)
16V429
50.0 (16.0)
16V430
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
332458G
System Control Drawing 16P577
NON--HAZARDOUS LOCATION ONLY
NON
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
NON-HAZARDOUS LOCATION ONLY
CLASS 1, DIV 1, GROUP D, T3 (USAAND CANADA)
CLASS 1, ZONE 1, GROUP IIA, T3 (ATEXAND IECEx)
Ta = 2
C TO 50 C
POWER IN
250 VAC MAXIMUM SUPPL
Y VOLTAGE
BOOTH CONTROL
(24M731)
FM13ATEX0026
IECEx FMG 13.0011
INTRINSIC SAFE APPARATUS
5
COMMUNICA
TION
BARRIE
R
(24M485)
J4
OR
CABLE (16V
429)
CABLE (16V
429)
J3
CABLE
(16V426)
FM13ATEX0026
IECEx FMG 13.0011
ASSOCIATED APPARATUS
CABLE
(16V426)
POWER
BARRIE
R
(248192)
SPLITTER
17L058
PROMIX PD2K
ELECTRICAL ENCLOSURE
(24M672)
COLOR CHANGE MODULE
(24R219, 24R220, 24R221, 24R222)
(24V406, 24V407, 24V408)
(24V409, 24V410, 24V411)
FM13ATEX0026
IECEx FMG 13.0011
INTRINSIC SAFE APPARATUS
COLOR CHANGE MODULE
(24R219, 24R220, 24R221, 24R222)
(24V406, 24V407, 24V408)
(24V409, 24V410, 24V411)
FM13ATEX0026
IECEx FMG 13.0011
INTRINSIC SAFE APPARATUS
BOOTH CONTROL
(24M731)
FM13ATEX0026
IECEx FMG 13.0011
INTRINSIC SAFE APPARATUS
Figure 9 System Control Drawing 16P577
332458G
13
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.
Component
Description
Fluid Pumps (A, B)
The base models include two fluid pumps, one for resin and one for catalyst.
Install in the non-hazardous area.
Solvent Flow Switch (C)
Confirms solvent flow to gun during purge. The base models include two
solvent flow switches; one for resin, 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 setup, monitor, and
control the system. Install the ADM in the non-hazardous area.
CAN cable (F)
The CAN cable connects the Gateway communication module to the IS
remote mix control module.
14
332458G
Configure Your System
HAZARDOUS (CLASSIFIED) LOCATION
NON--HAZARDOUS LOCATION ONLY
NON
Figure 10 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 (accessory)
T
Supply Line Drain Valves (accessory, required, not shown)
332458G
15
Configure Your System
HAZARDOUS (CLASSIFIED) LOCATION
NON--HAZARDOUS LOCATION ONLY
NON
Figure 11 Typical Dual Panel Installation (AC1002
and AC2002 only)
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 Switches
E★
Electrical Control Box
F★
Advanced Display Module
Components G through K are included in optional color change kits.
G
Color Change Valves (accessory)
H
Color Change Module (accessory)
J
Catalyst Change Valves (accessory)
K
Catalyst Change Module (accessory)
Components L through T are accessories and must be ordered separately.
L
IS Remote Mix Control Module (accessory, hazardous area)
M
Remote Mix Manifold (accessory, hazardous area)
N
Automatic Spray Gun (accessory)
P
Remote Color Change Manifold (accessory, hazardous area)
R
CAN Communication Cable (accessory)
S
Gun Fluid Hose (accessory)
T
Supply Line Drain Valves (accessory, required, not shown)
U
Fluid/Air Hose Bundle (accessory)
16
332458G
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
Thick Resin (A)
1/4 ʺ A
3/8 ʺ B
7.5:1
5:1
2.5:1
1:1
1:2.5
Equal Viscosities
Thin Catalyst (B)
1:5
1:7.5
1:10
Thin Resin (A)
Thick Catalyst (B)
Viscosity Ratio (Resin [A] : Catalyst [B]
332458G
17
Configure Your System
1/4 in. (6 mm) ID Hoses
Application
Material
Moisture-Lok
Catalyst
Nylon
Resin
Nylon
Solvent
Nylon
Atomizing
Air
Nylon
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
3. Select Remote Mix Manifold
The following remote mix manifold kits are available. The mix manifolds may be attached to the wall, in the hazardous
area, allowing mixing to occur close to the point of spray. See the Color Change and Remote Mix Manifold Kits
manual in Related Manuals, page 2 , for more information.
Mix Manifold
Description
Maximum Fluid Working Pressure
25D543
Low Pressure Remote Mix Manifold
300 psi (2.1 Mpa, 21 bar)
25D605
High Pressure Remote Mix Manifold
1500 psi (10.5 Mpa, 105 bar)
NOTE: This configuration requires installation of
a second solvent flow switch kit (24T787), sold
separately. A Dual Panel system will require two
solvent flow switch kits.
4. 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
Conventional Air Spray
AirPro
313516
100 psi (0.7 MPa, 7 bar)
Electrostatic Air Spray
Pro Xs
309297
100 psi (0.7 MPa, 7 bar)
Conventional Air-Assisted
Spray
G40
311052
4000 psi (28 MPa, 280 bar)
Electrostatic Air-Assisted
Spray
Pro Xs AA
309298
3000 psi (21 MPa, 210 bar)
18
332458G
Configure Your System
5. Select Color and Catalyst Change
Control Module Kits
6. Select Color and Catalyst Change
Manifold Kits
Using the following tables, choose color/catalyst
change control module kits that meet your
application’s requirements. The kits include a control
module with solenoid valves. See the Color Change
Kits and Color Change and Remote Mix Manifold
Kits manuals in Related Manuals, page 2 , for more
information.
Using the following tables, choose color/catalyst
change control manifold kits that meet your
application’s requirements. The kits include a
manifold with valves. See the Color Change Kits and
Color Change and Remote Mix Manifold Kits manuals
in Related Manuals, page 2 , for more information.
NOTE: All Color/Catalyst Control Module kits are to
be mounted outside of the hazardous location only.
If your application requires remote color change and
the control modules be mounted in the hazardous
location. See the Color Change and Remote Mix
Manifold Kits manual in Related Manuals, page 2 ,
for legacy kits that include IS-approved control
modules.
Table 1 Color/Catalyst Change Control Kits (300 psi
[2.068 Mpa, 20.06 bar])
Kit Part No.
Kit Description
25D328
Control module with 4
solenoids
Table 2 Low Pressure Color/Catalyst Change
Manifold
Kit Part No.
Kit Description
Non--Circulating Kits
Low Pressure Pumps Non
24Y936
2 valve manifold
24Y938
3 valve manifold
24Y940
4 valve manifold
24Y942
5 valve manifold
24Y944
6 valve manifold
24Y946
7 valve manifold
24Y948
8 valve manifold
25D329
Control module with 5
solenoids
24Y950
9 valve manifold
24Y952
10 valve manifold
25D474
Control module with 6
solenoids
26A272
11 valve manifold
25D475
Control module with 7
solenoids
26A274
12 valve manifold
26A286
13 valve manifold
25D476
Control module with 8
solenoids
26A276
14 valve manifold
25D477
Control module with 9
solenoids
26A278
15 valve manifold
26A280
16 valve manifold
26A282
17 valve manifold
26A284
18 valve manifold
25D478
Control module with 10
solenoids
25D479
Control module with 11
solenoids
25D480
Control module with 12
solenoids
24Y937
2 valve manifold
24Y939
3 valve manifold
25D481
Control module with 13
solenoids
24Y941
4 valve manifold
25D482
Control module with 14
solenoids
24Y943
5 valve manifold
24Y945
6 valve manifold
24Y947
7 valve manifold
24Y949
8 valve manifold
24Y951
9 valve manifold
Low Pressure Circulating Kits
25D483
Control module with 15
solenoids
25D484
Control module with 16
solenoids
25D485
Control module with 17
solenoids
24Y953
10 valve manifold
26A273
11 valve manifold
Control module with 18
solenoids
26A275
12 valve manifold
25A605
13 valve manifold
26A277
14 valve manifold
26A279
15 valve manifold
25D486
332458G
19
Configure Your System
Kit Part No.
Kit Description
Kit Part No.
Kit Description
26A281
16 valve manifold
24T663
18 valve manifold
26A283
17 valve manifold
26A285
18 valve manifold
Table 3 High Pressure Color/Catalyst Change
Manifold
Kit Part No.
Non-High Pressure Acid Compatible Non
Circulating Kits
24X360
2 valve manifold
24U182
3 valve manifold
24U183
4 valve manifold
Kit Description
Non--Circulating Kits
High Pressure Pumps Non
High Pressure Circulating Kits
24T677
2 valve manifold
24T647
2 valve manifold
24T678
3 valve manifold
24T648
3 valve manifold
24T679
4 valve manifold
24T649
4 valve manifold
24T680
5 valve manifold
24T650
5 valve manifold
24T681
6 valve manifold
24T651
6 valve manifold
24T682
7 valve manifold
24T652
7 valve manifold
24T683
8 valve manifold
24T653
8 valve manifold
24T684
9 valve manifold
24T654
9 valve manifold
24T685
10 valve manifold
24T655
10 valve manifold
24T686
11 valve manifold
24T656
11 valve manifold
24T687
12 valve manifold
24T657
12 valve manifold
24T688
13 valve manifold
24T658
13 valve manifold
24T689
14 valve manifold
24T659
14 valve manifold
24T690
15 valve manifold
24T660
15 valve manifold
24T691
16 valve manifold
24T661
16 valve manifold
24T692
17 valve manifold
24T662
17 valve manifold
24T693
18 valve manifold
20
332458G
Configure Your System
7. Select Pump Expansion Kits
8. Select Communication Options
NOTE: These are not required for Acid systems
which only use a single catalyst, or for Dual Panel
systems since they already include four pumps.
1. If your application requires integration with a
PLC:
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.
Kit Part No.
Kit Description
a. 24W829, CGM Kit for PD2K
26A303, CGM Kit for PD2K Dual Panel
25D997, CGM Kit for PD2K Dual Panel with
ProfiNet
b. CGMEP0, Ethernet IP
CGMDN0, Device Net
CGMPN0, ProfiNet*
24W462, Modbus TCP
* Two CGM modules included with 25D997,
CGM Kit for PD2K Dual Panel with ProfitNet.
Low Pressure Pumps
(300 psi [2.068 MPa, 20.68 bar])
24R968
Low pressure resin
70cc pump
24R970
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
2. If your application requires AWI:
a. 24W829, CGM Kit for PD2K
b. 24W462, Modbus TCP**
c.
15V337, AWI Module
NOTE: AWI is not currently available for Dual
Panel systems.
** AWI requires its own Modbus TCP module.
If the PLC is also communicating over
Modbus TCP, then two 24W462 modules are
necessary.
9. Accessory Tool Kit
The following kit includes an assortment of tools for
maintenance and repair of the PD2K system.
332458G
Kit Part No.
Kit Description
25D980
PD2K Maintenance
Tool Kit
21
General Information
General Information
Location
• 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. Clean the screens with a dry cloth
if necessary.
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 50.
• 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.
22
332458G
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.
2. Snap the Advanced Display Module into the
bracket.
Figure 13 Advanced Display Module Connection
Ports
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).
Item
Description
J
Battery Cover
K
Model Number
L
USB Drive Interface
M
CAN Cable Connection
N
ADM Status LEDs
P
Accessory Cable
Connection
R
Token Access Cover
NOTE: For a list of alternate cable lengths, see
Electrical Schematics, page 37. The total length of
all cable used in the system must not exceed 150
ft (45 m).
332458G
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 air
regulator/filter 17M842, and then 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 gun atomizing air.
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 for System Control Air: Use supplied
air regulator/filter 17M842 to provide clean and dry
air to system control solenoids.
• Air Line Filter for Atomizing Air: Provided by others
to filter oil and water out of the air supply and help
avoid paint contamination.
See Technical Data, page 51, for air filtration
requirements.
Figure 14 Atomizing Air and Air Manifold Connections
Key
24
Connection
Description
A
Air inlet
C
Air cutoff output
(plugged)
M
Exhaust muffler
S
Solvent cutoff output
(plugged)
332458G
Fluid Supply
Fluid Supply
Fluid Requirements
• 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.
• 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.
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:
• 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.
• For low pressure systems, ± 100 psi (0.7 MPa, 7
bar) of setpoint.
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.
332458G
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.
25
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).
Solvent Connections
3. Make the same connections on the catalyst side.
1. Connect the solvent supply line for the resin to
the inlet fitting (17) for solvent flow switch 1 (FS1).
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.
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 resin 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 15 Pump Inlet and Outlet Connections
26
Figure 16 Solvent Connections
332458G
Fluid Supply
Dual Panel Solvent Connections
1. Connect the solvent supply line for the resin for
Mix Unit #1 to the inlet fitting (17) for solvent flow
switch 1 (FS1).
2. Connect the solvent supply line for the catalyst
for Mix Unit #1 to the inlet fitting (17) for solvent
flow switch 2 (FS2).
3. Connect the solvent outlet line for the resin Mix
Unit #1 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
Mix Unit #2 to the solvent flow switch 2 (FS2)
outlet fitting (74) and then to the appropriate
remote color change valve.
5. Repeat steps 1–4 for Mix Unit #2 using solvent
flow switch 3 (FS3) and solvent flow switch
4 (FS4) for resin and catalyst supply lines,
respectively.
Figure 17 Dual Panel Solvent Connections
332458G
27
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.
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.
Figure 18 Install TSL Cup Kit
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.
28
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).
332458G
TSL Cup Kit
4. Repeat for the lower throat cartridge.
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.
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).
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: 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.
332458G
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.
29
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.
30
Alternate TSL Plumbing for
Highly--Reactive/Moisture
Reactive/Moisture--Sensitive
Highly
ISO Catalyst PD2K Pumps
NOTE: Graco recommends this alternate TSL (Throat
Seal Liquid) plumbing installation only on Catalyst
pumps, as the open rod guard of resin pumps does
not generate TSL displacement.
The alternate TSL plumbing of the Catalyst pump
allows TSL to flow through the upper seal and
bearing cartridge by using the rod guard and
lower-rod displacement. This flow purges isocyanateand moisture- contaminated TSL from the throat
area; preventing the crystallization reaction of the
isocyanate and moisture from accumulating and
damaging the pump seals, displacement rod, and
bearings.
1. Replace a plug (73d) with a barbed fitting (73b)
on a second port of the pump’s upper throat
cartridge (only one will be plugged). 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 third port is plugged (73d).
332458G
TSL Cup Kit
2. Connect the tubing (73c1) from the barbed fitting
(73b) on the lower throat cartridge to one of
the barbed fittings (73b) on the upper throat
cartridge.** Connect tubing (73c2) from the other
barbed fitting (73b) on the upper throat cartridge
to a TSL cup fitting.
Additional Maintenance and Precautions
The TSL fluid in the TSL reservoir must be replaced
more frequently when the alternate TSL plumbing
is used. This requirement prevents contaminated
TSL from accumulating in the reservoir, causing
fluid line contamination and increased pressure in
the TSL tubes due to thickening viscosity. The TSL
replacement frequency is determined by a number of
factors: Catalyst reactivity, temperature and humidity
of the pump environment, and seal wear condition.
In severe environmental conditions, the TSL can
require weekly replacement.
Another maintenance procedure that extends pump
life is bleeding the fresh TSL into the rod guard during
TSL replacement. This bleed process ensures that
all of the air is removed from the guard and bearing
cartridge, eliminating wet air contamination during
the TSL replacement process.
1. Remove and thoroughly clean the rod guard.
2. Refill the rod guard with fresh TSL.
3. Place the rod guard over the rod.
4. Fill the Reservoir, and let gravity fill the TSL lines.
5. Thread the guard back on to the pump when the
TSL begins to overflow the guard.
NOTICE
The rod guard displacement-flow volume through
the bearing and barb fittings of the upper cartridge
during high-cycle rates of the pump, or from filling
and the color change process, can create fluid
pressure in the TSL line between the pump’s lower
and upper cartridges. Route and anchor the TSL
lines to prevent equipment damage if the lines
develop leaks or separate from a barb fitting.
* No additional fittings or tubing are needed for
the alternate TSL plumbing if the barb fitting
(73b) from the TSL cup (73) and the second
plug (73d) from the throat cartridge are used by
swapping their positions.
332458G
NOTICE
The TSL lines are flexible, clear, and compatible
with TSL. These features make installation
much easier, and allow for visual feedback of
the TSL condition. The TSL tubing should be
replaced to prevent equipment damage from
tubing fluid compatibility failure if the lines become
contaminated with catalyst material for extended
periods of time.
31
Solvent Meter Accessory
Solvent Meter Accessory
Light Tower Accessory
To install Solvent Meter Kit 280555, see manual
308778.
To install Light Tower Kit 24K337, see manual
3A1906.
NOTE: Install the solvent meter downstream of the
solvent cutoff switch near the base unit.
32
332458G
Electrical Supply
Electrical Supply
Electrical Connections
See Electrical Schematics, page 37.
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
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.
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.
6. Follow instructions in Grounding, page 35.
Wire Key
Wire
Description
L
Line Power
N
Neutral
G
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.
Figure 19 Control Box Electrical Connection
332458G
33
Electrical Supply
Field Bus Connections
If used, connect the ethernet cable to the CGM as
applicable. Connect the other end of the cable to the
FieldBus device.
NOTE: Connect the CGM 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.
1. Locate fitting (F) on the Electrical Control Box.
2. Remove the nut on fitting (F).
3. Remove the fitting far enough to allow
disassembly of the fitting and to open the
grommet.
4. Route FieldBus cable (EC) through the left
wireway up to the grommet. 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 fitting.
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.
8. Attach the FieldBus cable to the CGM.
34
332458G
Grounding
Grounding
See illustration on next page.
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.
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.
Air and Fluid Hoses
Use grounded hoses only.
Object Being Sprayed
Electrical Control Box
Follow local code.
The electrical control box has two ground points.
Both connections must be made.
Solvent Reservoir or Purge Station
• 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 33.
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
To ensure proper grounding and reduce risk of fire
and explosion, resistance between components
and true earth ground must be less than 1 ohm.
Spray Gun
Figure 20 Ground Screw and Power Switch
Fluid Supply Container
Follow local code.
Color Change Module
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.
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.
332458G
35
Grounding
HAZARDOUS LOCATION
NON--HAZARDOUS LOCATION
NON
Figure 21 System Grounding
Key
1
Electrical Control Box ground screw
2
Electrical Control Box ground wire
3
Color Change Module (CC) ground
wires
4
36
Intrinsically Safe (IS) cable
5
True Earth Ground; check local code
for requirements
6
Non-Intrinsically Safe cable
7
Remote Mix Control Module ground
wire
332458G
Electrical Schematics
Electrical Schematics
Standard Models (AC1000, AC2000, AC3000, AC4000)
NOTE: The electrical schematic illustrates all possible
wiring expansions in a ProMix PD2K system; models
AC1000 and AC2000. Some components shown are
not included with all systems.
NOTE: See Optional Cables and Modules, page 49 for
a list of cable options.
CABLE
16H078
AWI
GATEWAY
(24R910)
2
CABLE
(15V206)
CABLE
(15V206)
2
CATALYST CHANGE
MODULE 6
6
(24N935)
CATALYST CHANGE
MODULE 5
6
(24N935)
COLOR CHANGE
MODULE 4
6
(24N935)
COLOR CHANGE
MODULE 3
6
(24N935)
2
CABLE
(15V206)
MAC SERIES 46
SOLENOID
(16P812)
PUMP V/P FOR
FLUID REG.
UP
DOWN
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
PUMP V/P FOR
FLUID REG.
MAC SERIES 46
SOLENOID
(16P812)
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
BREAKOUT MODULE PUMP 3
(24N527)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
UP
DOWN
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
SOLVENT METER (258718)
1
CABLE (16V429)
LIGHT
TOWER
(15X472)
COLOR CH
ANGE MODULE 7
(24R219)
7
1
CABLE
(16T280)
CABLE (16T659)
CABLE (16T659)
CABLE (16T659)
CABLE (16T659)
SOLVENT
FLOW
INPUTS
SAFETYINTERLOCK SWITC
H
1 CABLE
(16V426)
FAN
(24P658)
ENCODERAND MOT
OR
(16P036, 16P037)
WIRE HARNESS
(24P684, 24P685)
SWITCH (120278)
3
ADVANCED
CABLE
DISPLAY MODULE
(121003)
(24E451)
4
GFB
INTERF
ACES
SOLVENTCUTOFF (121324)
SWITCH (120278)
FLOW RATE ANALOG IN
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
FAN
(24P658)
ENCODER AND MOT
OR
(16P036, 16P037)
WIRE HARNESS
(24P684, 24P685)
UP
DOWN
BARRIER
BOARD
(248192)
PRESSURE SW (121323)
GCA
MODULE
EFCM
(24N913)
FLOW RATE ANALOG IN
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
PUMP V/P FOR
FLUID REG.
SPLITTER
(16P243)
SOLENOID (121324)
FLOW RATE ANALOG IN
UP
DOWN
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
BREAKOUT MODULE PUMP 2
(24N527)
MAC SERIES 46
SOLENOID
(16P812)
PUMP V/P FOR
FLUID REG.
PUMP INLET
TRANSDUCER
(16P289, 16P290)
COLOR CH
ANGE MODULE 8
(24R219)
7
BOOTH CO
NTROL(24M731)
BREAKOUT MODULE PUMP 4
(24N527)
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
ENCODERAND MOT
OR
(16P036, 16P037)
WIRE HARNESS
(24P684, 24P685)
MAC SERIES 46
SOLENOID
(16P812)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
FAN
(24P658)
BREAKOUT MODULE PUMP 1
(24N527)
ENCODER AND MOT
OR
(16P036, 16P037)
WIRE HARNESS
(24P684, 24P685)
119159
119159
119159
119159
16T072
CAN
IS BOARD
(24M485)
FAN
(24P658)
GUNTRIGGER INPUTS
CABLE
(16V426)
16W159
16W159
POWER IN
16W159
16W159
TERMINAL
BLOCKS WITH FUSES
FLOW RATE ANALOG IN
TERMINAL BLOCK
(114095)
3 CABLE
(121227)
2
5
COLOR CHANGE
MODULE 2
6
(24N935)
48V-10APOWER SUPPLY
(16U820)
3 CABLE
(121001)
3
CABLE
(121227)
LINEFILTER
(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
RELAY
2 POSITION
SWITCH
(16U725)
HAZARDOUS LOCATION
NON-HAZARDOUS LOCATION
Figure 22 Electrical Schematic, Sheet 1
332458G
37
Electrical Schematics
CONTINUED ON P
AGE 3
CONTINUED ON P
AGE 3
UNUSED
UNUSED
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
(NONIS)
(IS)
4
CABLE
1
2
3
4
5
1
2
3
4
5
(121227)
P3
P4
5
12345
1
2
3
UNUSED
54 3 2 1
SOLVENT CUTOFF (121324)
PWR (RED)
SIG (WHITE)
COM(BLACK)
SHIELD/GRN
SOLVENT
UNUSED
BARRIER
BOARD
(248192)
+24VDC
COM
UNUSED
UNUSED
+24VDC
COM
+24VDC
COM
UNUSED
1
RED WIRE (06
5161)
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
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)
UNUSED
UNUSED
CABLE
(16T280)
GFB INTERFACE
(121324)
123
UNUSED
UNUSED
GCAMODULE
EFCM
(24N913)
3
3
(24M485)
12345
SPLITTER
(16P243)
(121001)
INTEGR
ATION
GATEWAY
3
5
1
CABLE
1
2
3
4
5
4
25 PIN D-SUB CABLE
(16T659)
BLAC
K 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 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
1
3
2
12345
1234
4
BREAK
OUT MODULE PUMP 2 (24N527)
7
6
5
12345
12345
1234
13 A1(+) A2(-)
8
12 34
12 34
5678
7
6
5
12345
1234
12 3 4
8
12 34
5678
+24VDC
COM
+24VDC
COM
PUMP 2
UP
PUMP 2
DOWN
MANIFOLD
MAC SERIES 46
(16P812 QTY 2)
+-+-+-+-
LINE
FILTER
(16V446)
V/P FOR FLUID REG.
PUMP 2
OUTLET TRANSDUCER
PUMP 2
(16P289 OR 16P290)
SEE DET
AILAOR B
INLET TRANSDUCER
PUMP 2
(16P289 OR 16P290)
FAN PUMP 1
(24P658)
PWR (RED)
SIG (WHITE)
COM(BLACK)
SHIELD/GRN
+24VDC
COM
+24VDC
COM
PUMP 1
UP
ENCODER/MO
TOR
AND
WIRE HARN
ESS
PUMP2
MANIF
OLD
MAC SERIES 46
(16P812 QTY 2)
F2
F1
F4
N
F3
+-+-+-+-
POWER MODULE
(24R257)
N04
4
12345
PUMP 1
DOWN
SEE DET
AILAOR B
V/P FOR FLUID REG.
PUMP 1
+ -
CABLE
(16T658)
L
ENCODER/MOT
OR
AND
WIRE HARN
ESS
PUMP1
N03
2 POSITION
SWITCH
(16U725)
N04
INLET TRANSDUCER
PUMP 1
(16P289 OR 16P290)
N (BLUE)
L (BROWN)
N03
GRND
48V-10A
POWER SUPPLY
(16U820)
OUTLET TRANSDUCER
PUMP 1
(16P289 OR 16P290)
14
N L
3
1234
+48V
COM
+48V
COM
RELAY
2
12345
+48V
COM
+48V
COM
BREAK
OUT MODULE PUMP 1 (24N527)
GRND (GRN/YEL)
PWR (RED)
SIG (WHITE)
COM(BLACK)
SHIELD/GRN
2
P4
P3
16T072
12345
1
1
2
3
4
5
FAN PUMP 2
(24P658)
CABLE (121227)
CABLE
(15V206)
CABLE (16V429)
2
UNUSED
3
G3000
METER
PUMP 1
(EITHER, 239716,
258718,16M510,
OR 16M519)
GRND
SCREW
TWIST
ED PAIR CABLE (16W159)
G3000
METER
PUMP 2
(EITHER, 239716,
258718,16M510,
OR 16M519)
GRND
SCREW
TWIST
ED PAIR CABLE (16W159)
L GRND N
MOTOR
MOUNTING
SCREW
1 2 3 4 5 6 78 9
1011 12
WIRE HARN
ESS
(24P685)
1 2 3 4 5 6 78 9
12
10
PUMP ENCODER AND MOTOR
(16P037)
1 2 3 4 5 67 8 9
MOTOR
MOUNTING
SCREW
1011 12
UNUSED
UNUSED
UNUSED
DRAIN/FOIL
UNUSED
DRAIN/FOIL
UNUSED
UNUSED
DRAIN/FOIL
UNUSED
UNUSED
UNUSED
UNUSED
DRAIN/FOIL
DRAIN/FOIL
MOTOR
GROUND
SCREW
UNUSED
UNUSED
UNUSED
UNUSED
WIRE HARN
ESS
(24P684)
L N GRND
3
1234
1 2 3 4 5 67 8 9
UNUSED
UNUSED
12345
1234
UNUSED
UNUSED
12345
BREAKOUT MODULE
(24N527)
2
3
UNUSED
UNUSED
UNUSED
2
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
BREAKOUT MODULE
(24N527)
TERMINAL
BLOCK
(114095)
UNUSED
L N GRND
POWER IN
DETAIL B, HIGH PRESSURE PUMPS
(24M707, 24M71
5, 24T800)
DETAILA, LOW PRESSURE PUMPS
(24M706, 24M714, 24T799)
UNUSED
CABLE
(16H078)
10
PUMP ENCODER AND MOTOR
(16P036)
Figure 23 Electrical Schematic, Sheet 2, Part 1
CONTINUED ON THE NEXT PAGE
38
332458G
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 24 Electrical Schematic, Sheet 2, Part 2
CONTINUED ON THE NEXT PAGE
332458G
39
Electrical Schematics
FROMCAN IS BOARD (24M485)
2 CABLE(15V206)
12 34 5
COLOR
CHANGE
MODULE 1
(COLORS
1 THRU 8)
MANIFOLD
FLUSH
COLOR1
COLOR2
COLOR3
COLOR4
COLOR5
COLOR6
COLOR7
COLOR8
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3
4
5
6
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3
4
5
6
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3
4
5
6
J8
MANIFOLD
J9
6
5
4
3
2
1
COM
+24VDC
COM
+24VDC
COM
+24VDC
J16
6
5
4
3
2
1
COM
+24VDC
COM
+24VDC
COM
+24VDC
J10
6
5
4
3
2
1
COM
+24VDC
COM
+24VDC
COM
+24VDC
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)
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3
4
5
6
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3 J15
4
5
6
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3
4
5
6
J9
J8
6
J16
J14
MANIFOLD
MANIFOLD
J10
6
5
4
3
2
1
COM
+24VDC
COM
+24VDC
COM
+24VDC
6
5
4
3
2
1
COM
+24VDC
COM
+24VDC
COM
+24VDC
6
5
4
3
2
1
COM
+24VDC
COM
+24VDC
COM
+24VDC
DUMP*
FLUSH
COLOR9
CATALYST 1
COLOR10
CATALYST 2
COLOR11
CATALYST 3
COLOR12
CATALYST 4
COLOR13
COLOR14
COLOR15
COLOR16
CATALYST
CHANGE
MODULE 5
(CATALYST
1 THRU 4)
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3
4
5
6
+24VDC
COM
+24VDC
COM
UNUSED
UNUSED
1
2
3
4
5
6
J15
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
J14
J8
COLOR17
COLOR18
COLOR19
COLOR20
COLOR21
COLOR22
COLOR23
COLOR24
12 34 5
COLOR
CHANGE
MODULE 3
(COLORS
17 THRU 24)
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3
4
5
6
J8
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3
4
5
6
J15
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3
4
5
6
J14
J9
6
J16
6
5
4
3
2
1
COM
+24VDC
COM
+24VDC
UNUSED
UNUSED
J10
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
DUMP
CATALYST 1
CATALYST 2
CATALYST 3
CATALYST 4
12 34 5
2
CABLE
(15V206)
2
CABLE
MANIFOLD
J9
COM
+24VDC
COM
+24VDC
COM
+24VDC
6
12 34 5
*FLUSH
MANIFOLD
6
5
4
3
2
1
MANIFOLD
MANIFOLD
6
5
4
3
2
1
COM
+24VDC
COM
+24VDC
COM
+24VDC
6
5
COM
+24VDC
COM
+24VDC
COM
+24VDC
J16 43
2
1
6
5
4
J10 3
2
1
COM
+24VDC
COM
+24VDC
COM
+24VDC
*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)
+24VDC
COM
+24VDC
COM
+12VDC
COM
1
2
3
4
5
6
J8
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3
4
5
6
J15
+24VDC
COM
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
J14
J9
6
J16
J10
MANIFOLD
6
5
4
3
2
1
COM
+24VDC
COM
+24VDC
COM
+24VDC
6
5
4
3
2
1
COM
+24VDC
COM
+24VDC
COM
+24VDC
6
5
4
3
2
1
COM
+24VDC
UNUSED
UNUSED
UNUSED
UNUSED
DUMP*
COLOR25
COLOR26
COLOR27
COLOR28
COLOR29
COLOR30
12 34 5
2
CABLE(15V206)
Figure 25 Electrical Schematic, Sheet 3
* May be unused in some configurations.
CONTINUED ON THE NEXT PAGE
40
332458G
Electrical Schematics
CATALYST
CHANGE
MODULE 6
(CATALYST
3 THRU 4)
MANIFOLD
FLUSH
CATALYST 3
CATALYST 4
+24VDC
COM
+24VDC
COM
+24VDC
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
+24VDC
COM
+24VDC
COM
+24VDC
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
+24VDC
COM
+24VDC
COM
+24VDC
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
CHANGE
MODULE 5
(CATALYST
1 THRU 2)
+24VDC
COM
+24VDC
COM
+24VDC
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
CHANGE
MODULE 4
(COLORS
25 THRU 32
)
ALTERNATE CONFIGURATION
FOR CATALYST CHANGE CONTROL
Figure 26 Electrical Schematic, Sheet 3, Alternate
Configuration for Catalyst Change Control
CONTINUED ON THE NEXT PAGE
332458G
41
Electrical Schematics
FROMCAN IS BOARD (24M485)
NON-HAZARDOUS LOCATION
HAZARDOUS LOCATION
MANIFOLD
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
CHANG
E
MODULE 7
(COLORS
33 THRU 40)
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
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
MANIFOLD
COLOR 13
COLOR 14
COLOR 15
COLOR 16
COLOR 17
COLOR 18
COLOR 19
COLOR 20
COLOR 21
12 34 5
COLOR
CHANG
E
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
MANIFOLD
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
J9
7
J14
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 2 1
BOOTH CONTROL
(24M731)
Figure 27 Electrical Schematic, Sheet 3, Hazardous
Location
42
332458G
Electrical Schematics
Dual Panel Models (AC1002, AC2002, AC3002, AC4002)
NOTE:The electrical schematic illustrates all possible
NOTE:
wiring expansions in a ProMix PD2K system; models
AC1002 and AC2002. Some components shown are
not included with all systems.
NOTE: See Optional Cables and Modules, page 49 for
a list of cable options.
CABLE
16H078
16W159
CABLE 126232
OR 17N315
SOLVENT
METER 1
(258718)
MAC SERIES 46
SOLENOID
(16P812)
PUMPV/PFOR
FLUID REG.
UP
DOWN
FLOW SENSOR
(120278)
OR G3000 ME
TER
(239716, 258718
16M510, 16M519)
ENCODERAND MOT
OR
(16P036, 16P037)
WIRE HARNESS
(24P684, 24P685)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
PUMPV/PFOR
FLUID REG.
MAC SERIES 46
SOLENOID
(16P812)
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
BREAKOUT MODULE PUMP 3
(24N527)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
CABLE
(16T280)
SPLITTER
(16P243)
GCA
MODUL
E
EFCM
(24N913)
17L058
BARRIER
BOARD
(248192)
UP
DOWN
FLOW SENSOR
(120278)
OR G3000 ME
TER
(239716, 258718
16M510, 16M519)
CATALYST CHANGE
MODULE 6
6
(24N935)
CATALYST CHANGE
MODULE 5
6
(24N935)
COLOR CHANGE
MODULE 4
6
(24N935)
GFBPRESS. SW. 1 (121323)
GFBPRESS. SW. 2 (121323)
AIR
CONTROL
MODULE
(26A231)
SOLVENT CUTOFF VALVE (121324)
SOLVENT CUTOFF VALVE (121324)
SWITCH (120278)
SOLVENT
FLOW
INPUTS
SWITCH (120278)
SWITCH (120278)
SWITCH (120278)
SAFETY INTERLOCK SWITCH
CABLE
(121003) 3
ADV
ANCED DISPLA
Y MODULE
(24E451)
COLOR CHANGE
MODULE 7
(24R219)
7
COLOR CHANGE
MODULE 8
(24R219)
7
4 CABLE (16T659)
FAN
(24P658)
CABLE
(15V206)
GFBVALVE 1 (121324)
GFBVALVE 2 (121324)
SOLVENT
METER 2
(258718)
FAN
(24P658)
ENCODERAND MOT
OR
(16P036, 16P037)
WIRE HARNESS
(24P684, 24P685)
UP
DOWN
2
AIR FLOW SW. 2 (119159)
PLC DISCRETE 1 (4-20mA)
UP
DOWN
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
BREAKOUT MODULE PUMP 4
(24N527)
MAC SERIES 46
SOLENOID
(16P812)
CABLE 126232
OR 17N315
PUMP INLET
TRANSDUCER
(16P289, 16P290)
BREAKOUT MODULE PUMP 2
(24N527)
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
ENCODERAND MOT
OR
(16P036, 16P037)
WIRE HARNESS
(24P684, 24P685)
MAC SERIES 46
SOLENOID
(16P812)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
FAN
(24P658)
BREAKOUT MODULE PUMP 1
(24N527)
ENCODERAND MOT
OR
(16P036, 16P037)
WIRE HARNESS
(24P684, 24P685)
CABLE
(15V206)
CABLE
15V819
16T072
CAN
IS BOARD
(24M485)
FAN
(24P658)
2
AIR FLOW SW. 1 (119159)
PLC DISCRETE 2 (4-20mA)
16W159
16W159
16W159
TERMINAL BLOCK WITH FUSES
POWER IN
CABLE
(15V206)
3 CABLE
(121227)
TERMINAL
BLOCK
(114095)
2
5
RELAY 2
2
RELAY 1
AWI
GATEWAY
(24R910)
COLOR CHANGE
MODULE 3
6
(24N935)
LINE FIL
TER
(16V446)
3 CABLE
(121001)
CABLE (15V206)
48V-10APOWER SUPPLY
(16U820)
3
CABLE
(121227)
5
24V
POWER
SUPPLY
(16T660)
COLOR CHANGE
MODULE 2
6
(24N935)
COLOR CHANGE
MODULE 1
6
(24N935)
INTEGRA
TION
GATEWAY
2 POSITION
SWITCH
(16U725)
CABLE
16T658
2 CABLE
(15V206)
2 CABLE
(15V206)
POWERMODULE
(26A189)
1
CABLE (16V429)
LIGHT
TOWER
(15X472)
1
BOOTHCONTROL
(24M731)
CABLE
(16V426) WITH SHUNT
(17M540)
1
CABLE
(16V426)
BOOTH
CONTROL
(24M731)
HAZARDOUS LOCA
TION
NON-HAZARDOUS LOCA
TION
Figure 28 Electrical Schematic, Sheet 1
332458G
43
Electrical Schematics
UNUSED
UNUSED
2
UNUSED
CABLE
(15V206)
3
CABLE (121227)
1
2
3
4
5
CANIS BOARD
2
(NON IS)
(IS)
4
SPLITTER
(17L058)
SPLITTER
(16P243)
UNUSED
3
1
2
3
4
5
P4
(121001)
INTEGRA
TION
GATEWAY
5
1
2
3
4
5
8
3
1
2
3
+24VDC
COM
+24VDC
SOLVENTCUTOFF VALVE 2 (121324)
COM
GREEN/BLACK +24VDC
ORANGE/BLACK COM
GFBOUTPUT VALVE 1
BLUE/BLACK +24VDC
RED/WHITE COM
GFBOUTPUT VALVE 2
UNUSED
SIG
SAFETYINTERLOCK SWITCH
COM
UNUSED
J5
J4
1
2
3
4
5
6
7
8
9
10
11
12
6
1
2
3
4
5
6
7
8
9
10
11
12
7
1
2
3
4
5
6
7
8
9
10
11
12
9
1
2
3
4
5
GCAMODULE
EFCM
(24N913)
5
SOLVENTCUTOFF VALVE 1 (121324)
123
5
1
4
3
2
BARRI
ER
BOARD
(248192)
UNUSED
54 3 2 1
UNUSED
UNUSED
(121227)
P3
10
12345
CABLE
(16T280)
1
1
2
3
4
5
1
2
3
4
5
CABLE
3
(24M485)
12345
1
2
3
4
5
AWI
GATEWAY
(24R910)
1
UNUSED
UNUSED
2X CABLE (16V429)
16T072
12345
12345
1
2
3
4
5
P4
P3
CABLE
5
4
3
2
1
25 PIN D-SUB
CABLE(16T659)
4
GROUND
BAR
24V
POWER
SUPPLY
(16T660)
1
BREAKOUT
MODULEUMP
P 1 (24N527)
3
2
12345
1234
4
7
6
5
1 2 3 45
12345
1234
1
BREAKOUT
MODULE PUMP 2 (24N527)
12 34
8
12 34
5678
3
2
12345
1234
4
12345
7
6
5
12345
1234
12 34
8
12 34
5678
BLACK
RED
RED
+48V
COM
+48V
COM
RED
BLACK
RED
BLACK
FAN PUMP 2
(24P658)
RED
PWR
WHITE
SIG
BLACK
COM
GRN SHIELD
PUMP2
MANIFOLD
SOLVENT
METER1
(258718)
GND
SCREW
BLACK
RED
BLACK
N
LINE
FILTER
(16V446)
+24VDC
COM
+24VDC
COM
UP
PUMP1
MANIF
OLD
DOWN
OUTLET
TRANSDUCER
PUMP 2
(16P289 OR 16P290)
INLET
TRANSDUCER
PUMP 2
(16P289 OR 16P290)
RED
BLACK
RED
BLACK
FAN PUMP 1
(24P658)
+24VDC
COM
+24VDC
COM
SEE DET
AILAOR B
CABLE (126232 OR 17N315)
RED
L
CABLE (126232 OR 17N315)
+ - + - +- + 4 3 2 1
BLACK
CABLE
(16T658)
WHITE
BLACK
N04 N04
BROWN (UNUSED)
DRAIN (UNUSED)
BLUE
BLACK
ENCODER/MOT
OR
AND
WIRE HARNESS
PUMP2
MAC SERIES 46
(16P812 QTY 2)
2 POSITION
SWITCH
(16U725)
15 RELA
Y
A1
1
18
A2
RED
PWR
WHITE
SIG
BLACK
COM
GRN SHIELD
POWER MODULE
(26A189)
N (BLUE)
L (BROWN)
N03 N03
15 RELA
Y
A1
2
18
A2
BROWN (UNUSED)
DRAIN (UNUSED)
BLUE
BLACK
UP
SEE DET
AILAOR B
--++
DOWN
ENCODER/MOT
OR
AND
WIRE HARNESS
PUMP1
MAC SERIES 46
(16P812 QTY 2)
GRND
48V-10A
POWER SUPPLY
(16U280)
OUTLET
TRANSDUCER
PUMP 1
(16P289 OR 16P290)
N L
INLET
TRANSDUCER
PUMP 1
(16P289 OR 16P290)
+48V
COM
+48V
COM
GRND (GRN/YEL)
SOLVENT
METER2
(258718)
GND
SCREW
TWISTED PAIR CABLE (16W159)
TWISTEDPAIR CABLE (16W159)
MOTOR
GROUND
SCREW
MOTOR
MOUNTING
SCREW
123456789
12
10
PUMP ENCODER AND MOTOR
(16P037)
1 2 3 4 5 67 8 9
MOTOR
MOUNTING
SCREW
1011 12
UNUSED
UNUSED
UNUSED
DRAIN/FOIL
UNUSED
UNUSED
DRAIN/FOIL
1011 12
UNUSED
UNUSED
1 2 34 5 6 7 8 9
DRAIN/FOIL
UNUSED
UNUSED
UNUSED
UNUSED
DRAIN/FOIL
DRAIN/FOIL
L N GND
3
1234
WIRE HARNESS
(24P685)
123456789
UNUSED
UNUSED
12345
1234
WIRE HARNESS
(24P684)
UNUSED
UNUSED
1 2 34 5
BREAKOUT
MODULE
(24N527)
2
3
UNUSED
UNUSED
UNUSED
2
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
BREAKOUT
MODULE
(24N527)
TERMI
NAL
BLOCK
(114095)
UNUSED
L N GND
POWER IN
DETAIL B, HIGH PRESSURE PUMPS
(24M707, 24M715, 24T800)
DETAILA, LOW PRESSURE PUMPS
(24M706, 24M714, 24T799)
UNUSED
UNUSED
UNUSED
UNUSED
CABLE
(16H078)
WHITE
GRN
BLACK
L GND N
10
PUMP ENCODER AND MOTOR
(16P036)
Figure 29 Electrical Schematic, Sheet 2, Part 1
CONTINUED ON THE NEXT PAGE
44
332458G
Electrical Schematics
8
GCAMODULE
EFCM
(24N913)
7
SIG
COM
SIG
COM
SIG
COM
SIG
COM
SIG
COM
SIG
COM
1
2
3
4
5
6
7
8
9
10
11
12
PLC DISCRETE 4-20mAINPUT 1
PLC DISCRETE 4-20mACOMMON 1
PLC DISCRETE 4-20mAINPUT 2
PLC DISCRETE 4-20mACOMMON 2
UNUSED
UNUSED
UNUSED
UNUSED
SIG
ORANGE
COM BLUE
SIG
WHITE/BLACK
COM RED/BLACK
5
9
1
2
3
4
AIR FLOW SWITCH 1
1
2
3
4
5
6
7
8
9
10
11
12
1
2
3
4
5
BLACK
WHITE
RED
GREEN
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
TERMINAL
BLOCKS
GFB INPUT PRESSURE SWITCH 1
1
2
3
4
5
1
2
3
4
5
ADVANCED
DISPLAY MODULE
(24E451)
1
2
3
4
5
6
7
8
9
10
11
12
BLAC
K
WHITE
RED
GREEN
ORANGE
BLUE
WHITE/BLACK
RED/BLACK
GREEN/BLACK
ORANGE/BLACK
BLUE/BLACK
RED/WHITE
CABLE
15V819
GFB INPUT PRESSURE SWITCH 2
CABLE
(121003)
AIR CONTROL MODULE (26A231)
SOLVENT FLOW SW. 4 (120278) RIGHT BRKT
LIGHT
TOWER
(15X472)
+ SIG
- COM
+ SIG
- COM
+ SIG
- COM
+ SIG
- COM
+ 24VDC
- COM
+ 24VDC
- COM
AIR FLOW SWITCH 1
119159
AIR FLOW SWITCH 2
119159
GFB INPUT PRESSURE SWITCH 1
121323
GFB INPUT PRESSURE SWITCH 2
121323
RED
BLAC
K
RED
BLAC
K
GFB OUTPUT VALVE 1
121324
GFB OUTPUT VALVE 2
121324
3
25 PIN D-SUB
CABLE (16T659)
1
2
1234
1
BREAKOUT MODULE PUMP 3 (24N527)
4
12345
12345
7
6
5
1234
12 34
8
12 34
5678
2
3
12345
1234
BREAKOUT MODULE PUMP 4 (24N527)
4
12345
5
12345
7
6
1234
12 34
8
12 34
5678
RED
PWR
WHITE
SIG
BLACK
COM
GRN SHIELD
DOWN
V/P FOR FLUID REG.
PUMP 4
UP
PUMP 4
MANIFOLD
PUMP 3
MANIFOLD
G3000
METER
PUMP 3
MAC SERIES 46
(16P812 QTY 2)
MAC SERIES 46
(16P812 QTY 2)
+24VDC
COM
+24VDC
COM
OUTLET
TRANSDUCER
PUMP 4
(16P289 OR 16P290)
INLET
TRANSDUCER
PUMP 4
(16P289 OR 16P290)
RED
BLACK
RED
BLACK
ENCODER/M
OTOR
AND
WIRE HARNESS
PUMP 4
SEE DET
AILAOR B
FAN PUMP 3
(24P658)
RED
PWR
WHITE
SIG
BLACK
COM
GRN SHIELD
DOWN
V/P FOR FLUID REG.
PUMP 3
+24VDC
COM
+24VDC
COM
UP
OUTLET
TRANSDUCER
PUMP 3
(16P289 OR 16P290)
ENCODER/M
OTOR
AND
WIRE HARNESS
PUMP 3
SEE DET
AILAOR B
INLET
TRANSDUCER
PUMP 3
(16P289 OR 16P290)
+48V
COM
+48V
COM
12345
3
4
+48V
COM
+48V
COM
6
RED
BLACK
RED
BLACK
1
2
3
4
5
6
7
8
9
10
11
12
10
FAN PUMP 4
(24P658)
5
4
3
2
1
1
2
3
4
5
(EITHER, 239716,
258718,16M510,
OR 16M519)
GND
SCREW
G3000
METER
PUMP 4
(EITHER, 239716,
258718,16M510,
OR 16M519)
GND
SCREW
TWISTED PAIR CABLE (16W159)
TWISTED PAIR CABLE (16W159)
Figure 30 Electrical Schematic, Sheet 2, Part 2
CONTINUED ON THE NEXT PAGE
332458G
45
Electrical Schematics
FROMCAN IS BOARD (24M485)
2 CABLE(15V206)
12 34 5
COLOR
CHANGE
MODULE 1
(COLORS
1 THRU 8)
MAN
IFOLD
FLUSH
COLOR 1
COLOR 2
COLOR 3
COLOR 4
COLOR 5
COLOR 6
COLOR 7
COLOR 8
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3
4
5
6
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3
4
5
6
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3
4
5
6
J8
MAN
IFOLD
J9
6
5
4
3
2
1
COM
+24VDC
COM
+24VDC
COM
+24VDC
J16
6
5
4
3
2
1
COM
+24VDC
COM
+24VDC
COM
+24VDC
J10
6
5
4
3
2
1
COM
+24VDC
COM
+24VDC
COM
+24VDC
6
J15
J14
DUMP
COLOR 1
COLOR 2
COLOR 3
COLOR 4
COLOR 5
COLOR 6
COLOR 7
COLOR 8
MAN
IFOLD
*FLUSH
COLOR 9
COLOR 10
COLOR 11
COLOR 12
COLOR 13
COLOR 14
COLOR 15
COLOR 16
12 34 5
COLOR
CHANGE
MODULE 2
(COLORS
9 THRU 16)
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3
4
5
6
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3 J15
4
5
6
J16
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3
4
5
6
J10
J9
J8
6
J14
MAN
IFOLD
MAN
IFOLD
6
5
4
3
2
1
COM
+24VDC
COM
+24VDC
COM
+24VDC
6
5
4
3
2
1
COM
+24VDC
COM
+24VDC
COM
+24VDC
6
5
4
3
2
1
COM
+24VDC
COM
+24VDC
COM
+24VDC
DUMP*
FLUSH
COLOR 9
CATALYST 1
COLOR 10
CATALYST 2
COLOR 11
CATALYST 3
COLOR 12
CATALYST 4
COLOR 13
COLOR 14
COLOR 15
COLOR 16
CATALYST
CHANGE
MODULE 5
(CATALYST
1 THRU 4)
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3
4
5
6
+24VDC
COM
+24VDC
COM
UNUSED
UNUSED
1
2
3
4
5
6
J15
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
J14
J8
COLOR 17
COLOR 18
COLOR 19
COLOR 20
COLOR 21
COLOR 22
COLOR 23
COLOR 24
12 34 5
COLOR
CHANGE
MODULE 3
(COLORS
17 THRU 24)
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3
4
5
6
J8
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3
4
5
6
J15
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3
4
5
6
J14
J9
6
J16
6
5
4
3
2
1
COM
+24VDC
COM
+24VDC
UNUSED
UNUSED
J10
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
DUMP
CATALYST 1
CATALYST 2
CATALYST 3
CATALYST 4
12 34 5
2
CABLE
(15V206)
2
CABLE
MAN
IFOLD
J9
COM
+24VDC
COM
+24VDC
COM
+12VDC
6
12 34 5
*FLUSH
MAN
IFOLD
6
5
4
3
2
1
MAN
IFOLD
MAN
IFOLD
6
5
4
3
2
1
COM
+24VDC
COM
+24VDC
COM
+24VDC
6
5
COM
+24VDC
COM
+24VDC
COM
+24VDC
J16 43
2
1
6
5
4
J10 3
2
1
COM
+24VDC
COM
+24VDC
COM
+24VDC
*FLUSH
DUMP*
COLOR 17
COLOR 25
COLOR 18
COLOR 26
COLOR 19
COLOR 27
COLOR 20
COLOR 28
COLOR 21
COLOR 29
COLOR 22
COLOR 30
COLOR 23
COLOR 24
54 3 2 1
(15V206)
2
CABLE
(15V206)
12 34 5
12 34 5
COLOR
CHANGE
MODULE 4
(COLORS
25 THRU 32)
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3
4
5
6
J8
+24VDC
COM
+24VDC
COM
+24VDC
COM
1
2
3
4
5
6
J15
+24VDC
COM
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
J14
J9
6
J16
J10
MAN
IFOLD
6
5
4
3
2
1
COM
+24VDC
COM
+24VDC
COM
+24VDC
6
5
4
3
2
1
COM
+24VDC
COM
+24VDC
COM
+24VDC
6
5
4
3
2
1
COM
+24VDC
UNUSED
UNUSED
UNUSED
UNUSED
DUMP*
COLOR 25
COLOR 26
COLOR 27
COLOR 28
COLOR 29
COLOR 30
12 34 5
2
CABLE(15V206)
Figure 31 Electrical Schematic, Sheet 3, Part 1
* May be unused in some configurations.
CONTINUED ON THE NEXT PAGE
46
332458G
Electrical Schematics
FROMCAN IS BOARD (24M485)
1
CABLE (16V429)
NON-HAZARDOUS LOCATION
HAZARDOUS LOCATION
MANIFOLD
COLOR FLUSH
COLOR 1
COLOR 2
COLOR 3
COLOR 4
COLOR 5
COLOR 6
COLOR 7
COLOR 8
RED
+12VDC
BLACK COM
RED
+12VDC
BLACK COM
RED
+12VDC
BLACK COM
1
2
3
4
5
6
RED
+12VDC
BLACK COM
RED
+12VDC
BLACK COM
RED
+12VDC
BLACK COM
1
2
3
4
5
6
RED
+12VDC
BLACK COM
RED
+12VDC
BLACK COM
RED
+12VDC
BLACK COM
1
2
3
4
5
6
12 34 5
COLOR
CHANGE
MODULE 7
(COLORS
6
33 THRU 40) 5
4
J9 3
J8
2
1
7
J15
J16
J14
J10
MANIFOLD
COM BLACK
+12VDC
RED
COM BLACK
+12VDC
RED
COM BLACK
+12VDC
RED
CATALYST FLUSH
6
5
4
3
2
1
COM BLACK
+12VDC
RED
COM BLACK
+12VDC
RED
COM BLACK
+12VDC
RED
CATALYST 3
6
5
4
3
2
1
COM BLACK
+12VDC
RED
COM BLACK
+12VDC
RED
COM BLACK
+12VDC
RED
CATALYST 1
CATALYST 2
CATALYST 4
COLOR 9
COLOR 10
COLOR 11
COLOR 12
1
CABLE
(16V426)
54 32 1
54 32 1
BOOTH CONTROL
(24M731)
WITH SHUNT
(17M540)
MANIFOLD
COLOR 13
COLOR 14
17M540
COLOR 15
COLOR 16
COLOR 17
12 34 5
J1
COLOR 18
COLOR 19
COLOR 20
COLOR 21
RED
+12VDC
BLACK
COM
RED
+12VDC
BLACK
COM
RED
+12VDC
BLACK
COM
1
2
3
4
5
6
RED
+12VDC
BLACK
COM
RED
+12VDC
BLACK
COM
RED
+12VDC
BLACK
COM
1
2
3
4
5
6
RED
+12VDC
BLACK
COM
RED
+12VDC
BLACK
COM
RED
+12VDC
BLACK
COM
1
2
3
4
5
6
12 34 5
COLOR
CHANGE
MODULE 8
(COLORS
41 THRU 48)
J8
MANIFOLD
6
5
4
3
2
1
COM BLACK
+12VDC
RED
COM BLACK
+12VDC
RED
COM BLACK
+12VDC
RED
COLOR 22
J9
COM BLACK
+12VDC
RED
COM BLACK
+12VDC
RED
COM BLACK
+12VDC
RED
COLOR 25
J16
6
5
4
3
2
1
J10
6
5
4
3
2
1
COM BLACK
+12VDC
RED
COM BLACK
+12VDC
RED
COM BLACK
+12VDC
RED
7
J15
J14
COLOR 23
COLOR 24
COLOR 26
COLOR 27
COLOR 28
COLOR 29
COLOR 30
1
CABLE
(16V426)
54 3 2 1
5 4 3 2 1
BOOTH CONTROL
(24M731)
Figure 32 Electrical Schematic, Sheet 3, Part 2
CONTINUED ON THE NEXT PAGE
332458G
47
Electrical Schematics
+24VDC
COM
+24VDC
COM
+24VDC
COM
CATALYST
CHANGE
MODUL
E6
(CA
TALYST
1
2 3 THRU 4)
3
J9
4 J8
5
6
6
5
4
3
2
1
COM
+24VDC
COM
+24VDC
COM
+24VDC
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
J16
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
J10
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
6
5
4
3
2
1
COM
+24VDC
COM
+24VDC
COM
+24VDC
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
MANIFOLD
FLUSH
CATALYST 3
CATALYST 4
MANIFOLD
6
J15
J14
DUMP
CATALYST 3
CATALYST 4
2
CABLE
(15V206)
12 34 5
+24VDC
COM
+24VDC
COM
+24VDC
COM
54 3 2 1
CATALYST
CHANGE
MODUL
E5
1 (CATALYST
1
THRU
2)
2
3
J9
4 J8
5
6
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
MANIFOLD
FLUSH
CATALYST 1
CATALYST 2
6
J15
J14
MANIFOLD
DUMP
CATALYST 1
CATALYST 2
(15V206)
2
CABLE
12 34 5
12 34 5
COLOR
CHANGE
MODUL
E4
(COLORS
25 THRU 32)
ALTERNATE CONFIGURATION
FOR CATALYST CHANGE CONTROL
INNON-HA
ZARDOUS LOCATION
Figure 33 Electrical Schematic, Sheet 4, Alternate
Configuration for Catalyst Change Control
48
332458G
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 37.
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)
16V425
6.0 (2.0)
16V426
10.0 (3.0)
16V427
15.0 (5.0)
16V428
25.0 (8.0)
16V429
50.0 (16.0)
16V430
100.0 (32.0)
15U531
15U532
15V205
15V206
15V207
15V208
15U533
15V213
Non--Hazardous
M12 CAN Cables, for Non
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)
Non--Hazardous
CAN Cables, for Non
Locations Only
Cable Part No.
Length ft (m)
125306
1.0 (0.3)
123422
1.3 (0.4)
121000
1.6 (0.5)
121227
2.0 (0.6)
121001
3.0 (1.0)
121002
5.0 (1.5)
121003
10.0 (3.0)
120952
13.0 (4.0)
332458G
121201
121004
121228
20.0 (6.0)
25.0 (8.0)
50.0 (15.0)
Non--Hazardous
25 Pin D-SUB Cables, for Non
Locations Only
16T659
2.5 (0.8)
16V659
6.0 (1.8)
See 8. Select Communication
Options, page 21.
Alternates for Color Change Modules
by Part Number (Factory Configuration), for
Non--Hazardous Locations Only
Non
Module Part No.
Description
24T557
2 color/2 catalyst
24T558
4 color/4 catalyst
24T559
6 color/6 catalyst
24T560
8 color/8 catalyst
Alternates for Color Change Modules
by Part Number (Factory Configuration), for
Hazardous Locations Only
24T571
2 color/2 catalyst
24T572
4 color/2 catalyst
24T573
6 color/2 catalyst
24T574
8 color/2 catalyst, 13–24
color
24T774
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
24T779
13–18 color
49
Dimensions
Dimensions
Figure 35
Figure 34
Figure 36
A
65.3 in.
(1659
mm)
50
B
with
ADM
without
ADM
14.5 in.
(368
mm)
11.12 in.
(282
mm)
C
D
E
F
G
H
J
22.5 in.
(572
mm)
19.26 in.
(489
mm)
2.25 in.
(57 mm)
18.0 in.
(457
mm)
17.26 in.
(438
mm)
0.52 in.
(13 mm)
Minimum
6in (152 mm)
from mounting
surface
332458G
Technical Data
Technical Data
Positive Displacement
Proportioner
U.S.
Metric
AC1000 and AC1002 Air
Spray Systems
300 psi
2.1 MPa, 21 bar
AC2000 and AC2002
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 fluid working
pressure:
Maximum working air
pressure:
Air supply:
Air filter inlet size for air
logic:
1/4 npt(f)
Air filter inlet size for
atomizing air:
3/8 npt(f)
Air filtration for air logic:
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 component:
• 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:
AC1000, AC1002,
AC3000, and AC3002
17–4PH, 303, 304 SST, Tungsten carbide (with nickel binder),
perfluoroelastomer; PTFE, PPS, UHMWPE
AC2000, AC2002,
AC4000, and AC4002
17–4PH and 316 SST, PEEK,
perfluoroelastomer; PTFE, PPS, UHMWPE
332458G
51
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 332458
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
2014,, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Copyright 2014
www.graco.com
Revision G, March 2018

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