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

Installation
ProMix® PD2K Proportioner for
Automatic Spray Applications
332458D
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 ......................... 13
Configure Your System ....................................... 15
1. Select a Base Model ................................ 15
2. Select Hoses ........................................... 18
3. Select a Spray Gun .................................. 19
4. Select Non- IS Color and Catalyst
Change Kits ................................... 20
5. Select IS Remote Color Change
Kits ................................................ 21
6. Select Pump Expansion Kits ..................... 22
7. Select Communication Options ................. 22
General Information ............................................ 23
Location ............................................................. 23
Install the Display Module.................................... 24
Air Supply .......................................................... 25
Fluid Supply ....................................................... 26
Fluid Requirements ...................................... 26
Single Color Connections ............................. 27
Color Change Connections........................... 27
Solvent Connections .................................... 27
Dual Panel Solvent Connections ................... 28
TSL Cup Kit........................................................ 29
Solvent Meter Accessory..................................... 31
Light Tower Accessory........................................ 31
Electrical Supply ................................................. 32
Electrical Requirements................................ 32
Electrical Connections .................................. 32
Grounding .......................................................... 34
Electrical Schematics.......................................... 37
Standard Models (AC1000, AC2000,
AC4000) ........................................ 37
Dual Panel Models (AC1002, AC2002,
AC4000) ........................................ 43
Optional Cables and Modules.............................. 49
Dimensions ........................................................ 50
Technical Data ................................................... 51
Related Manuals
Current manuals are available at www.graco.com.
Manual No.
Description
Manual No.
Description
332454
332709
PD2K Proportioner Repair-Parts
Manual, Automatic Systems
Color Change Valve Repair-Parts
Manual
333282
PD2K Proportioner Operation
Manual, Automatic Systems
Color Change Kits InstructionsParts Manual
332456
PD2K Dual Panel Proportioner
Manual, Automatic Systems
3rd and 4th Pump Kits
Instructions-Parts Manual
334494
ProMix PD2K CGM Installation Kits
Instructions-Parts Manual
332564
3A4486
332339
2
Pump Repair-Parts Manual
332458D
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)
AC2000
AC2002
A
100 psi (0.7 MPa, 7.0 bar)
1500 psi (10.34 MPa,
103.4 bar)
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)
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.
SERIES
MFG. YR.
SERIAL
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
®
ProMix PD2K / PD1K
PART NO. SERIES NO. MFG. YR.
POWER REQUIREMENTS
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
GRACO INC.
P.O. Box 1441
Install per 16P577
Minneapolis, MN FM16US0241
55440 U.S.A.
FM16CA0129 Um: 250 V
Figure 2 24M672 and 26A188 Control Box
Identification Label
332458D
VOLTS
II (2) G
[Ex ia] IIA Gb
FM13 ATEX 0026
IECEx FMG 13.0011
Artwork No. 294024 Rev. D
Figure 1 Model AC1000 and AC1002 (Low Pressure)
Identification Label
Continued on the next page.
3
Models
®
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 and AC2002 (High
Pressure) Identification Label
®
ProMix PD2K / PD1K
Electronic Proportioner
II 2 G
Ex ia IIA T3
FM13 ATEX 0026
IECEx FMG 13.0011
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. D
Read Instruction Manual
.7
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 4 Model AC0500 and AC0502 Identification
Label
Figure 5 Non-Intrinsically Safe Color Change Control (Accessory) Identification Label
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
4
332458D
Models
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
332458D
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 symbol refers to procedure-specific risks. When these
symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard
symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or
solvent flowing through the equipment can cause static sparking. To help prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic
drop cloths (potential static arc).
• Ground all equipment in the work area. See Grounding instructions.
• Never spray or flush solvent at high pressure.
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable
fumes are present.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are antistatic or conductive.
• Stop operation immediately if static sparking occurs or you feel a shock, Do not use equipment until
you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause
electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
6
332458D
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.
332458D
7
Warnings
WARNING
TOXIC FLUID OR FUMES
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read Safety Data Sheet (SDS) for handling instructions and to know the specific hazards of the
fluids you are using, including the effects of long-term exposure.
• When spraying, servicing equipment, or when in the work area, always keeps work area well
ventilated and always wear appropriate personal protective equipment. See Personal Protective
Equipment warnings in this manual.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Always wear appropriate personal protective equipment and cover all skin when spraying, servicing
equipment, or when in the work area. Protective equipment helps prevent serious injury, including
long-term exposure; inhalation of toxic fumes, mists, or vapors; allergic reactions; burns; eye injury
and hearing loss. This protective equipment includes, but is not limited to:
• A properly fitting respirator, which may include a supplied-air respirator, chemically impermeable
gloves, protective clothing and foot coverings as recommended by the fluid manufacturer and local
regulatory authority.
• Protective eyewear, and hearing protection.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request SDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and
create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
8
332458D
Important Isocyanate (ISO) Information
Important Isocyanate (ISO) Information
Isocyanates (ISO) are catalysts used in two
component materials.
Self--ignition
Material Self
Isocyanate Conditions
Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings
and Safety Data Sheet (SDS).
Spraying or dispensing fluids that contain
isocyanates creates potentially harmful mists,
vapors, and atomized particulates
• Read and understand the fluid manufacturer’s
warnings and Safety Data Sheet (SDS) to know
specific hazards and precautions related to
isocyanates.
• Use of isocyanates involves potentially
hazardous procedures. Do not spray with the
equipment unless you are trained, qualified,
and have read and understood the information
in this manuals and in the fluid manufacturer’s
application instructions and SDS.
• Use of incorrectly maintained or mis-adjusted
equipment may result in improperly cured
material. Equipment must be carefully
maintained and adjusted according to
instructions in the manual.
Keep Components A and B Separate
Cross-contamination can result in cured
material in fluid lines which could cause serious
injury or damage equipment. To prevent
cross-contamination:
• Never interchange component A and component
B wetted parts.
• Never use solvent on one side if it has been
contaminated from the other side.
• To prevent inhalation of isocynate mists, vapors,
and atomized particulates, everyone in the
work area must wear appropriate respiratory
protection. Always wear a properly fitting
respirator, which may include a supplied-air
respirator. Ventilate the work area according to
instructions in the fluid manufacturer’s SDS.
• Avoid all skin contact with 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.
332458D
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
NOTE: The amount of film formation and rate of
crystallization varies depending on the blend of ISO,
the humidity, and the temperature.
Changing Materials
NOTICE
Partially cured ISO will reduce performance and
the life of all wetted parts.
Changing the material types used in your
equipment requires special attention to avoid
equipment damage and downtime.
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere.
Never store ISO in an open container.
• When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.
• Keep the ISO pump wet cup or reservoir (if
installed) filled with appropriate lubricant. The
lubricant creates a barrier between the ISO and
the atmosphere.
• Use only moisture-proof hoses compatible with
ISO.
• Never use reclaimed solvents, which may
contain moisture. Always keep solvent
containers closed when not in use.
• Always clean the fluid inlet strainers after
flushing.
• Check with your material manufacturer for
chemical compatibility.
• When changing between epoxies and urethanes
or polyureas, disassemble and clean all fluid
components and change hoses. Epoxies often
have amines on the B (hardener) side. Polyureas
often have amines on the A (resin) side.
• Always lubricate threaded parts with an
appropriate lubricant when reassembling.
10
332458D
Important Acid Catalyst Information
Important Acid Catalyst Information
The PD2K MC3000 and MC4000 Proportioner is designed for acid catalysts (“acid”) currently used in two-component,
wood-finishing materials. Current acids in use (with pH levels as low as 1) are more corrosive than earlier acids.
More corrosion-resistant wetted materials of construction are required, and must be used without substitution, to
withstand the increased corrosive properties of these acids.
Acid Catalyst Conditions
Acid is flammable, and spraying or dispensing acid creates potentially harmful mists, vapors, and atomized
particulates. To help prevent fire and explosion and serious injury:
• Read and understand the acid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific hazards
and precautions related to the acid.
• Use only genuine, manufacturer’s recommended acid-compatible parts in the catalyst system (hoses, fittings,
etc). A reaction may occur between any substituted parts and the acid.
• To prevent inhalation of acid mists, vapors, and atomized particulates, everyone in the work area must wear
appropriate respiratory protection. Always wear a properly fitting respirator, which may include a supplied-air
respirator. Ventilate the work area according to instructions in the acid manufacturer’s SDS.
• Avoid all skin contact with acid. Everyone in the work area must wear chemically impermeable gloves, protective
clothing, foot coverings, aprons, and face shields as recommended by the acid manufacturer and local regulatory
authority. Follow all acid manufacturer recommendations, including those regarding handling of contaminated
clothing. Wash hands and face before eating or drinking.
• Regularly inspect equipment for potential leaks and remove spills promptly and completely to avoid direct contact
or inhalation of the acid and its vapors.
• Keep acid away from heat, sparks, and open flames. Do not smoke in the work area. Eliminate all ignition
sources.
• Store acid in the original container in a cool, dry, and well-ventilated area away from direct sunlight and
away from other chemicals in accordance with acid manufacturer’s recommendations. To avoid corrosion of
containers, do not store acid in substitute containers. Reseal the original container to prevent vapors from
contaminating the storage space and surrounding facility.
332458D
11
Important Acid Catalyst Information
Moisture Sensitivity of Acid Catalysts
Acid catalysts can be sensitive to atmospheric
moisture and other contaminants. It is recommended
the catalyst pump and valve seal areas exposed to
atmosphere are flooded with ISO oil, TSL, or other
compatible material to prevent acid build-up and
premature seal damage and failure.
NOTICE
Acid build-up will damage the valve seals and
reduce the performance and life of the catalyst
pump. To prevent exposing acid to moisture:
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere.
Never store acids in an open container.
• Keep the catalyst pump and the valve seals filled
with the appropriate lubricant. The lubricant
creates a barrier between the acid and the
atmosphere.
• Use only moisture-proof hoses compatible with
acids.
• Always lubricate threaded parts with an
appropriate lubricant when reassembling.
12
332458D
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.
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
332458D
13
System Control Drawing 16P577
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
14
332458D
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.
332458D
15
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)
16
332458D
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)
332458D
17
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]
18
332458D
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 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)
332458D
19
Configure Your System
Non-- IS Color and Catalyst Change Kits
4. Select Non
Using the following table, choose the non-IS color/catalyst change kits that meet your application’s requirements. The
kits include a manifold with valves and a control module for installation in the non-hazardous area. See color change
kit manual 333282 for further information.
Table 1 . Low Pressure Color/Catalyst Change Kits
(300 psi [2.068 MPa, 20.68 bar])
Kit Part No.
Kit Description
Table 2 . High Pressure Color/Catalyst Change Kits
(1500 psi [10.34 MPa, 103.4 bar])
Kit Part No.
Non--Circulating Kits
Low Pressure Non
Kit Description
Non--Circulating Kits
High Pressure Non
24X316
1 color or 1 catalyst
change valve
24X318
1 color or 1 catalyst
change valve
24R915
2 color or 2 catalyst
change valves
24R959
2 color or 2 catalyst
change valves
24R916
4 color or 4 catalyst
change valves
24R960
4 color or 4 catalyst
change valves
24R917
6 color change valves
24R961
6 color change valves
24R918
8 color change valves
24R962
8 color change valves
Low Pressure Circulating Kits
24X317
1 color or 1 catalyst
change valve
24R919
2 color or 2 catalyst
change valves
24R920
4 color or 4 catalyst
change valves
24R921
6 color change valves
24R922
8 color change valves
20
High Pressure Acid
Acid--Compatible Non
Non-Circulating Kits
24T579
2 catalyst change valves
24T580
4 catalyst change valves
High Pressure Circulating Kits
24X319
1 color or 1 catalyst
change valve
24R963
2 color or 2 catalyst
change valves
24R964
4 color or 4 catalyst
change valves
24R965
6 color change valves
24R966
8 color change valves
332458D
Configure Your System
5. Select IS Remote Color Change Kits
IS remote color change manifold kits include a manifold with valves and a control module, which may be installed
in the hazardous area. The remote color change manifold kit must have the same number of color valves and
catalyst valves as the color/catalyst change kit you selected in the previous step. The remote color change manifolds
attach to the robot arm or wall, allowing mixing to occur close to the point of spray. See color change kit manual
333282 for further information.
Non--Circulating Remote
Table 3 . Low Pressure, Non
Color Change Manifold Kits
(300 psi [2.068 MPa, 20.68 bar])
Number
of Color
+ Solvent
Valves
Number of Catalyst + Solvent Valves
1
24V157
2
24V158
24V331
4
24V159
24V332
6
24V160
8
High--Pressure, Non
Non--Circulating Remote
Table 5 . High
Color Change Manifold Kits
(1500 psi [10.34 MPa, 103.4 bar])
Number
of Color
+ Solvent
Valves
Number of Catalyst + Solvent Valves
1
24V359
2
24V360
24V381
24V343
4
24V361
24V382
24V396
24V333
24V344
6
24V362
24V383
24V397
24V161
24V334
24V345
8
24V363
24V384
24V398
12
24V162
24V335
24V346
12
24V364
24V385
24V399
13–18
24V163
13–18
24V365
13–24
24V164
13–24
24V366
13–30
24V165
13–30
24V367
1
2
4
Table 4 . Low Pressure, Circulating Remote Color
Change Manifold Kits
(300 psi [2.068 MPa, 20.68 bar])
Number
of Color
+ Solvent
Valves
Number of Catalyst + Solvent Valves
1
24V166
2
24V167
24V336
4
24V308
24V337
6
24V309
8
1
2
4
High--Pressure, Circulating Remote Color
Table 6 . High
Change Manifold Kits
(1500 psi [10.34 MPa, 103.4 bar])
Number
of Color
+ Solvent
Valves
Number of Catalyst + Solvent Valves
1
24V369
2
24V370
24V389
24V347
4
24V371
24V390
24V402
24V338
24V348
6
24V372
24V391
24V403
24V326
24V339
24V349
8
24V373
24V392
24V404
12
24V327
24V340
24V350
12
24V374
24V393
24V405
13–18
24V328
13–18
24V375
13–24
24V329
13–24
24V376
13–30
24V330
13–30
24V377
332458D
1
2
4
1
2
4
21
Configure Your System
6. Select Pump Expansion Kits
7. 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.
The following table lists available kits to add AWI
capabilities or to support an alternate PLC protocol.
See the CGM Installation Kits manual (334494) for
further information.
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
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
High pressure resin
70cc pump
24R971
High pressure catalyst
35cc pump
22
Kit Part No.
Kit Description
15V337
AWI Module
24W829
CGM Kit (for adding
AWI or changing PLC
protocols)
24W462
Modbus TCP-CGM (for
adding AWI)
CGMEP0
EtherNet/IP-CGM
(alternate PLC protocol)
CGMDN0
DeviceNet-CGM
(alternate PLC protocol)
CGMPN0
PROFINET-CGM
(alternate PLC protocol)
332458D
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.
332458D
23
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
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
Figure 12 Install Display Module
3. Connect one end of the 5 ft (1.5 m) CAN cable
(provided) to the Advanced Display Module
(M). The other end of the cable comes from the
factory connected to the Enhanced Fluid Control
Module (EFCM).
NOTE: For a list of alternate cable lengths, see
Electrical Schematics, page 37. The total length of
all cable used in the system must not exceed 150
ft (45 m).
24
332458D
Air Supply
Air Supply
Air Requirements
Air Connections
• Compressed air supply pressure: 85-100 psi
(0.6–0.7 MPa, 6.0-7.0 bar).
1. Tighten all system air and fluid line connections
as they may have loosened during shipment.
• Air hoses: use grounded hoses that are correctly
sized for your system.
2. Connect the main air supply line to the main air
inlet (136). This air line supplies the solenoids,
valves, and pumps. Do not use this line to supply
the gun’s atomizing air.
• Air regulator and bleed-type shutoff valve: include
in each air line to fluid supply equipment. Install
an additional shutoff valve upstream of all air line
accessories to isolate them for servicing.
3. Connect a separate, dedicated, clean air supply
line to the air inlet of the 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: to filter oil and water out of the air
supply and help avoid paint contamination and
clogged solenoids. See Technical Data, page 51,
for air filtration requirements.
Figure 14 Atomizing Air and Air Manifold Connections
Key
332458D
Connection
Description
A
Air inlet
C
Air cutoff output
(plugged)
M
Exhaust muffler
S
Solvent cutoff output
(plugged)
25
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.
• To reduce the risk of injury, including skin
injection, you must install a shutoff valve
between each fluid supply line and the mix
manifold. Use the valves to shut off fluid during
maintenance and service.
Models are available to operate air spray (300 psi) or
air-assisted (1500 psi) systems with a capacity of up
to 800 cc/minute (depending on material viscosity).
• Fluid supply pressure tanks, feed pumps, or
circulating systems can be used to supply fluid to
the system.
• Materials can be transferred from their original
containers or from a central paint recirculating line.
26
NOTE: The fluid supply must be free of pressure
spikes, which are commonly caused by pump stroke
changeover. Read the supply pressure on the gauge
(P, see figure on next page). Supply capability for
each pump must be at least 2 times the maximum
operating flow rate. Supply pressure must be as
close as possible to the pressure setpoint:
• For low pressure systems, ± 100 psi (0.7 MPa, 7
bar) of setpoint.
NOTE: For low pressure systems, it is
recommended the supply pressure should be
maintained at 1/2 to 2/3 of the system operating
spray pressure.
• For high pressure systems, ± 300 psi (2.1 MPa,
21 bar) of setpoint.
If necessary, install pressure regulators or a surge
tank on the pump fluid inlet lines to reduce pulsation.
Contact your Graco distributor for additional
information.
332458D
Fluid Supply
Single Color Connections
Color Change Connections
NOTE: Check valves (J, L) are provided on the inlet
(K) and outlet (H) manifolds of each pump.
If you are installing the color change accessory kit,
make the fluid connections as described in manual
333282.
1. Connect the color supply line to the pump fluid
inlet fitting (S).
2. Connect the color outlet line to the pump fluid
outlet fitting (R).
3. Make the same connections on the catalyst side.
NOTE: For isocyanate catalyst materials, moisture
resistant hose is required to supply fluid to the system
and also as a fluid line between the pump and the
mix manifold.
Solvent Connections
1. Connect the solvent supply line for the resin to
the inlet fitting (17) for solvent flow switch 1 (FS1).
2. Connect the solvent supply line for the catalyst
to the inlet fitting (17) for solvent flow switch 2
(FS2).
3. Connect the solvent outlet line for the 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
332458D
Figure 16 Solvent Connections
27
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.
28
Figure 17 Dual Panel Solvent Connections
332458D
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.
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.
332458D
Figure 18 Install TSL Cup Kit
NOTE: The pump’s upper throat cartridge has
three ports (two are plugged). Move a plug (73d)
if necessary so the barbed fitting (73b) can be
put in the port closest to the TSL cup.
3. Check that the o-ring is in place on the barbed
fitting (73b). Apply low strength thread adhesive
and install the fitting in the upper throat cartridge
port. Be sure the other two ports are plugged
(73d).
29
TSL Cup Kit
4. Catalyst (35 cc) pumps: Repeat for the lower
throat cartridge.
5. If you are lubricating the dosing valves, remove
the plug (73d) and gasket from the valve port (V)
closest to the TSL cup.
NOTE: Choose the valve port in the upward
facing position. This will allow liquid to flow into
the valve while allowing air to rise out of the
valve.
Check that the o-ring is in place on the barbed
fitting (73b). Apply low strength thread adhesive
and install the fitting in the valve port (V).
NOTE: Do not confuse the valve port (V) with the
air port (W).
NOTE: If you are not lubricating the dosing
valves, remove the unused barbed fittings (73b)
from the bottom of the TSL cup (73). Apply low
strength thread adhesive and install the plugs
and gaskets supplied with the kit.
6. Cut the tubing (73c) to length as required.
Connect the TSL cup fittings to the fittings on the
pump and valves. TSL is gravity-fed from the
cup to the pump and valves; position the fittings
and tubing to prevent kinks and enable the TSL
to flow freely down to the valve and air to rise
up and out of the valve.
7. Fill the cup to the level of the lower black
horizontal line with either TSL or ISO oil, as
appropriate for the resin and catalyst materials
being used.
NOTE: If TSL leaks from the rod guard of the
color (70 cc) pump, be sure the lower u-cup seal
is installed in the lower throat cartridge.
NOTE: The fluid levels in the TSL cups should be
checked daily. Fluid levels should remain static
for an extended period of time. Rising or falling
fluid levels in a TSL cup can be an indication of a
condition which needs immediate attention. Refer
to the troubleshooting steps in the repair manual for
guidance.
30
332458D
Solvent Meter Accessory
ISO Oil Fill Procedure
When using polyurethane coatings with isocyanate
catalysts in high-humidity environments, use of ISO
oil on the catalyst pump TSL cup is recommended
instead of TSL. The ISO oil will present a barrier
that will prevent catalyst hardening from contact with
moisture. When performing the first fill of a cup with
ISO oil, it will be necessary to bleed the air out of the
feed line.
NOTE: If not already present on the TSL cup, draw
the two horizontal lines at, and slightly above, the
vertical center of the front of the cup before filling.
Solvent Meter Accessory
To install Solvent Meter Kit 280555, see manual
308778.
NOTE: Install the solvent meter downstream of the
solvent cutoff switch near the base unit.
Light Tower Accessory
To install Light Tower Kit 24K337, see manual
3A1906.
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.
332458D
31
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
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.
1. Verify that electrical power at the main panel is
shut off. Open the Control Box cover.
2. Thread the electrical cord wires through the
strain relief (S).
3. Connect the wires (L, N, G) securely to the
corresponding terminals of the terminal block (T),
as shown.
4. Tighten the strain relief nut securely.
5. Close the Control Box. Restore power.
6. Follow instructions in Grounding, page 34.
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
32
332458D
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 fittling.
6. Insert the fitting through the Electrical Control
Box wall and install the nut. Tighten finger tight.
7. Attach a ferrite (3) near the end of the FieldBus
cable.
8. Attach the FieldBus cable to the CGM.
332458D
33
Grounding
Grounding
See illustration on next page.
Fluid Supply Container
Follow local code.
This equipment must be grounded to reduce the
risk of static sparking and electric shock. Electric
or static sparking can cause fumes to ignite or
explode. Improper grounding can cause electric
shock. Grounding provides an escape wire for the
electric current.
Electrical Control Box
The electrical control box has two ground points.
Both connections must be made.
• Connect the ground wire (Y) to the ground screw
on the electrical control box. Connect the clamp
end to a true earth ground.
• The power supply must be grounded according to
local codes. Connect the power supply ground
wire to the Ground terminal in the electrical control
box. See Electrical Connections, page 32.
Color Change Module
Connect a ground wire from the color change module
to a true earth ground.
Intrinsically safe color change modules located in the
hazardous area must be connected to a true earth
ground in the hazardous area.
Feed Pumps or Pressure Pots
Connect a ground wire and clamp from a true earth
ground to the pumps or pots. See pump or pressure
pot manual.
Air and Fluid Hoses
Use grounded hoses only.
Spray Gun
Follow the grounding instructions in your gun manual.
• Non-Electrostatic: Ground the spray gun through
connection to a Graco-approved grounded fluid
supply hose.
• Electrostatic: Ground the spray gun through
connection to a Graco-approved grounded air
supply hose. Connect the air hose ground wire to
a true earth ground.
Figure 20 Ground Screw and Power Switch
34
332458D
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
332458D
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
35
Grounding
Object Being Sprayed
Check Resistance
Follow local code.
Solvent Reservoir or Purge Station
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.
36
To ensure proper grounding and reduce risk of fire
and explosion, resistance between components
and true earth ground must be less than 1 ohm.
332458D
Electrical Schematics
Electrical Schematics
Standard Models (AC1000, AC2000, 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)
FAN
(24P658)
ENCODERAND MOTOR
(16P036, 16P037)
WIRE HARN
ESS
(24P684, 24P685)
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
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 INLET
TRANSDUCER
(16P289, 16P290)
BREAKOUT MODULE PUMP 3
(24N527)
FAN
(24P658)
ENCODERAND MOTOR
(16P036, 16P037)
WIRE HARN
ESS
(24P684, 24P685)
UP
DOWN
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
SOLVENT METER (258718)
SAFETY INTERLOCK SWITCH
CABLE
(16T280)
3
CABLE
(121003)
4
CABLE (16T659)
CABLE (16T659)
CABLE (16T659)
CABLE (16T659)
SOLVENT
FLOW
INPUTS
1
ADVANCED
DISPLAY MODULE
(24E451)
CABLE (16V429)
LIGHT
TOWER
(15X472)
COLOR CH
ANGE MODUL
E7
(24R219)
7
1
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
SWITCH (120278)
CABLE
(16V426)
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
UP
DOWN
BARRIER
BOARD
(248192)
GFB
INTERFACES
SOLVENT CUTOFF (121324)
SWITCH (120278)
FLOW RATE ANALOG IN
UP
DOWN
PUMP V/P FOR
FLUID REG.
SPLITTER
(16P243)
PRESSURE SW (121323)
GCA
MODULE
EFCM
(24N913)
FLOW RATE ANALOG IN
MAC SERIES 46
SOLENOID
(16P812)
PUMP V/P FOR
FLUID REG.
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
SOLENOID (12132
4)
FLOW RATE ANALOG IN
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
MAC SERIES 46
SOLENOID
(16P812)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
BREAKOUT MODULE PUMP 2
(24N527)
ENCODERAND MOTOR
(16P036, 16P037)
WIRE HARN
ESS
(24P684, 24P685)
COLOR CH
ANGE MODUL
E8
(24R219)
7
BOOTH CONTR
OL (24M731)
BREAKOUT MODULE PUMP 4
(24N527)
ENCODERAND MOTOR
(16P036, 16P037)
WIRE HARN
ESS
(24P684, 24P685)
BREAKOUT MODULE PUMP 1
(24N527)
FAN
(24P658)
119159
119159
119159
119159
16T072
CAN
IS BOARD
(24M485)
FAN
(24P658)
GUNTRIGGER INPUTS
1 CABLE
(16V426)
16W159
16W159
POWERIN
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
332458D
37
Electrical Schematics
CONTINUED ON PAGE 3
CONTINUED ON PAGE 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
(NON IS)
(IS)
1
2
3
4
5
(121227)
P3
P4
INTEGRATION
GATEWAY
3
5
1
GCAMODULE
EFCM
(24N913)
3
5
12345
UNUSED
UNUSED
CABLE
(16T280)
GFBINTERFACE
(121324)
123
1
2
3
SOLVENT CUTOFF (121324)
PWR (RED)
SIG (WHITE)
COM (B
LACK)
SHIELD/GRN
SOLVENT
UNUSED
1
RED WIRE (065161)
2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
METER
(258718)
GROUND BAR
4
25 PIN D-SUB CABLE
(16T659)
BLACK WIRE (065159)
24V
POWER
SUPPLY
(16T660)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
1
3
2
12345
1234
4
7
6
5
12345
12345
1234
13 A1(+) A2(-)
8
12 34
12 34
5678
2
12345
3
1234
4
12345
7
6
5
12345
1234
12 34
PUMP 2
UP
8
12 34
5678
LINE
FILTER
(16V446)
FAN PUMP 2
(24P658)
MANI
FOLD
MAC SERIES 46
(16P812 QTY 2)
+-+-+-+-
PWR (RED)
SIG (WHITE)
COM(BLACK)
SHIELD/GRN
INLET TRANSDUCER
PUMP 2
(16P289 OR 16P290)
FAN PUMP 1
(24P658)
PWR (RED)
SIG (WHITE)
COM(BLACK)
SHIELD/GRN
+24VDC
COM
+24VDC
COM
SEE DETAILAOR B
PUMP 1
DOWN
PUMP 1
UP
ENCODER/MOTOR
AND
WIRE HARNESS
PUMP2
MANI
FOLD
MAC SERIES 46
(16P812 QTY 2)
F1
F3
F4
N
F2
+-+-+-+-
V/P FOR FLUID REG.
PUMP 1
SEE DET
AILAOR B
POWER MODULE
(24R257)
N04
OUTLET TRANSDUCER
PUMP 1
(16P289 OR 16P290)
+ -
CABLE
(16T658)
L
ENCODER/MO
TOR
AND
WIRE HARNESS
PUMP1
N03
2 POSITION
SWITCH
(16U725)
N04
INLET TRANSDUCER
PUMP 1
(16P289 OR 16P290)
GRND
48V-10A
POWERSUPPLY
(16U820)
N (BLUE)
L (BROWN)
N03
L
1
+48V
COM
+48V
COM
RELAY
14
N
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
BREAKO
UT MODULE PUMP 2 (24N527)
+48V
COM
+48V
COM
BREAKOUT
MODULE PUMP
1 (24N527)
GRND (GRN/YEL)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
+24VDC
COM
+24VDC
COM
UNUSED
BARRIER
BOARD
(248192)
+12VDC
COM
UNUSED
UNUSED
+12VDC
COM
+12VDC
COM
PUMP 2
DOWN
UNUSED
54 3 2 1
UNUSED
UNUSED
(121001)
3
(24M485)
12345
SPLITTER
(16P243)
1
2
3
4
5
V/P FOR FLUID REG.
PUMP 2
4
1
2
3
4
5
CABLE
OUTLET TRANSDUCER
PUMP 2
(16P289 OR 16P290)
2
P4
P3
16T072
12345
1
1
2
3
4
5
CABLE
4 25 PIN
D-SUB CABLE
(16T659)
3
CABLE
(15V206)
CABLE (16V429)
2
UNUSED
CABLE (121227)
G3000
METER
PUMP 1
(EITHER, 239716,
258718,16M510,
OR 16M519)
GRND
SCREW
TWISTEDPAIR CABLE (16W159)
G3000
METER
PUMP 2
(EITHER, 239716,
258718,16M510,
OR 16M519)
GRND
SCREW
TWISTEDPAIR CABLE (16W159)
L GRND N
123456789
12
10
PUMP ENCODER AND MOTOR
(16P037)
MOTOR
MOUNTING
SCREW
1 2 3 4 5 6 78 9
1011 12
DRAIN/FOIL
UNUSED
UNUSED
UNUSED
UNUSED
DRAIN/FOIL
1011 12
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
123456789
DRAIN/FOIL
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
DRAIN/FOIL
MOTOR
MOUNTING
SCREW
3
1234
WIRE HARNESS
(24P685)
123456789
UNUSED
UNUSED
12345
1234
WIRE HARNESS
(24P684)
L N GRND
UNUSED
UNUSED
12345
BREAKOUT
MODULE
(24N527)
2
3
UNUSED
2
UNUSED
UNUSED
UNUSED
BREAKOUT
MODULE
(24N527)
TERMINAL
BLOCK
(114095)
UNUSED
L N GRND
POWER IN
DETAILB, HIG
H PRESSURE
PUMPS (24M
707, 24M715)
DETAILA, LOW PRESSURE
PUMPS (24M706, 24M714)
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
CABLE
(16H078)
10
PUMP ENCODER AND MOTOR
(16P036)
Figure 23 Electrical Schematic, Sheet 2, Part 1
CONTINUED ON THE NEXT PAGE
38
332458D
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
332458D
39
Electrical Schematics
FROMCAN IS BOARD (24M485) ON PAGE 2
FROMCAN IS BOARD (24M485) ON PAGE 2
2 CABLE(15V206)
12 34 5
COLOR
CHANGE
MODULE 1
(COLORS
1 THRU 8)
MANIFOLD
FLUSH
COLOR1
COLOR2
COLOR3
COLOR4
COLOR5
COLOR6
COLOR7
COLOR8
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J8
MANIFOLD
J9
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J16
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J10
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
J15
J14
DUMP
COLOR1
COLOR2
COLOR3
COLOR4
COLOR5
COLOR6
COLOR7
COLOR8
MANIFOLD
*FLUSH
COLOR9
COLOR10
COLOR11
COLOR12
COLOR13
COLOR14
COLOR15
COLOR16
12 34 5
COLOR
CHANGE
MODULE 2
(COLORS
9 THRU 16)
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3 J15
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J9
J8
6
J16
J14
MANIFOLD
MANIFOLD
J10
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
DUMP*
FLUSH
COLOR9
CATALYST 1
COLOR10
CATALYST 2
COLOR11
CATALYST 3
COLOR12
CATALYST 4
COLOR13
COLOR14
COLOR15
COLOR16
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
UNUSED
UNUSED
1
2
3
4
5
6
J15
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
J14
COLOR17
COLOR18
COLOR19
COLOR20
COLOR21
COLOR22
COLOR23
COLOR24
12 34 5
COLOR
CHANGE
MODULE 3
(COLORS
17 THRU 24)
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J8
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J15
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J14
J9
6
J9
COM
+12VDC
COM
+12VDC
COM
+12VDC
J16
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
UNUSED
UNUSED
J10
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
6
2
CABLE
(15V206)
2
CABLE
MANIFOLD
J8
MANIFOLD
6
5
4
3
2
1
DUMP
CATALYST 1
CATALYST 2
CATALYST 3
CATALYST 4
12 34 5
12 34 5
*FLUSH
CATALYST
CHANGE
MODULE 5
(CATALYST
1 THRU 4)
MANIFOLD
MANIFOLD
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
COM
+12VDC
COM
+12VDC
COM
+12VDC
J16 43
2
1
6
5
4
J10 3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
*FLUSH
DUMP*
COLOR17
COLOR25
COLOR18
COLOR26
COLOR19
COLOR27
COLOR20
COLOR28
COLOR21
COLOR29
COLOR22
COLOR30
COLOR23
COLOR24
54 3 2 1
(15V206)
2
CABLE
(15V206)
12 34 5
12 34 5
COLOR
CHANGE
MODULE 4
(COLORS
25 THRU 32)
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J8
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J15
+12VDC
COM
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
J14
J9
6
J16
J10
MANIFOLD
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
UNUSED
UNUSED
UNUSED
UNUSED
DUMP*
COLOR25
COLOR26
COLOR27
COLOR28
COLOR29
COLOR30
12 34 5
2
CABLE(15V206)
Figure 25 Electrical Schematic, Sheet 3
* May be unused in some configurations.
CONTINUED ON THE NEXT PAGE
40
332458D
Electrical Schematics
CATALYST
CHANG
E
MODULE 6
(CATALYST
3 THRU 4)
MANIFOLD
FLUSH
CATALYST 3
CATALYST 4
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J8
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
J15
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
MANIFOLD
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J16
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
J10
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J16
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
J10
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
J9
6
J14
DUMP
CATALYST 3
CATALYST 4
2
CABLE
(15V206)
12 34 5
MANIFOLD
FLUSH
CATALYST 1
CATALYST 2
54 3 2 1
CATALYST
CHANG
E
MODULE 5
(CATALYST
1 THRU 2)
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J8
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
J15
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
MANIFOLD
J9
6
J14
DUMP
CATALYST 1
CATALYST 2
(15V206)
2
CABLE
12 34 5
12 34 5
COLOR
CHANG
E
MODULE 4
(COLORS
25 THRU 32)
Figure 26 Electrical Schematic, Sheet 3, Alternate
Configuration for Catalyst Change Control
CONTINUED ON THE NEXT PAGE
332458D
41
Electrical Schematics
FROM CAN IS
BOARD (24M485)
ON PAGE 2
NON-HAZARDOUS LOCATION
HAZARDOUS LOCATION
MAN
IFOLD
COLOR FLUSH
COLOR 1
COLOR 2
COLOR 3
COLOR 4
COLOR 5
COLOR 6
COLOR 7
COLOR 8
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
12 34 5
COLOR
CHANGE
MODULE 7
(COLORS
33 THRU 40)
J8
MAN
IFOLD
J9
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J16
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
7
J15
J14
J10
CATALYST FLUSH
CATALYST 1
CATALYST 2
CATALYST 3
CATALYST 4
COLOR 9
COLOR 10
COLOR 11
COLOR 12
1
CABLE
(16V426)
12 34 5
MAN
IFOLD
COLOR 13
COLOR 14
COLOR 15
COLOR 16
COLOR 17
COLOR 18
COLOR 19
COLOR 20
COLOR 21
12 34 5
COLOR
CHANGE
MODULE 8
(COLORS
41 THRU 48)
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J8
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J15
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J14
MAN
IFOLD
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J9
7
J16
J10
COLOR 22
COLOR 23
COLOR 24
COLOR 25
COLOR 26
COLOR 27
COLOR 28
COLOR 29
COLOR 30
1
CABLE
(16V426)
54 3 2 1
5 4 3 21
BOOTH CONTROL
(24M731)
Figure 27 Electrical Schematic, Sheet 3, Hazardous
Location
42
332458D
Electrical Schematics
Dual Panel Models (AC1002, AC2002, AC4000)
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
ENCODER ANDMOTOR
(16P036, 16P037)
WIREHARNESS
(24P684, 24P685)
ENCODER ANDMOTOR
(16P036, 16P037)
WIREHARNESS
(24P684, 24P685)
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
MAC SERIES 46
SOLENOID
(16P812)
PUMPV/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)
PUMPV/P FOR
FLUID REG
.
MAC SERIES 46
SOLENOID
(16P812)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
BREAKOUT MODULE PUMP 3
(24N527)
FAN
(24P658)
UP
DOWN
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
CABLE
(16T280)
CATALYST CHANGE
MODULE 6
(24N935)
CATALYST CHANGE
MODULE 5
(24N935)
COLOR CHANGE
MODULE 4
(24N935)
COLOR CHANGE
MODULE 3
(24N935)
SOLVENT CUTOFF VALVE (121324)
SOLVENT CUTOFF VALVE (121324)
SWITCH (120278)
SOLVENT
FLOW
INPUTS
SWITCH (120278)
SWITCH (120278)
SWITCH (120278)
CABLE
(121003)
SOLVENT
METER 2
(258718)
FAN
(24P658)
GFBPRESS. SW. 2 (121323)
SAFETY INTERLOCK SWITCH
CABLE (16T659)
CABLE (16V429)
PLC DISCRETE 4-20mAIN 2
SOLVENT
METER 1
(258718)
UP
DOWN
BARRIER
BOARD
(248192)
GCA
MODULE
EFCM
(24N913)
PLC DISCRETE 4-20mACOM2
UP
DOWN
CABLE 126232
OR 17N315
SPLITTER
(16P243)
17L058
AIR
CONTROL
MODULE
(26A231)
GFBPRESS. SW. 1 (121323)
GFBVALVE 1 (121324)
GFBVALVE 2 (121324)
PLC DISCRETE 4-20mAIN 1
MAC SERIES 46
SOLENOID
(16P812)
CABLE 126232
OR 17N315
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
BREAKOUT MODULE PUMP 4
(24N527)
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
MAC SERIES 46
SOLENOID
(16P812)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
BREAKOUT MODULE PUMP 2
(24N527)
ENCODER ANDMOTOR
(16P036, 16P037)
WIREHARNESS
(24P684, 24P685)
AIR FLOW SW. 2 (119159)
CABLE
15V819
PLC DISCRETE 4-20mACOM1
16W159
16W159
16W159
ENCODER ANDMOTOR
(16P036, 16P037)
WIREHARNESS
(24P684, 24P685)
BREAKOUT MODULE PUMP 1
(24N527)
FAN
(24P658)
AIR FLOW SW. 1 (119159)
16T072
CAN
IS BOARD
(24M485)
FAN
(24P658)
CABLE
(15V206)
CABLE
(15V206)
RELAY
TERMINAL BLOCK WITH FUSES
POWER IN
CABLE
(15V206)
CABLE
(121227)
RELAY
TERMINAL
BLOCK
(114095)
AWI
GATEWAY
(24R910)
COLOR CHANGE
MODULE 2
(24N935)
LINE F
ILTER
(16V446)
CABLE
(121001)
CABLE (15V206)
48V-10APOWER SUPPLY
(16U820)
CABLE
(121227)
24V
POWER
SUPPLY
(16T660)
COLOR CHANGE
MODULE 1
(24N935)
INTEGRATION
GATEWAY
2 POSITION
SWITCH
(16U725)
CABLE
16T658
CABLE
(15V206)
CABLE
(15V206)
POWERMODU
LE
(26A189)
ADV
ANCED DISPLAY MODULE
(24E451)
LIGHT
TOWER
(15X472)
COLOR CHANGE
MODULE 7
(24R219)
7
CABLE
(16V426)
BOOTH CONTROL
(24M731)
WITH SHUNT
(17M540)
COLOR CHANGE
MODULE 8
(24R219)
7
CABLE
(16V426)
BOOTH
CONTROL
(24M731)
HAZAR
DOUS LOCA
TION
NON-HAZARDO
US LOCATION
Figure 28 Electrical Schematic, Sheet 1
332458D
43
Electrical Schematics
CONTINUED ON PAGE 3
UNUSED
UNUSED
UNUSED
CABLE (121227)
CABLE
(15V206)
1
2
3
4
5
CAN IS BO
ARD
2
4
SPLITTER
(16P243)
UNUSED
(121001)
INTEGRA
TION
GATEWAY
3
CABLE
(16T280)
1
2
3
+12VDC
COM
+12VDC
SOLVENT CUTOFF VALVE 2 (121324)
COM
GREEN/BLACK
+12VDC
ORANGE/BLACK COM
GFB OUTPUT VALVE 1
BLUE/BLACK
+12VDC
RED/WHITE
COM
GFB OUTPUT VALVE 2
UNUSED
SIG
SAFETY INTERLOCK SWITCH
COM
UNUSED
1
2
3
4
5
8
J5
J4
1
2
3
4
5
6
7
8
9
10
11
12
SOLVENT CUTOFF VALVE 1 (121324)
123
GCAMODULE
EFCM
(24N913)
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
5
1
4
3
2
BARRIER
BOARD
(248192)
UNUSED
54 3 2 1
UNUSED
UNUSED
1
2
3
4
5
P4
12345
SPLITTER
(17L058)
1
2
3
4
5
(121227)
P3
10
3
(24M485)
12345
1
2
3
4
5
AWI
GATEWAY
(24R910)
1
2
3
4
5
CABLE
1
(NON IS)
(IS)
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)
GROUND
BAR
24V
POWER
SUPPLY
(16T660)
1
BREAKOUT
MODULE PUMP 1 (24N527)
3
2
12345
1234
12345
7
6
5
4
12345
1234
1
BREAKOUT
MODULE PUMP 2 (24N527)
12 34
8
12 34
5678
2
12345
3
4
1234
12345
7
6
5
12345
1234
12 34
8
12 34
5678
+48V
COM
+48V
COM
RED
BLACK
RED
BLACK
RED
PWR
WHITE
SIG
BLACK
COM
GRN SHIELD
FAN PUMP 2
(24P658)
UP
DOWN
+24VDC
COM
+24VDC
COM
UNUSED
UNUSED
BLUE
BLACK
PUMP 2
MANIFOLD
MAC SERIES 46
(16P812 QTY 2)
MAC SERIES 46
(16P812 QTY 2)
SOLVENT
METER 1
(258718)
CABLE (126232 OR 17N315)
OUTLET TRANSDUCER
PUMP 2
(16P289 OR 16P290)
FAN PUMP 1
(24P658)
INLET TRANSDUCER
PUMP 2
(16P289 OR 16P290)
+48V
COM
+48V
COM
RED
BLACK
RED
BLACK
RED
PWR
WHITE
SIG
BLACK
COM
GRN SHIELD
+24VDC
COM
+24VDC
COM
UP
SEE DETAILAOR B
PUMP 1
MANIFOLD
BLACK
LINE
FILTER
(16V446)
ENCODER/MOTOR
AND
WIRE HARNESS
PUMP 2
GND
SCREW
RED
N
RED
L
CABLE (126232 OR 17N315)
+-+-+-+4 3 2 1
RED
CABLE
(16T658)
BLACK
N04
WHITE
BLACK
N04
RED
2 POSITION
SWITCH
(16U725)
BLACK
N03
15 A1
RELA
Y1
18 A2
15 A1
RELA
Y2
18 A2
BLACK
N03
SEE DET
AILAOR B
POWER MODULE
(26A189)
N (BLUE)
L (BROWN)
--++
DOWN
ENCODER/M
OTOR
AND
WIRE HARNESS
PUMP 1
UNUSED
UNUSED
BLUE
BLACK
GRND
48V-10A
POWER SUPPLY
(16U280)
INLET TRANSDUCER
PUMP 1
(16P289 OR 16P290)
N L
OUTLET TRANSDUCER
PUMP 1
(16P289 OR 16P290)
GRND (GRN/YEL)
SOLVENT
METER 2
(258718)
GND
SCREW
TWISTED PAIR CABLE (16W159)
TWISTED PAIR CABLE (16W159)
MOTOR
MOUNTING
SCREW
123456789
12
10
PUMP ENCODER AND MOTOR
(16P037)
123456789
MOTOR
MOUNTING
SCREW
1011 12
UNUSED
UNUSED
UNUSED
DRAIN/F
OIL
UNUSED
UNUSED
DRAIN/FOIL
1011 12
UNUSED
UNUSED
123456789
DRAIN/F
OIL
UNUSED
UNUSED
UNUSED
UNUSED
DRAIN/FOIL
L N GND
3
1234
WIRE HARNESS
(24P685)
123456789
UNUSED
UNUSED
12345
1234
WIRE HARNESS
(24P684)
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 GND
POWER IN
DETAIL B, HIGH PRESSURE
PUMPS (24M707, 24M715)
DETAILA, LOW PRESSURE
PUMPS (24M706, 24M714)
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
332458D
Electrical Schematics
5
4
3
2
1
1
2
3
4
5
1
2
3
4
5
6
7
8
9
10
11
12
10
6
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
AIR CONTROL MODULE (26A231)
SOLVENT FLOW SW. 4 (120278) RIGHT BRKT
TERMINAL
BLOCKS
GFB INPUT PRESSURE SWITCH 1
1
2
3
4
5
(121003)
CABLE
15V819
GFB INPUT PRESSURE SWITCH 2
CABLE
1
2
3
4
5
ADVANCED
DISPLAY MODULE
(24E451)
1
2
3
4
5
6
7
8
9
10
11
12
BLACK
WHITE
RED
GREEN
ORANGE
BLUE
WHITE/BLACK
RED/BLACK
GREEN/BLACK
ORANGE/BLACK
BLUE/BLACK
RED/WHITE
LIGHT
TOWER
(15X472)
+ SIG
- COM
+ SIG
- COM
+ SIG
- COM
+ SIG
- COM
+ 12VDC
- COM
+ 12VDC
- COM
AIR FLOW SWITCH 1
119159
AIR FLOW SWITCH 2
119159
GFBINPUT PRESSURE SWITCH 1
121323
GFBINPUT PRESSURE SWITCH 2
121323
RED
BLACK
RED
BLACK
GFBOUTPUT VALVE 1
121324
GFBOUTPUT VALVE 2
121324
25 PIN D-SUB
CABLE (16T659)
1234
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
INLET TRANSDUCER
PUMP 4
(16P289 OR 16P290)
OUTLET TRANSDUCER
PUMP 4
(16P289 OR 16P290)
RED
BLACK
RED
BLACK
ENCODER/MOTOR
AND
WIRE HARNESS
PUMP 4
SEE DETAILAOR 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
INLET TRANSDUCER
PUMP 3
(16P289 OR 16P290)
OUTLET TRANSDUCER
PUMP 3
(16P289 OR 16P290)
ENCODER/MOTOR
AND
WIRE HARNESS
PUMP 3
SEE DETAILAOR B
+48V
COM
+48V
COM
12345
1
BREAKOUT MODULE PUMP 3 (24N527)
4
RED
BLACK
RED
BLACK
3
+48V
COM
+48V
COM
2
FAN PUMP 4
(24P658)
1
(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
332458D
45
Electrical Schematics
FROMCAN IS BOARD (24M485) ON PAGE 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
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J8
J15
J14
MAN
IFOLD
J9
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J16
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
J10
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
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)
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3 J15
4
5
6
J16
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J10
J8
J14
MAN
IFOLD
MAN
IFOLD
+12VDC
COM
+12VDC
COM
+12VDC
COM
J9
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
DUMP*
FLUSH
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)
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
UNUSED
UNUSED
1
2
3
4
5
6
J15
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
J14
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)
+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
J9
MAN
IFOLD
MAN
IFOLD
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
COM
+12VDC
COM
+12VDC
COM
+12VDC
J16 43
2
1
J14
J16
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
UNUSED
UNUSED
J10
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
CABLE
(15V206)
CABLE
MAN
IFOLD
J9
COM
+12VDC
COM
+12VDC
COM
+12VDC
DUMP
CATALYST 1
CATALYST 2
CATALYST 3
CATALYST 4
12 34 5
12 34 5
*FLUSH
MAN
IFOLD
6
5
4
3
2
1
(15V206)
CABLE
(15V206)
12 34 5
6
5
4
J10 3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
*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
12 34 5
COLOR
CHANGE
MODULE 4
(COLORS
25 THRU 32)
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J8
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
J15
+12VDC
COM
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
J14
J9
J16
J10
MAN
IFOLD
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
6
5
4
3
2
1
COM
+12VDC
UNUSED
UNUSED
UNUSED
UNUSED
DUMP*
COLOR 25
COLOR 26
COLOR 27
COLOR 28
COLOR 29
COLOR 30
12 34 5
CABLE(15V206)
Figure 31 Electrical Schematic, Sheet 3, Part 1
* May be unused in some configurations.
CONTINUED ON THE NEXT PAGE
46
332458D
Electrical Schematics
FROMCAN IS BOARD (24M485) ON PAGE 2
CABLE (16V429)
NON-HAZARDOUS LOCATION
HAZARDOUS LOCATION
MANI
FOLD
COLORFLUSH
COLOR1
COLOR2
COLOR3
COLOR4
COLOR5
COLOR6
COLOR7
COLOR8
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
CHANG
E
MODULE 7
(COLORS
33 THRU 40)
J8
J15
MANIFOLD
6
5
4
2
1
COM BLACK
+12VDC
RED
COM BLACK
+12VDC
RED
COM BLACK
+12VDC
RED
CATALYST FLUSH
J9 3
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
J16
J14
J10
CATALYST 1
CATALYST 2
CATALYST 4
COLOR 9
COLOR 10
COLOR 11
COLOR 12
CABLE
(16V426)
54 32 1
54 32 1
BOOTHCONTROL
(24M731)
WITH SHUNT
(17M540)
MANIFOLD
COLOR13
COLOR14
17M540
COLOR15
COLOR16
COLOR17
12 34 5
J1
COLOR18
COLOR19
COLOR20
COLOR21
12 34 5
COLOR
CHANGE
MODULE 8
(COLORS
41 THRU 48)
RED
+12VDC
BLAC
K
COM
RED
+12VDC
BLAC
K
COM
RED
+12VDC
BLAC
K
COM
1
2
3
4
5
6
RED
+12VDC
BLAC
K
COM
RED
+12VDC
BLAC
K
COM
RED
+12VDC
BLAC
K
COM
1
2
3
4
5
6
J15
RED
+12VDC
BLAC
K
COM
RED
+12VDC
BLAC
K
COM
RED
+12VDC
BLAC
K
COM
1
2
3
4
5
6
J14
J8
MANIFOLD
6
5
4
3
2
1
COM
BLAC
K
+12VDC
RED
COM
BLAC
K
+12VDC
RED
COM
BLAC
K
+12VDC
RED
COLOR 22
J9
COM
BLAC
K
+12VDC
RED
COM
BLAC
K
+12VDC
RED
COM
BLAC
K
+12VDC
RED
COLOR 25
J16
6
5
4
3
2
1
J10
6
5
4
3
2
1
COM
BLAC
K
+12VDC
RED
COM
BLAC
K
+12VDC
RED
COM
BLAC
K
+12VDC
RED
COLOR 23
COLOR 24
COLOR 26
COLOR 27
COLOR 28
COLOR 29
COLOR 30
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
332458D
47
Electrical Schematics
+12VDC
COM
+12VDC
COM
+12VDC
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
+12VDC
COM
+12VDC
COM
+12VDC
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
J15
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
J14
J10
6
5
4
3
2
1
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
+12VDC
COM
+12VDC
COM
+12VDC
COM
54 3 2 1
CATALYST
CHANGE
MODULE 5
(CA
TALYST
1
2 1 THRU 2)
3
J9
4 J8
5
6
6
5
4
3
2
1
COM
+12VDC
COM
+12VDC
COM
+12VDC
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
MANIFO
LD
FLUSH
CATALYST 3
CATALYST 4
MANIFOLD
DUMP
CATALYST 3
CATALYST 4
CABLE
(15V206)
12 34 5
MANIFO
LD
FLUSH
CATALYST 1
CATALYST 2
J15
J14
MANIFOLD
DUMP
CATALYST 1
CATALYST 2
(15V206)
CABLE
12 34 5
12 34 5
COLOR
CHANGE
MODUL
E4
(COLORS
25 THRU 32)
ALTERNATE CONFIGURATION
FOR CATALYST CHANGE CONTROL
INNON-HAZA
RDOUS LOCATION
Figure 33 Electrical Schematic, Sheet 4, Alternate
Configuration for Catalyst Change Control
48
332458D
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)
121201
20.0 (6.0)
121004
25.0 (8.0)
121228
50.0 (15.0)
332458D
Non--Hazardous
25 Pin D-SUB Cables, for Non
Locations Only
16T659
2.5 (0.8)
16V659
6.0 (1.8)
Alternates for Communication Module 24W462
Module Part No.
Module Part No.
CGMDN0*, DeviceNet
CGMPN0*, Profinet
CGMEP0*, Ethernet IP
* You must purchase CGM Installation Kit 24W829
for use with these kits.
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
58.20
in.
(1478
mm)
50
B
with
ADM
without
ADM
14.5 in.
(368
mm)
11.12 in.
(282
mm)
C
D
E
F
G
H
J
22.0 in.
(559
mm)
19.26 in.
(489
mm)
2.0 in.
(51 mm)
18.0 in.
(457
mm)
17.26 in.
(438
mm)
0.52 in.
(13 mm)
Minimum
6in (152 mm)
from mounting
surface
332458D
Technical Data
Technical Data
U.S.
Metric
AC1000 and AC1002 Air
Spray Systems
300 psi
2.1 MPa, 21 bar
AC2000, AC2002,
AC4000, and AC4002
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)
Positive Displacement
Proportioner
Maximum fluid working
pressure:
Maximum working air
pressure:
Air supply:
Air filter inlet size:
3/8 npt(f)
Air filtration for air logic
(user-supplied):
5 micron (minimum) filtration required; clean and dry air
Air filtration for atomizing
air (user-supplied):
30 micron (minimum) filtration required; clean and dry air
Mixing ratio range:
Fluids handled:
0.1:1 to 50:1, ±1%
one or two 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,
AC2000, and AC2002
17–4PH, 303, 304 SST, Tungsten carbide (with nickel binder),
perfluoroelastomer; PTFE, PPS, UHMWPE
AC4000 and AC4002
316 SST, 17–4PH SST, PEEK,
perfluoroelastomer; PTFE, PPS, UHMWPE
332458D
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 D, October 2016

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