Graco 332709H, ProMix® PD2K Proportioner for Automatic Spray Applications, Repair-Parts Owner's Manual

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Graco 332709H, ProMix® PD2K Proportioner for Automatic Spray Applications, Repair-Parts Owner's Manual | Manualzz

Repair-Parts

Electronic automatic

Important

Read all warnings and instructions in this manual and in your installation, operation, and associated component manuals. Save these instructions.

See page 3 for model part numbers and approvals information.

332709H

EN

PROVEN QUALITY. LEADING TECHNOLOGY.

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

Related Manuals ................................................ 5

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

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

Material Self-ignition..................................... 9

Troubleshooting.................................................. 11

System Troubleshooting ............................... 11

Error Code Troubleshooting.......................... 12

Power Barrier Board Diagnostics .................. 25

Isolation Board Diagnostics .......................... 26

Enhanced Fluid Control Module (EFCM)

Diagnostics .................................... 27

Pump Module Diagnostics ............................ 28

Advanced Display Module Diagnostics ........... 29

Electrical Schematics .......................................... 30

Standard Models (AC1000 and

AC2000) ........................................ 30

Dual Panel Models (AC1002 and

AC2002) ........................................ 37

Optional Cables and Modules ....................... 43

Communications Options (for PLC and

AWI) ............................................. 44

Repair................................................................ 45

Before Servicing .......................................... 45

Pressure Relief Procedure............................ 46

Repairing the Advanced Display Module

(ADM) ............................................ 47

Servicing the Control Box ............................. 48

Servicing the Fluid Section ........................... 57

Parts.................................................................. 61

Proportioner Parts (Standard Models) ........... 61

Proportioner Parts (Dual Panel

Models).......................................... 64

Control Box Parts......................................... 67

Control Box Parts (Dual Panel Models) ........... 70

Solenoid Manifold Parts................................ 73

Technical Specifications...................................... 74

California Proposition 65 ..................................... 75

2 332709H

See Figs. 1–7 for component identification labels, including approval information and certification.

Series Maximum

AC0500

AC0502

AC1000

AC1002

AC2000

AC2002

A

A

A

100 psi (0.7 MPa,

7.0 bar)

100 psi (0.7 MPa,

7.0 bar)

100 psi (0.7 MPa,

7.0 bar)

300 psi (2.068 MPa, 20.68 bar)

300 psi (2.068 MPa, 20.68 bar)

1500 psi (10.34 MPa,

103.4 bar)

II 2 G

Models

Figure 1 Model AC1000 and AC1002 Identification

Label

Figure 2 24M672 and 26A188 Control Box

Identification Label

Continued on the next page.

332709H 3

Models

Figure 3 Model AC2000 and AC2002 Identification

Label

Figure 4 Model AC0500 and AC0502 Identification Label

PART NO.

ProMix

®

PD

COLOR CHANGE CONTROL

SERIES SERIAL MFG. YR.

MAX AIR WPR

.7

7

MPa bar

100

PSI

GRACO INC.

P.O. Box 1441

Minneapolis, MN

55440 U.S.A.

294057d

Figure 5 Non-Intrinsically Safe Color Change Control (Accessory) Identification Label

Figure 6 Intrinsically Safe Color Change Control (Accessory) Identification Label

Figure 7 Pump Expansion Kit (Accessory) Identification Label

4 332709H

Current manuals are available at www.graco.com.

Manual No.

Description

332458 PD2K Proportioner Installation

Manual, Automatic Systems

332564

3A4486

3A6287

PD2K Proportioner Operation

Manual, Automatic Systems

PD2K Dual Panel Proportioner

Operation Manual, Automatic

Systems

PD3K+ Operation Manual,

Automatic Systems

332339

332454

Pump Repair-Parts Manual

Color Change Valve Repair-Parts

Manual

Related Manuals

Manual No.

Description

332455 Color Change Kits Instructions-

Parts Manual

333282

332456

334183

Remote Mix Manifold

Instructions-Parts Manual

Pump Expansion Kits

Instructions-Parts Manual

Modbus TCP Gateway Module

Instructions-Parts Manual

334494

334512

ProMix PD2K CGM Installation Kits

Instructions-Parts Manual

Isolated Pump Expansion Kits

Instructions-Parts Manual

332709H 5

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.

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).

• 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.

you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

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 332709H

Warnings

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.

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin.

• Do not point dispensing device at anyone or at any part of the body.

• Do not put your hand over the fluid outlet.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

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,

332709H

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDSs to know the specific hazards of the fluids you are using.

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

• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.

7

8

Warnings

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

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 complete information about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

• 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.

332709H

Important Isocyanate (ISO) Information

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

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

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

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

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

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

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

• Avoid all skin contact with iscocyanates.

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

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

Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination:

B wetted parts.

• Never use solvent on one side if it has been contaminated from the other side.

332709H 9

Important Isocyanate (ISO) Information

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.

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.

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

• Use only moisture-proof hoses compatible with

ISO.

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

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

crystallization varies depending on the blend of ISO, the humidity, and the temperature.

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

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

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

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

10 332709H

Troubleshooting

Unit will not operate.

Pump output low on both strokes.

Pump output low on only one stroke.

No output.

Pump operates erratically.

Inadequate power supply.

Power switch is off.

Main power is shut off.

See

Technical Specifications, page 74 .

Turn switch on.

Turn main power switch on.

Exhausted fluid supply.

Refill and reprime pump.

Clogged fluid outlet line, valves, etc.

Clear.

Fluid dried on piston rod.

Inadequate power supply.

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

See

Technical Specifications, page 74 .

Exhausted fluid supply.

Refill and reprime pump.

Clogged fluid outlet line, valves, etc.

Clear.

Worn piston packings.

Held open or worn dosing valves.

Worn piston packing.

Improperly installed dosing valves.

Replace. See pump manual.

Check and repair. See pump manual.

Replace. See pump manual.

Exhausted fluid supply.

Held open or worn dosing valves.

Worn piston packing.

Check solenoid connections to valves. See pump manual.

Refill and reprime pump.

Check and repair. See pump manual.

Replace. See pump manual.

332709H 11

Troubleshooting

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

Advisory, Deviation, and Alarm.

AC2002, AC3002, and AC4002) as well as ProMix

PD3K+ Systems, have most of the same error codes as the ProMix PD2K. However, there are some unique codes that apply to each system, and in the case of Dual Mix, codes are specific to one of two mix units. Refer to the ProMix Dual Mix Operation

Manual or PD3K+ Operation Manual for a complete

list of error codes. See Related Manuals, page 5

.

clear itself after 60 seconds. The four-digit error code will be followed by “-V”.

not shut down the equipment. The deviation must be acknowledged by the user. The four-digit error code will be followed by “-D”.

error code will be followed by “-A”.

If any of the three system error types occur:

• Alarm buzzer sounds (unless in silent mode).

• Alarm popup screen shows the active alarm code.

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

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

background. These are informational only and can be reviewed on the Events screen, which displays the 200 most recent events, with date, time, and description.

the code before resetting it. If you forget which code occurred, the Errors screen displays the 200 most recent errors, with date, time, and description.

is shown as the last digit. This symbol represents the applicable pump number, which can vary. The unit’s display will show the applicable pump number as the last digit in the code.

Figure 8 Alarm Popup Screen

All alarms have a QR code screen. A mobile device with internet access and a QR reader may use the QR code to access additional information on a webpage hosted by help.graco.com.

Figure 9 Error QR Code Screen

A number of the alarms that are most likely to be encountered during typical operation have detailed troubleshooting information screens. The troubleshooting screens will replace the QR code screen, though the QR code may still be accessed by pressing .

When a system alarm occurs, a help screen is available to provide timely and relevant troubleshooting information for the user. On the alarm popup screen, press to access the help screens. The help screens may also be accessed at any time by going to the Errors Screen and selecting an alarm in the log.

Figure 10 Error Troubleshooting Screen

12 332709H

Troubleshooting

ETE0

SPD1

Record Purge Not

Complete

Alarm

Description Problem

Gun Purge

Incomplete

The system was unable to complete a purge sequence.

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

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

Solvent flow switch not working.

Solvent flow is too low to actuate the solvent switch.

Gun is not triggered.

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

No action required.

Replace switch.

Increase solvent pressure to drive a high purge flow rate

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

Set manifold to flush position.

332709H 13

Troubleshooting

F7S1

F7S2

QPD1 Alarm, then

Deviation

QP##

SND1

Alarm

Alarm

Deviation

Alarm

Description Problem

Flow

Detected

Solvent Gun

Flow

Detected

Solvent Mix

Potlife

Expired

The solvent flow switch is indicating unexpected solvent flow.

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

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

Solvent flow switch is stuck in flow position.

There is a leak through the solvent cutoff valve.

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

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

Purge process was not completed.

Solvent supply shut off or empty.

Clean or replace switch.

Check for leaks and repair valve.

Clean or replace the switch(es).

Check for leaks and repair valve(s).

Make sure purge process is completed.

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

Potlife

Expired

Recipe ##

Mix Fill

Incomplete

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

(potlife volume) through the mixed material line.

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

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

*This only applies to systems with multiple guns.

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

An inactive gun has mixed material for recipe

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

Mix manifold not set to spray position.

Spray gun was not triggered.

Restrictions in mixer, manifold, or spray gun.

Purge the inactive gun.

Set manifold to spray.

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

Fix restrictions.

14 332709H

Troubleshooting

component number, which can vary. The unit’s display will show the applicable number as the last digit in the code. For example, the F1S# code listed in this table will be displayed as F1S1 if the affected component is pump

1, F1S2 for pump 2, and so on.

DA0#

Type Description

Alarm Exceeded

Maximum

Flow Pump

#

Pump was driven to its maximum allowed speed.

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

Pump is cavitating, cycling without restriction.

Viscosity of material is too thin for nozzle size.

Inspect system for leaks.

Verify that the pump is being supplied with material.

Reduce nozzle size to create more restriction.

Reduce paint pressure to lower the flow rate.

Reduce the pressure or the Flow Setpoint.

DE0# Alarm Leak

Detected

Pump #

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

Pressure.” Will fault after

30 seconds.

System pressure or

Flow Setpoint is too high

(causing the pump to work too hard).

No material in the pump or line.

Leak in the system.

DF0#

DG0#

DH0#

Alarm

Alarm

Alarm

No Stall Up

Pump #

No Stall

Down Pump

#

No Stall

Pump #

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

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

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

Valve failure, seal failure, worn rod or cylinder.

Valve failure, seal failure, worn rod or cylinder.

Valve failure, seal failure, worn rod or cylinder.

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

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

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

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

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

Replace rod and cylinder as necessary.

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

Replace rod and cylinder as necessary.

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

Replace rod and cylinder as necessary.

332709H 15

Troubleshooting

DKD#

DKF#

EBH#

EF0#

EF1#

ETD#

F1A#

F1D#

Alarm

Alarm

Record

Alarm

Alarm

Position

Failed

Pump #

Position

Overspeed

Pump #

Home

Complete

Pump #

Timeout

Startup

Pump #

Timeout

Shutdown

Pump #

Pump was unable to reach it’s drive position.

Pump moved beyond it’s drive position.

Record of pump homing is complete.

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

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

Pump dose valves did not actuate.

Motor could not drive pumps and linear actuator.

Pump stroke length is shortened by mechanical system tolerance.

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

Not enough air is supplied to the dosing valves.

The pressure at the pump outlet is too high.

The pump was knocked out of position.

Pump dose valves did not actuate.

Ensure that at least 85

PSI is being supplied to the dosing valves.

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

1/2 – 1/3 of the target pressure.

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

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

No action required.

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

Verify motor is driving the pump.

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

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

6.0 bar).

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

Record

Alarm

Auto

Pressure

Relief Pump

#

Flow Low

Dispense

Pump #

Record of pump completing an auto pressure relief.

The pump was unable to maintain its target flow rate.

Alarm Flow Low Mix

Pump #

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

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

Motor or drive is worn or damaged.

Pump outlet pressure exceeded relief threshold.

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

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

No action required.

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

Check for restrictions in the hose along the entire fluid path after the pump and also that the gun is triggered.

16 332709H

F1F#

F1S#

F7D#

F8D1

F9D#

Troubleshooting

Type Description

Alarm Flow Low Fill

Pump #

Alarm

Alarm

Alarm

Alarm

Flow Low

Purge Pump

#

Flow

Detected

Pump #

Flow Not

Detected

Flow

Unstable

Pump #

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

Thick viscosity paint requires more pressure to pump.

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

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

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

The pump flow exceeded

20 cc/min flow coming into Idle mode.

No flow while mixing.

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

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

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

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

Potential leak in the system.

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

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

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

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

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

Do not trigger the gun without atomizing air.

Make sure there are no restrictions in the system.

Check the system for leaks and run manual stall test.

332709H 17

Troubleshooting

component number, which can vary. The unit’s display will show the applicable number as the last digit in the code. For example, the P6F# code listed in this table will be displayed as P6F1 if the affected component is pump

1, P6F2 for pump 2, and so on.

P1D#

P1F#

P2F#

P3D#

P3F#

P4D#

P4F#

P4P#

P6D#

P6F#

P9D#

Type Description Problem

Alarm Pressure

Low Outlet

Pump #

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

Alarm

Deviation

Deviation

Pressure

Low Inlet

Pump #

Pressure

Low Inlet

Pump #

Pressure

High Outlet

Pump #

* This alarm is only enabled with Flow

Control.

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

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

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

Deviation

Pressure

High Inlet

Pump #

Alarm

Alarm

Alarm

Alarm

Pressure

High Outlet

Pump #

Pressure

High Inlet

Pump #

Pressure

High Supply

Pump #

Press. Sens.

Removed

Outlet #

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

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

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

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

Pressure.

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

Alarm

Alarm

Press. Sens.

Removed

Inlet #

Press. Sens.

Failed Outlet

#

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

Outlet pressure transducer has failed.

There is no fluid pressure or pump is cavitating.

The supply pump pressure is too high.

Disconnected transducer.

Disconnected transducer.

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

Check the supply for pump #, increase feed pressure if necessary.

Increase inlet pressure.

Increase inlet pressure.

Relieve system pressure.

Decrease inlet pressure.

Relieve system pressure.

Decrease inlet pressure.

Check supply for pump

#, decrease supply pressure.

Verify transducer is connected properly.

Replace if reconnecting does not eliminate the alarm.

Verify transducer is connected properly.

Replace if reconnecting does not eliminate the alarm.

Relieve system pressure.

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

18 332709H

Troubleshooting

P9F#

QADX

QBDX

Type Description Problem

Alarm

Alarm

Alarm

Press. Sens.

Failed Inlet #

Differential

Pressure A

Over B

Differential

Pressure B

Over A

Inlet pressure transducer has failed.

Low differential pressure.

This alarm is active only during Mix mode.

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

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

There is a leak on the B side.

The B side pump is cavitating.

There is a leak on the A side.

The A side pump is cavitating.

Relieve system pressure.

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

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

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

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

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

332709H 19

Troubleshooting

EB00

EBIX

EBCX

EC00

EL00

EM00

EMIX

Type Description

Record

Record

Record

Record

Record

Record

Advisory

Stop Button

Pressed

Pumps

Off Button

Pressed

Pumps

Off PLC

Command

Setup

Value(s)

Changed

System

Power On

System

Power Off

Pump Off

EP0X

ES00

Record

Advisory

Auto Pump

Parked

Factory

Defaults

WSN1 Alarm Config Error

Color

WSN2 Alarm Config Error

Catalyst

Record of a stop button press.

Record of a pump power off button press.

Record of a pump power off PLC command.

Record of changing setup variables.

Record of power cycle

(ON).

Record of power cycle

(OFF).

The pumps are not powered and are unable to move.

Indicates system stop key on ADM was pressed.

Indicates pump power key o ADM pressed to power down pumps.

Indicates a system command to power off pumps was sent by the

PLC.

Indicates date and time when setup values were changed.

Indicates date and time when system was started.

Indicates date and time when system was turned off.

Pump power was turned off or an error occurred.

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

Start pumps by pressing pump start key on

Advanced Display module.

No action required.

Record of pumps being auto parked.

Record of defaults being loaded.

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

*This only applies to systems with multiple guns.

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

*This only applies to systems with multiple guns.

The auto park operation was completed.

One or more colors is missing a valid gun assignment.

One or more catalyst is missing a valid gun assignment.

Too many catalyst gun assignments exist.

n/a

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

Pump Screen 4.

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

Pump Screen 4.

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

20 332709H

Troubleshooting

component number, which can vary. The unit’s display will show the applicable number as the last digit in the code. For example, the CAC# code listed in this table will be displayed as CAC1 if the affected component is color change board 1, CAC2 for board 2, and so on.

CA0X

CAC#

Alarm

Alarm

CADX Alarm

CAGX

CAG#

CANX

CDC#

CDDX

CDNX

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Comm. Error

ADM

Comm. Error

Color Change

#

Comm. Error

Fluid Module

Comm. Error

Gateway

Comm. Error

Modbus

Gateway

System does not detect the Advanced Display

Module (ADM).

System does not detect the Color Change

Module #.

System does not see the Enhanced

Fluid Control Module

(EFCM).

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

Module.

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

Module #.

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

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

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

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

The Modbus CGM is not connected/failed.

Check CAN cable connecting ADM to the

EFCM.

Check CAN cable connections to the Color Change

Module # and any interconnected modules.

Check CAN cables connecting ADM to the

EFCM. Replace Cable or EFCM as necessary.

Unplug the Modbus

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

Check that the Modbus

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

Check CAN cable connecting the Booth

Control to the network.

Comm. Error

Booth Control

Duplicate Color

Change #

Duplicate Fluid

Module

Duplicate

Booth Control

System does not detect the Booth Control

Module.

System detects two or more identical Color

Change Modules.

System sees two or more identical

Enhanced Fluid

Control Modules

EFCM).

System detects two or more identical Booth

Control Modules.

This communication error indicates that the network has lost communication with the Booth Control.

More than one Color

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

More than one EFCM is connected in the system.

More than one Booth

Control Module is connected in the system.

Check the system and remove the extra color change module.

Check the system and remove the extra

EFCM.

Remove the extra

Booth Control Module.

332709H 21

Troubleshooting

EAUX

EBUX

EQU0

EQU1

EQU2

EQU3

EQU4

EQU5

EVUX

MMUX

WSUX

WXUD

WXUU

Advisory

Record

Advisory

USB Busy

USB Drive

Removed

USB Idle

USB drive is inserted, download is in progress.

USB drive was removed while downloading or uploading.

USB download completed, drive may be removed.

Settings were downloaded to USB drive.

Record

Record

Record

Record

USB Sys.

Settings

Downloaded

USB Sys.

Settings

Uploaded

USB Custom

Lang.

Downloaded

USB Custom

Lang.

Uploaded

Settings were uploaded from USB drive.

Custom language was downloaded to USB drive.

Custom language was uploaded from USB drive.

Record USB Logs

Downloaded

Data logs were downloaded to USB drive.

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

Advisory Maint. USB

Logs Full

USB memory is more than 90% full.

Indicates USB port is uploading or downloading data.

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

Data transfer is completed to the USB device.

User installed USB device in ADM USB port.

User installed USB device in ADM USB port.

User installed USB device in ADM USB port.

User installed USB device in ADM USB port.

User installed USB device in ADM USB port.

Configuration of system is blocking data transfer.

Configuration parameter on system is enabled to generate this advisory.

A software update was not completed successfully.

Advisory

Advisory USB Download

Err.

Advisory

USB Config.

Err.

USB Upload

Err.

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

An error occurred while downloading to the

USB drive.

An error occurred while uploading from the

USB drive.

User installed incompatible USB device in ADM USB port.

User installed incompatible USB device in ADM USB port.

Wait for USB Idle.

Replace the USB device and begin process again.

Remove USB device from ADM.

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

Change configuration to enable USB download function.

Complete download to ensure no data is lost.

Reinstall software.

Repeat process with compatible USB device.

Repeat process with compatible USB device.

22 332709H

Troubleshooting

component number, which can vary. The unit’s display will show the applicable number as the last digit in the code. For example, the B9D# code listed in this table will be displayed as B9D1 if the affected component is pump

1, B9D2 for pump 2, and so on.

B9A0

B9AX

B9B0

B9BX

B9D#

B9S0

B9SX

WX00

Advisory

Advisory

Advisory

Advisory

Advisory Volume

Rollover Pump

#

Advisory

Advisory

Alarm

Volume

Rollover A

Current

Volume

Rollover A

Lifetime

Volume

Rollover B

Current

Volume

Rollover B

Lifetime

Volume

Rollover

Solvent

Current

Volume

Rollover

Solvent

Lifetime

Software

Errors

Batch counter for material A rolled over.

Grand total counter for material A rolled over.

Batch counter for material B rolled over.

Grand total counter for material B rolled over.

Grand total counter for pump # rolled over.

Batch counter for solvent rolled over.

Grand total counter for solvent rolled over.

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

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

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

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

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

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

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

An unexpected software error has occurred.

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

Call Graco technical support.

component number, which can vary. The unit’s display will show the applicable number as the last digit in the code. For example, the ENT# code listed in this table will be displayed as ENT1 if the affected component is pump

1, ENT2 for pump 2, and so on.

END#

ENS0

ENT#

Record

Record

Record

Calibration Pump #

Calibration Solvent Meter

A calibration test was run on the pump.

A calibration test was run on the solvent meter.

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

332709H 23

B

C

9

A

6

7

8

D

E

F

3

4

5

1

2

Troubleshooting

MAD#

MAT#

MEB#

MED#

MEF#

MEG#

MEN#

MES#

MFF#

MFS0

MGH0

MGP0

MJP# component number, which can vary. For example, the MAD# code listed in this table will be displayed as MAD1 if the affected component is pump 1, MAD2 for pump 2, and so on.

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

MEDZ represents outlet valve 30.

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Advisory

Maint. Outlet Pump # Maintenance is due on pump.

Maint. Stall Test Pump

#

Maintenance stall test is due on pump.

Maint. Valve Catalyst

(B) #

Maint. Valve Outlet #

Maintenance is due on catalyst valve.

Maint. Valve Inlet #

Maint. Valve Gun #

Maintenance is due on outlet valve.

Maintenance is due on inlet valve.

Maintenance is due on gun valve.

Maint. Valve Auxiliary Maintenance is due on auxiliary valve.

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

Maint. Meter Flow #

Maint. Meter Solvent

Maintenance is due on flow meter.

Maintenance stall test is due on solvent meter.

Maint. Filter Fluid

Maint. Filter Air

Maint. Valve Air

Maintenance is due on fluid filter.

Maintenance is due on air filter.

Maintenance is due on air valve.

9

10

11

12

6

7

8

13

14

15

3

4

5

1

2

N

P

R

L

M

J

K

G

H

T

U

Y

Z

V

W

20

21

22

23

24

16

17

18

19

25

26

27

28

29

30

24 332709H

Troubleshooting

Figure 11 Power Barrier Board

D4

D5

F3

F4

J4

J5

LED (green)

LED (green)

Fuse, 400 mA, 250 V

Fuse, 400 mA, 250 V

Connector

Connector

IS Power

Power

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

24 Vdc power input

+12 Vdc intrinsically safe power output

332709H 25

Troubleshooting

Figure 12 Isolation Board

J3

J4

S1

D6

D7

D8

D14

J1

J2

S2

LED (yellow)

LED (green)

LED (green)

LED (yellow)

Connector

Connector

Connector

Connector

Pushbutton Switch

Pushbutton Switch

IS Communication

IS Power

Non-IS Power

Non-IS Communication

Non-IS, Gateway

Non-IS, Optional Color Change Module

Intrinsically Safe, Barrier Board

Intrinsically Safe, Optional Color Change Module

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

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

26 332709H

Troubleshooting

Figure 13 Enhanced Fluid Control Module

6

7

8

9

4

5

1

2

3

10

CPLD (D37)

POW (D19)

CAN (D69)

ERR (D38)

25 pin connector

25 pin connector

25 pin connector

25 pin connector

12 pin connector

12 pin connector

12 pin connector

5 pin connector

5 pin connector

5 pin connector

LED (orange)

LED (green)

LED (yellow)

LED (red)

Pump 1 Module

Pump 2 Module

Pump 3 Module (accessory)

Pump 4 Module (accessory)

Multiple purpose I/O

Multiple purpose I/O

Multiple purpose I/O

24 Vdc Power/CAN (Communication Barrier)

Advanced Display Module

24 Vdc Input

Heartbeat

Power

Communication.

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

332709H 27

Troubleshooting

Figure 14 Pump Module

8

9

6

7

10

11

24V

48V

3

4

5

1

2

25 pin connector

5 pin connector

5 pin connector

5 pin connector

5 pin connector

4 pin connector

8 pin connector

4 pin connector

LED (red)

LED (red)

LED (red)

LED (green)

LED (green)

Input from EFCM

Pump connection

Motor encoder connection

Pump Inlet Transducer

Pump Outlet Transducer

Motor Power Control (PD2K Dual Panel)

Dose Valve Solenoids

48 Vdc Input Power and fan connection

Pump Up Valve Output

Pump Down Valve Output

Not used

24 VDC power supplied

48 VDC power supplied

28 332709H

Troubleshooting

Figure 15 Advanced Display Module

D1

D6

J1

J2

J3

J7

LED (yellow/green)

LED (red/yellow/green)

8 pin connector

8 pin connector

5 pin connector

5 pin connector

Green: USB inserted

Yellow: USB communication

Green: Power

Yellow: Communication

Red: Error

Token port

USB port

Light tower (accessory)

CAN power/communication port

332709H 29

Electrical Schematics

wiring expansions in a ProMix PD2K system; models

AC1000 and AC2000. Some components shown are not included with all systems.

NOTE:

Optional Cables and Modules, page 43

for a list of cable options.

Figure 16 Electrical Schematic, Sheet 1

CONTINUED ON THE NEXT PAGE

30 332709H

Electrical Schematics

Figure 17 Electrical Schematic, Sheet 2, Part 1

CONTINUED ON THE NEXT PAGE

332709H 31

Electrical Schematics

Figure 18 Electrical Schematic, Sheet 2, Part 2

CONTINUED ON THE NEXT PAGE

32 332709H

Electrical Schematics

Figure 19 Electrical Schematic, Sheet 3

* May be unused in some configurations.

CONTINUED ON THE NEXT PAGE

332709H 33

Electrical Schematics

Figure 20 Electrical Schematic, Sheet 3, Alternate

Configuration for Catalyst Change Control

CONTINUED ON THE NEXT PAGE

34 332709H

Electrical Schematics

Figure 21 Electrical Schematic, Sheet 3, Hazardous

Location

CONTINUED ON THE NEXT PAGE

332709H 35

Electrical Schematics

Figure 22 Electrical Schematic, Sheet 4

36 332709H

Electrical Schematics

wiring expansions in a ProMix PD2K system; models

AC1002 and AC2002. Some components shown are not included with all systems.

NOTE:

Optional Cables and Modules, page 43

for a list of cable options.

POWER MODULE

(26A189)

2 POSITION

SWITCH

(16U725)

CABLE

16T658

(16V446)

CABLE

16H078

POWER IN

(114095)

24V

POWER

SUPPLY

(16T660)

48V-10A POWER SUPPLY

(16U820)

RELAY 1 RELAY 2

TERMINAL BLOCK WITH FUSES

GATEWAY

5

AWI

GATEWAY

(24R910)

5

16T072

CAN

IS BOARD

(24M485)

17L058 FAN

(24P658)

AND MOT

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

CABLE 126232

OR 17N315

UP

DOWN

SOLVENT

METER 1

(258718)

FAN

(24P658)

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

CABLE 126232

OR 17N315

UP

DOWN

SOLVENT

METER 2

(258718)

SPLITTER

(16P243)

BARRIER

BOARD

(248192)

2

CABLE

(15V206)

2 CABLE

(15V206)

2

CABLE

(15V206)

GCA

EFCM

(24N913)

2

CABLE

(15V206)

2

CABLE

(15V206)

CABLE

15V819

AIR FLOW SW. 1 (119159)

AIR FLOW SW. 2 (119159)

GFB PRESS. SW. 1 (121323)

GFB PRESS. SW. 2 (121323)

GFB VALVE 1 (121324)

GFB VALVE 2 (121324)

AIR

CONTROL

MODULE

(26A231)

SOLVENT CUTOFF VALVE (121324)

SOLVENT CUTOFF VALVE (121324)

SWITCH (120278)

SWITCH (120278)

SWITCH (120278)

SWITCH (120278)

SOLVENT

FLOW

INPUTS

SAFETY INTERLOCK SWITCH

CABLE

(121003)

3

(24E451)

TOWER

(15X472)

1 CABLE (16V429)

COLOR CHANGE

MODULE 7

(24R219)

7

1

CABLE

(16V426)

(24M731)

WITH SHUNT

(17M540)

COLOR CHANGE

MODULE 8

(24R219)

7

1

CABLE

(16V426)

BOOTH

CONTROL

(24M731) FAN

(24P658)

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

PUMP V/P FOR

FLUID REG.

UP

DOWN

FAN

(24P658)

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

PUMP V/P FOR

FLUID REG.

UP

DOWN

(120278) (120278)

(239716, 258718

16M510, 16M519)

(239716, 258718

16M510, 16M519)

Figure 23 Electrical Schematic, Sheet 1

4

CABLE (16T659)

332709H 37

Electrical Schematics

SPLITTER

(16P243)

5 4 3 2 1

1

4

5

2

3

3

4

5

1

2

16T072

1 2 3 4 5

2

4

CAN IS BOARD

1 2 3 4 5

1

(NON IS)

(IS)

(24M485)

3

1 2 3 4 5 1 2 3 4 5

UNUSED

1

2

3

J4

3

CABLE (121227)

1 2 3

J5

BOARD

(248192)

3

4

5

1

2

P3 P4

AWI

GATEWAY

(24R910)

3

4

1

2

5

5

CABLE

(121227)

3

UNUSED

UNUSED

3

4

5

1

2

P3 P4 3

4

1

2

5

UNUSED

CABLE

(121001)

3

GATEWAY

3

2

5

4

1

3

4

1

2

5

10

8

5

GFB OUTPUT VALVE 1

GFB OUTPUT VALVE 2

+24VDC

COM

+24VDC

COM

GREEN/BLACK +24VDC

ORANGE/BLACK COM

BLUE/BLACK +24VDC

RED/WHITE COM

UNUSED

SIG

COM

UNUSED

7

8

5

6

3

4

1

2

9

10

11

12

5

25 PIN D-SUB

4

1

GCA MODULE

EFCM

(24N913)

2 3 4

7

9

10

11

12

7

8

5

6

3

4

1

2

9 3

4

1

2

5

6

7

8

5

6

3

4

1

2

9

10

11

12

24V

POWER

SUPPLY

(16T660)

GROUND

BAR

2

1 2 3 4 5

1

3

1 2 3 4

4

1 2 3 4 5

5

1 2 3 4 5

6

1 2 3 4 1 2 3 4

7

5 6 7 8

8

1 2 3 4

2

1 2 3 4 5

1

3

1 2 3 4

4

1 2 3 4 5

5

1 2 3 4 5

6

1 2 3 4 1 2 3 4

7

5 6 7 8

8

1 2 3 4

N03 N03

2 POSITION

SWITCH

(16U725)

N04 N04

CABLE

(16T658)

L N

LINE

FILTER

(16V446)

L GND N

CABLE

(16H078)

L N GND

BLOCK

(114095)

L N GND

GRND (GRN/YEL)

N L GRND

48V-10A

POWER SUPPLY

(16U280)

- - + +

15

18

RELA

2

A1

A2

15

18

RELA

1

A1

A2

AND

WIRE HARNESS

PUMP 1

BROWN (UNUSED)

DRAIN (UNUSED)

BLUE

BLACK

BROWN (UNUSED)

DRAIN (UNUSED)

BLUE

BLACK

CABLE (126232 OR 17N315)

PUMP 1

SOLVENT

(258718)

- + -

4 3 2 1

GND

SCREW

DETAIL A, LOW PRESSURE PUMPS

(24M706, 24M714, 24T799)

2

1 2 3 4 5

(24N527)

3

1 2 3 4

WIRE HARNESS

(24P684)

DRAIN/FOIL

TWISTED PAIR CABLE (16W159)

DETAIL B, HIGH PRESSURE PUMPS

(24M707, 24M715, 24T800)

2

1 2 3 4 5

(24N527)

WIRE HARNESS

(24P685)

3

1 2 3 4

DRAIN/FOIL

AND

WIRE HARNESS

PUMP 2

CABLE (126232 OR 17N315)

TWISTED PAIR CABLE (16W159)

PUMP 2

MANIFOLD

SOLVENT

(258718)

GND

SCREW

MOTOR

GROUND

SCREW

MOTOR

MOUNTING

SCREW

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9

PUMP ENCODER AND MOTOR

(16P037)

10

MOTOR

MOUNTING

SCREW

1 2 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9

PUMP ENCODER AND MOTOR

(16P036)

Figure 24 Electrical Schematic, Sheet 2, Part 1

CONTINUED ON THE NEXT PAGE

10

38 332709H

Electrical Schematics

3

2

5

4

1

3

4

1

2

5

10

8

5

6

7

8

1

2

3

4

9

10

11

12

5

1

GCA MODULE

EFCM

(24N913)

2 3 4

6

5

6

7

8

1

2

3

4

9

10

11

12

SIG

COM

SIG

COM

SIG

COM

SIG

COM

SIG

COM

SIG

COM

BLACK

WHITE

RED

GREEN

AIR FLOW SWITCH 1

AIR FLOW SWITCH 2

SOLVENT FLOW SW. 1 (120278) LEFT BRKT

SOLVENT FLOW SW. 2 (120278) LEFT BRKT

SOLVENT FLOW SW. 3 (120278) RIGHT BRKT

SOLVENT FLOW SW. 4 (120278) RIGHT BRKT

7

4

5

6

7

1

2

3

10

11

12

8

9

9 3

4

1

2

5

PLC DISCRETE 4-20mA INPUT 1

PLC DISCRETE 4-20mA COMMON 1

PLC DISCRETE 4-20mA INPUT 2

PLC DISCRETE 4-20mA COMMON 2

UNUSED

UNUSED

UNUSED

UNUSED

SIG ORANGE

COM

SIG

COM

BLUE

WHITE/BLACK

RED/BLACK

CABLE

(121003)

3

3

4

1

2

5

ADVANCED

DISPLAY MODULE

(24E451)

GFB INPUT PRESSURE SWITCH 1

GFB INPUT PRESSURE SWITCH 2

3

4

2

1

5

LIGHT

TOWER

(15X472)

CABLE

15V819

AIR CONTROL MODULE (26A231)

WHITE

RED

GREEN

ORANGE

BLUE

WHITE/BLACK

RED/BLACK

GREEN/BLACK

ORANGE/BLACK

BLUE/BLACK

RED/WHITE

TERMINAL

BLOCKS

7

8

5

6

1

2

3

4

9

10

11

12

+ SIG

- COM

+ SIG

- COM

+ SIG

- COM

+ SIG

- COM

+ 24VDC

- COM

+ 24VDC

- COM

RED

RED

AIR FLOW SWITCH 1

119159

AIR FLOW SWITCH 2

119159

GFB INPUT PRESSURE SWITCH 1

121323

GFB INPUT PRESSURE SWITCH 2

121323

GFB OUTPUT VALVE 1

121324

GFB OUTPUT VALVE 2

121324

2

1 2 3 4 5

25 PIN D-SUB

CABLE (16T659)

4

3

1 2 3 4

1

BREAKOUT MODULE PUMP 3 (24N527)

4

1 2 3 4 5

5

1 2 3 4 5

6

1 2 3 4 1 2 3 4

7

5 6 7 8

8

1 2 3 4

2

1 2 3 4 5

1

BREAKOUT MODULE PUMP 4 (24N527)

3

1 2 3 4

4

1 2 3 4 5

5

1 2 3 4 5

6

1 2 3 4 1 2 3 4

7

5 6 7 8

8

1 2 3 4

AND

WIRE HARNESS

PUMP 3

AND

WIRE HARNESS

PUMP 4

PUMP 3

MANIFOLD

G3000

METER

PUMP 3

(EITHER, 239716,

258718,16M510,

OR 16M519)

GND

SCREW

PUMP 4

MANIFOLD

G3000

METER

PUMP 4

(EITHER, 239716,

258718,16M510,

OR 16M519)

GND

SCREW

TWISTED PAIR CABLE (16W159)

TWISTED PAIR CABLE (16W159)

Figure 25 Electrical Schematic, Sheet 2, Part 2

CONTINUED ON THE NEXT PAGE

332709H 39

Electrical Schematics

FROM CAN IS BOARD (24M485)

FLUSH

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

2

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

1 2 3 4 5

4

5

6

1

2

3

J8

COLOR

CHANGE

MODULE 1

(COLORS

1 THRU 8)

6

J9

1

2

3

4

5

6

J15 J16 4

3

2

6

5

1

6

5

4

3

2

1

3

4

5

1

2

6

J14

1 2 3 4 5

J10

4

3

6

5

2

1

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

*FLUSH

COLOR 9

COLOR 10

COLOR 11

COLOR 12

COLOR 13

COLOR 14

COLOR 15

COLOR 16

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

1 2 3 4 5

4

5

6

1

2

3

J8

COLOR

CHANGE

MODULE 2

(COLORS

9 THRU 16)

J9

6

1

2

3

4

5

6

J15 J16 4

3

2

6

5

1

4

3

2

6

5

1

3

4

5

1

2

6

J14 J10

1 2 3 4 5

6

5

4

3

2

1

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COLOR 9

COLOR 10

COLOR 11

COLOR 12

COLOR 13

COLOR 14

COLOR 15

COLOR 16

FLUSH

CATALYST 1

CATALYST 2

CATALYST 3

CATALYST 4

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

1

2

3

4

5

6

4

5

6

1

2

3

CATALYST

CHANGE

MODULE 5

(CATALYST

1 THRU 4)

J8

6

J9

4

3

2

6

5

1

J15 J16 4

3

2

6

5

1

3

4

5

1

2

6

J14

1 2 3 4 5

J10

6

5

4

3

2

1

COM

+24VDC

COM

+24VDC

COM

+12VDC

COM

+24VDC

COM

+24VDC

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

CATALYST 1

CATALYST 2

CATALYST 3

CATALYST 4

*FLUSH

COLOR 17

COLOR 18

COLOR 19

COLOR 20

COLOR 21

COLOR 22

COLOR 23

COLOR 24

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

1 2 3 4 5

COLOR

CHANGE

MODULE 3

(COLORS

17 THRU 24)

1

2

3

4

5

6

J8

3

4

5

1

2

6

J15

6

J9

J16 4

3

2

6

5

1

4

3

2

6

5

1

4

5

6

1

2

3

J14 J10

6

5

4

3

2

1

5 4 3 2 1

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

Figure 26 Electrical Schematic, Sheet 3, Part 1

* May be unused in some configurations.

CONTINUED ON THE NEXT PAGE

2

COLOR 17

COLOR 18

COLOR 19

COLOR 20

COLOR 21

COLOR 22

COLOR 23

COLOR 24

*FLUSH

COLOR 25

COLOR 26

COLOR 27

COLOR 28

COLOR 29

COLOR 30

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

1

2

3

4

5

6

J8

1 2 3 4 5

COLOR

CHANGE

MODULE 4

(COLORS

25 THRU 32)

J9

6

3

4

5

1

2

6

J15 J16 4

3

2

6

5

1

4

3

2

6

5

1

4

5

6

1

2

3

J14 J10

6

5

4

3

2

1

1 2 3 4 5

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

COM

+24VDC

UNUSED

UNUSED

UNUSED

UNUSED

COLOR 25

COLOR 26

COLOR 27

COLOR 28

COLOR 29

COLOR 30

40 332709H

FROM CAN IS BOARD (24M485)

1

CABLE (16V429)

NON-HAZARDOUS LOCATION

HAZARDOUS LOCATION

COLOR FLUSH

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

MANIFOLD

RED

BLACK

RED

BLACK

RED

BLACK

+12VDC

COM

+12VDC

COM

+12VDC

COM

RED

BLACK

RED

BLACK

RED

BLACK

+12VDC

COM

+12VDC

COM

+12VDC

COM

RED

BLACK

RED

BLACK

RED

BLACK

+12VDC

COM

+12VDC

COM

+12VDC

COM

3

4

1

2

5

6

3

4

1

2

5

6

1 2 3 4 5

COLOR

CHANGE

MODULE 7

(COLORS

33 THRU 40)

J8 J9

4

3

6

5

2

1

7

J15 J16 4

3

6

5

2

1

3

4

1

2

5

6

J14 J10

4

3

6

5

2

1

5 4 3 2 1

COM

+12VDC

COM

+12VDC

COM

+12VDC

BLACK

RED

BLACK

RED

BLACK

RED

COM

+12VDC

COM

+12VDC

COM

+12VDC

BLACK

RED

BLACK

RED

BLACK

RED

COM

+12VDC

COM

+12VDC

COM

+12VDC

BLACK

RED

BLACK

RED

BLACK

RED

MANIFOLD

CATALYST FLUSH

CATALYST 1

CATALYST 2

CATALYST 3

CATALYST 4

COLOR 9

COLOR 10

COLOR 11

COLOR 12

5 4 3 2 1

BOOTH CONTROL

(24M731)

WITH SHUNT

(17M540)

1 2 3 4 5

J1

COLOR 13

COLOR 14

COLOR 15

COLOR 16

COLOR 17

COLOR 18

COLOR 19

COLOR 20

COLOR 21

MANIFOLD

RED

BLACK

RED

BLACK

RED

BLACK

+12VDC

COM

+12VDC

COM

+12VDC

COM

RED

BLACK

RED

BLACK

RED

BLACK

+12VDC

COM

+12VDC

COM

+12VDC

COM

RED

BLACK

RED

BLACK

RED

BLACK

+12VDC

COM

+12VDC

COM

+12VDC

COM

3

4

1

2

5

6

J8

1 2 3 4 5

COLOR

CHANGE

MODULE 8

(COLORS

41 THRU 48)

J9

7

3

4

1

2

5

6

J15 J16 4

3

6

5

2

1

4

3

6

5

2

1

3

4

1

2

5

6

J14

5 4 3 2 1

J10

4

3

6

5

2

1

COM

+12VDC

COM

+12VDC

COM

+12VDC

BLACK

RED

BLACK

RED

BLACK

RED

COM

+12VDC

COM

+12VDC

COM

+12VDC

BLACK

RED

BLACK

RED

BLACK

RED

COM

+12VDC

COM

+12VDC

COM

+12VDC

BLACK

RED

BLACK

RED

BLACK

RED

MANIFOLD

COLOR 22

COLOR 23

COLOR 24

COLOR 25

COLOR 26

COLOR 27

COLOR 28

COLOR 29

COLOR 30

5 4 3 2 1

BOOTH CONTROL

(24M731)

Figure 27 Electrical Schematic, Sheet 3, Part 2

CONTINUED ON THE NEXT PAGE

Electrical Schematics

332709H 41

Electrical Schematics

FLUSH

CATALYST 3

CATALYST 4

MANIFOLD

+24VDC

COM

+24VDC

COM

+24VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

CATALYST

CHANGE

1

2

3

4

5

6

(CATALYST

3 THRU 4)

J8 J9

6

4

5

6

1

2

3 J15 J16

6

5

4

3

2

1

6

5

4

3

2

1

1

2

3

4

5

6

J14 J10

3

2

1

6

5

4

1 2 3 4 5

COM

+24VD

COM

+24VD

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

MANIFOLD

DUMP

CATALYST 3

CATALYST 4

FLUSH

CATALYST 1

CATALYST 2

MANIFOLD

+24VDC

COM

+24VDC

COM

+24VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

5 4 3 2

CATALYST

CHANGE

1

1

2

3

4

5

6

(CATALYST

1 THRU 2)

J8 J9

6

5

4

3

2

1

6

1

2

3

4

5

6

J15 J16

6

5

4

3

2

1

4

5

6

1

2

3

J14

1 2 3 4 5

J10

6

5

4

3

2

1

COM

C

COM

C

COM

C

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

MANIFOLD

DUMP

CATALYST 1

CATALYST 2

1 2 3 4 5

COLOR

CHANGE

(COLORS

25 THRU 32)

ALTERNATE CONFIGURATION

FOR CATALYST CHANGE CONTROL

Figure 28 Electrical Schematic, Sheet 4, Alternate

Configuration for Catalyst Change Control

42 332709H

Electrical Schematics

125306

123422

121000

121227

121001

121002

121003

120952

121201

121004

121228

Electrical Schematics, page 30 .

hazardous location must not exceed 120 ft (36 m).

16V423

16V424

16V425

16V426

16V427

16V428

16V429

16V430

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)

15U531

15U532

15V205

15V206

15V207

15V208

15U533

15V213

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)

1.0 (0.3)

1.3 (0.4)

1.6 (0.5)

2.0 (0.6)

3.0 (1.0)

5.0 (1.5)

10.0 (3.0)

13.0 (4.0)

20.0 (6.0)

25.0 (8.0)

50.0 (15.0)

16T659

16V659

2.5 (0.8)

6.0 (1.8)

See

Communications Options (for PLC and AWI) , page 44

24T557

24T558

24T559

24T560

24T571

24T572

24T573

24T574

24T774

24T775

24T776

24T777

24T778

24T779

25D980

26C416

2 color/2 catalyst

4 color/4 catalyst

6 color

8 color

2 color/2 catalyst

4 color/2 catalyst

6 color/2 catalyst

8 color/2 catalyst, 13–24 color

12 color/2 catalyst

4 color/4 catalyst

6 color/4 catalyst

8 color/4 catalyst

12 color/4 catalyst, 13–30 color

13–18 color

ProMix PD Tool Kit

PD3K+ Upgrade Kit

332709H 43

Electrical Schematics

1.

If your application requires integration with a

PLC: a.

24W829, CGM Kit for ProMix PD2K

26C284, CGM Kit for ProMix PD3K+

26A303, CGM Kit for ProMix PD Dual Mix

25D997, CGM Kit for ProMix PD Dual Mix with ProfiNet (includes two CGM modules) b.

CGMEP0, Ethernet IP

CGMDN0, Device Net

CGMPN0, ProfiNet

24W462, Modbus TCP

2.

If your application requires AWI: a.

24W829, CGM Kit for PD2K b.

24W462, Modbus TCP* c.

15V337, AWI Module

Panel systems.

* AWI requires its own Modbus TCP module.

If the PLC is also communicating over

Modbus TCP, then two 24W462 modules are necessary.

44 332709H

Repair

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

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

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

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

To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately.

To avoid electrical component damage, remove all system power before plugging any connectors.

1.

Flush the system as explained in your

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

Pressure Relief Procedure, page 46

before servicing fluid components.

2.

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

3.

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

4.

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

Figure 29 Control Box Power Switch

332709H 45

Repair

6.

Dual whenever you see this symbol.

air pressure in the system.

1.

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

2.

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

air pressure in the system. Use your control interface to issue the necessary commands to your system.

1.

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

valve on the supply line, command the system to

Mix. Cycle the dosing pumps a couple of times to drain the pumps through the spray device.

2.

Command the system to Standby. Trigger the spray device to relieve pressure.

3.

Flush the remote mix manifold and spray device.

4.

Shut off the solvent supply pump. To relieve pressure, command the system to Purge and trigger the spray device. When the pressure is relieved, command the system to Standby to avoid getting a Purge Incomplete alarm.

5.

If pressure remains in the solvent line between the solvent supply pump and the solvent valve:

• VERY SLOWLY loosen a fitting to relieve pressure gradually.

• Loosen the fitting completely.

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

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

3.

Trigger the gun to relieve pressure. From

Maintenance Screen 5 on the ADM, check the box in the field labeled Gun for each color in the system to manually open each color valve.

4.

Set the system to Recipe 0 to flush the pumps and to purge to the spray device. Hold the gun trigger open after the solvent valve shuts off to relieve all pressure. When flushing is complete the system will go to Standby.

5.

Shut off the solvent supply pump. Set the system to Recipe 0 to flush solvent from the pumps and to purge to the spray device. Command the system to Standby after just a couple of seconds, to avoid getting a Purge Incomplete alarm.

6.

If pressure remains in the solvent line between the solvent supply pump and the solvent valve:

• VERY SLOWLY loosen a fitting to relieve pressure gradually.

• Loosen the fitting completely.

7.

Verify on the ADM Home Screen that neither pump is showing any pressure.

8.

Dual Panel

46 332709H

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

Repair

5.

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

6.

Remove the token (T).

7.

Replace the blue key token.

operation.

8.

Replace the token access panel.

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

Figure 30 Replace the Advanced Display Module

1.

Shut off the ProMix PD power switch.

2.

Remove the token access panel.

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

1.

Turn off the ProMix PD power switch.

2.

Remove the rear access panel.

Figure 31 Remove Token Access Panel

3.

Remove blue key token.

4.

Insert and press black upgrade token (T) firmly into slot.

token.

Figure 33 Remove Battery Panel

3.

Remove the old battery and replace with a new

CR2032 battery.

4.

Replace the rear access panel.

5.

Turn the power switch on.

6.

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

Figure 32 Insert Token

332709H 47

Repair

8.

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

LEDs (D6, D14) are on. See Figure 24.

9.

Reinstall the cover (117) and tighten the screws

(124).

To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately.

To avoid electrical component damage, remove all system power before plugging any connectors.

1.

Follow the steps in

Before Servicing, page 45

.

2.

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

3.

Note the position of the isolation board cables. See the following table,

Electrical Schematics, page 30

, and Figure 24.

Disconnect the cables from the isolation board

(111). Remove the brackets (110).

J1 (non-intrinsically safe)

J2 (non-intrinsically safe)

J3 (intrinsically safe)

J4 (intrinsically safe)

Gateway Module

Optional Non-IS Color

Change Module

Barrier Board

Optional IS Color

Change Module

Figure 34 Replacing the Isolation Board

To reduce the risk of fire or explosion, be certain that the barrier board is connected to

J3, on the IS side of the isolation board. If connected incorrectly, the intrinsic safety of your system is compromised.

4.

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

5.

Install the new isolation board, using the screws

(128).

6.

Install the brackets (110). Reconnect the cables to the isolation board (111).

7.

Turn on power at the main circuit breaker.

Figure 35 Detail of Isolation Board Cable

Connections

48 332709H

Repair

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

barrier board will light if the board has power.

To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately.

To avoid electrical component damage, remove all system power before plugging any connectors.

1.

Follow the steps in

Before Servicing, page 45 .

2.

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

3.

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

4.

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

Electrical Schematics, page 30

. Disconnect the cables from the barrier board (106).

5.

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

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

6.

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

7.

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

8.

Install the barrier cover (107) and isolation board

(111).

9.

Turn on power at the main circuit breaker.

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

(124).

332709H

Figure 36 Replacing the Barrier Board

49

Repair

To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately.

To avoid electrical component damage, remove all system power before plugging any connectors.

1.

Follow steps 1–4 under

Replacing the Barrier Board, page 49 .

2.

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

3.

Snap the new fuse (Graco PN 15D979) into the fuseholder.

4.

Follow steps 7–11 under

Replacing the Barrier Board, page 49 .

To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately.

To avoid electrical component damage, remove all system power before plugging any connectors.

1.

Follow the steps in

Before Servicing, page 45

.

2.

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

3.

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

Electrical Schematics, page 30

.

Disconnect the cables from the EFCM (139).

4.

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

5.

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

6.

Reconnect the cables to the positions as noted above.

7.

Turn on power at the main circuit breaker.

8.

Load the software to the ADM. See

Install Key Token or Upgrade Token, page 47

.

9.

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

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

(124).

50

Figure 37 Replacing the EFCM Control Module

332709H

To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately.

To avoid electrical component damage, remove all system power before plugging any connectors.

1.

Follow the steps in

Before Servicing, page 45 .

2.

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

3.

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

Electrical Schematics, page 30

.

Disconnect the wires from the power supply

(120).

4.

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

5.

Install the new power supply, using the screws

(129).

6.

Reconnect the wires to the power supply.

Failure to follow the electrical schematic could result in damage to the electrical components.

7.

Reinstall the cover (117) and tighten the screws

(124).

Repair

8.

Turn on power at the main circuit breaker.

9.

Turn on the control box power switch.

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

Figure 38 Replacing the 24 Vdc Power Supply

332709H 51

Repair

To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately.

To avoid electrical component damage, remove all system power before plugging any connectors.

1.

Follow the steps in

Before Servicing, page 45

.

2.

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

3.

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

Electrical Schematics, page 30

.

Disconnect the wires from the power supply

(103).

4.

Remove the screws (128) and washers (176) holding the power supply din rail to the enclosure.

Remove the entire assembly, mounted to the din rail.

5.

Install the new power supply assembly, using the screws (128) and washers (176).

6.

Reconnect the wires to the power supply.

Failure to follow the electrical schematic could result in damage to the electrical components.

7.

Reinstall the cover (117) and tighten the screws

(124).

8.

Turn on power at the main circuit breaker.

9.

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

control modules (132) will light when operating.

Figure 39 Replacing the 48 Vdc Power Supply

52 332709H

Repair

9.

Reinstall the cover (117) and tighten the screws

(124).

To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately.

To avoid electrical component damage, remove all system power before plugging any connectors.

1.

Follow the steps in

Before Servicing, page 45 .

2.

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

3.

Note the position of the pump control module cables. See

Electrical Schematics, page 30

.

Disconnect the cables from the pump control module (132).

4.

Remove the screws (143) and washers (177) holding the pump control module to the enclosure. Remove the pump control module.

5.

Install the new pump control module, using the screws (143) and washers (177).

6.

Reconnect the cables to the pump control module (132).

7.

Turn on power at the main circuit breaker.

8.

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

wiring.

Figure 40 Replacing a Pump Control Module

332709H 53

Repair

To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately.

To avoid electrical component damage, remove all system power before plugging any connectors.

1.

Follow the steps in

Before Servicing, page 45

.

2.

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

3.

Remove the screws (182b) holding the communication gateway module (CGM) to the module base. Remove the CGM. You do not have to disconnect the cables.

4.

Install the new CGM (182a), using the screws

(182b).

5.

Turn on power at the main circuit breaker.

6.

Turn on the control box power switch. Check that the three status indicator lights are green.

7.

Reinstall the cover (117) and tighten the screws

(124).

Figure 41 Replacing a Communication Gateway

Module

54 332709H

To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately.

To avoid electrical component damage, remove all system power before plugging any connectors.

1.

Follow the steps in

Before Servicing, page 45 .

2.

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

3.

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

Electrical Schematics, page 30

.

Disconnect the wires from the line filter (115).

4.

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

5.

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

6.

Reconnect the wires to the line filter.

Failure to follow the electrical schematic could result in damage to the electrical components.

7.

Reinstall the cover (117) and tighten the screws

(124).

8.

Turn on power at the main circuit breaker.

Figure 42 Replacing the Line Filter

Repair

332709H 55

Repair

To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately.

To avoid electrical component damage, remove all system power before plugging any connectors.

1.

Follow the steps in

Before Servicing, page 45

.

2.

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

3.

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

Electrical Schematics, page 30

.

Disconnect the wires from the power switch

(112).

4.

Remove the switch terminal blocks (T), unscrew the retaining nut (N), and remove the switch.

5.

Install the new switch.

6.

Reconnect the wires to the power switch (112).

Failure to follow the electrical schematic could result in damage to the electrical components.

7.

Reinstall the cover (117) and tighten the screws

(124).

8.

Turn on power at the main circuit breaker.

Figure 43 Replacing the Power Switch

56 332709H

1.

Follow the steps in

Before Servicing, page 45 .

2.

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

3.

Disconnect the cable from the pump driver (101).

4.

Disconnect the air lines from the dosing valves

(V).

5.

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

6.

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

Repair

7.

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

8.

See manual 332339 to repair the pump.

1.

Slide the pump into the mounting bracket (4).

Tighten the jam nuts to secure.

2.

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

3.

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

4.

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

5.

Connect the cable to the pump driver (101).

6.

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

7.

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

8.

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

Figure 44 Installing a Pump

332709H 57

Repair

To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately.

To avoid electrical component damage, remove all system power before plugging any connectors.

1.

Follow the steps in

Before Servicing, page 45

.

2.

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

3.

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

4.

Disconnect the 2 solenoid wires from

J1 on the pump control module. See

Electrical Schematics, page 30

.

5.

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

6.

Install the new solenoid (305) with the screws

(303).

7.

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

Electrical Schematics, page 30

.

8.

Replace the covers (8, 117).

Figure 45 Solenoid Replacement

58 332709H

Repair

7.

Connect the 2 fan wires to the pump control module. Use terminal 8, pins 3 and 4. See

Electrical Schematics, page 30 .

To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately.

To avoid electrical component damage, remove all system power before plugging any connectors.

1.

Follow the steps in

Before Servicing, page 45 .

2.

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

3.

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

4.

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

Electrical Schematics, page 30 .

5.

Remove the 4 screws, nuts, and washers to remove the fan (9).

6.

Install the new fan (9) and attaching hardware.

8.

Replace the covers (8, 117).

Figure 46 Replacing a Fan

332709H 59

Repair

1.

Follow the steps in

Before Servicing, page 45

.

2.

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

3.

Disconnect the solvent flow switch wires from J6 pins 11–12 (Switch 1) or J7 pins 9–10 (Switch 2) on the EFCM. See

Electrical Schematics, page 30

.

4.

Disconnect the solvent lines.

5.

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

6.

Unscrew the solvent flow switch from the elbow

(18).

7.

Remove the solvent flow switch (159).

8.

Screw the new solvent flow switch onto the elbow

(18).

9.

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

10. Connect the wires to J6 pins 11–12 (Switch 1) or

J7 pins 9–10 (Switch 2). Reconnect the solvent lines.

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

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

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

switch should be mounted within 6 feet of the control box so the wires will reach the terminals on the

EFCM.

Solvent Flow Switch 1:

Mix Unit #1

Solvent Flow Switch 2:

Mix Unit #1

Solvent Flow Switch 3:

Mix Unit #2

Solvent Flow Switch 4:

Mix Unit #2

EFCM Connector J6

Pins 5–6

EFCM Connector J6

Pins 7–8

EFCM Connector J6

Pins 9–10

EFCM Connector J6

Pins 11–12 combination of mix manifolds which require different solvent connections for each component. Solvent should be plumbed through a unique solvent flow switch and into the remote solvent valve for each component. See the table below for the appropriate wiring terminals on the EFCM of each remote solvent flow switch.

Solvent Flow Switch 1:

Component A Remote

Solvent

Solvent Flow Switch 2:

Component B Remote

Solvent

Solvent Flow Switch 3:

Component C Remote

Solvent

Solvent Flow Switch 4:

Component D Remote

Solvent

EFCM Connector J6

Pins 11–12

EFCM Connector J7

Pins 9–10

EFCM Connector J6

Pins 7–8

EFCM Connector J6

Pins 9–10

60 332709H

Parts

332709H 61

Parts

Ref Part

1

— — —

2

— — —

3

4

5

— — —

— — —

24T790

24T791

6 24T788

24T789

7

8

— — —

24T771

9 24T770

10 277853

11

— — —

FRAME

CONTROL BOX, electrical; see

Control Box Parts, page 67

PANEL, fluid 1

BRACKET, mounting 2

1

1

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

Model AC1000; see manual 332339

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

Model AC2000; see manual 332339

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

Model AC1000; see manual 332339

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

Model AC2000; see manual 332339

BRACKET, mounting, pump

COVER; includes (2) of item 56

KIT, fan

1

1

1

1

2

1

2

BRACKET, mounting 1

SCREW, machine, pan head; M5 x 0.8;

10 mm

2

Ref Part

12

12a

24U602

16X039

26C283

14 24T772

15 C19798

16 16U655

17 104641

18 111763

27

28

29

19 24T787

— — —

— — —

— — —

MODULE, display, advanced; includes item 12a

TOKEN; latest version of software for the Advanced

Display Module; not shown

TOKEN; latest version of software for PD3K+

MANIFOLD, solenoid; see

Solenoid Manifold

Parts, page 73

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

(10 mm)

BRACKET, mounting, valve

FITTING, bulkhead

ELBOW; 1/4 npt

(mbe)

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

GUSSET

LEG, floor stand

1

1

2

8

2

2

4

2

PLUG, tube, square 6

2

2

62 332709H

Ref Part

30

— — —

31

— — —

32 — — —

33

34

— — —

— — —

43

— — —

— — —

45 15F741

50 115287

51

— — —

53

— — —

54

— — —

WASHER; 3/8

SCREW, cap, hex head; 3/8–16 x 2.75

in. (70 mm)

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

(22 mm)

NUT, lock; 3/8–16

SCREW, cap, hex head; 3/8–16 x 3 in.

(76 mm)

WIRE HARNESS; for

Model AC1000 (not shown)

WIRE HARNESS; for

Model AC2000 (not shown)

FITTING, adapter;

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

FITTING, Y-tube; for

1/4 in. (6 mm) OD tubing

TUBE, polyethylene;

1/4 in. (6 mm) OD x

3 ft

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

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

16

4

12

20

8

2

2

2

1

3

12

12

Parts

Ref Part

55

56

69

70

73

73a

223547

— — —

— — —

16V429

— — —

73b 24U617

73c

73d

73e

74

24T302

— — —

— — —

— — —

166421

GROUND WIRE

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

(19 mm)

GROMMET, cable

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

KIT, cup, TSL; includes items

73a-73e

BRACKET

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

TUBE, polyurethane;

1/4 in. (6 mm) OD;

10 ft (3.05 m); cut to fit

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

GASKET; for item

73d; not shown

NIPPLE, pipe; 1/4 npt

1

2

2

1

2

2

2

2

8

8

2

Items marked — — — are not available separately.

332709H 63

Parts

64 332709H

201

202

203

204

205

206

207

208

209

— — —

— — —

— — —

— — —

24T790

24T791

24T788

24T789

— — —

24T771

24T770

FRAME

CONTROL BOX, electrical; see

Control Box

Parts (Dual Panel

Models), page 70

PANEL, fluid

BRACKET, mounting

PUMP, 70 cc, A side, low pressure; for Model AC1002; see manual

332339

PUMP, 70 cc,

A side, high pressure; for

Models AC2002; see manual

332339

PUMP, 35 cc, B side, low pressure; for Model AC1002; see manual

332339

PUMP, 35 cc,

B side, high pressure; for Model

AC2002; see manual 332339

BRACKET, mounting, pump

COVER; includes

(2) of item 256

KIT, fan

1

1

1

2

1

1

1

1

2

1

2

Parts

216

217

218

219

227

228

229

210

211

212

212a

214

215

277853

— — —

24U602

17N631

24T772

C19798

17M103

104641

111763

24T787

— — —

— — —

— — —

BRACKET, mounting

SCREW, machine, pan head; M5 x

0.8; 10 mm

MODULE, display, advanced; includes item 212a

TOKEN; latest version of software for the Advanced

Display Module; not shown

MANIFOLD, solenoid; see

Solenoid Manifold

Parts, page 73

SCREW, cap, socket head;

1/4–20 x 3/8 in.

(10 mm)

1

2

1

1

2

8

BRACKET, mounting, valve

2

FITTING, bulkhead 4

ELBOW; 1/4 npt

(mbe)

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

GUSSET

4

4

4

LEG, floor stand

PLUG, tube, square

2

6

332709H 65

Parts

245

250

251

233

234

235

236

243

230

231

232

— — —

— — —

— — —

— — —

— — —

— — —

— — —

— — —

— — —

15F741

115287

— — —

253

— — —

WASHER; 3/8 16

SCREW, cap, hex head; 3/8–16 x

2.75 in. (70 mm)

4

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

12

NUT, lock; 3/8–16 20

SCREW, cap, hex head; 3/8–16 x 3 in. (76 mm)

8

WASHER, lock;

3/8

8

NUT, hex; 3/8–16 8

2 WIRE HARNESS; for Model AC1000

(not shown)

WIRE HARNESS; for Model AC2000

(not shown)

FITTING, adapter;

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

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

OD tubing

TUBE, polyethylene; 1/4 in. (6 mm) OD x 3 ft

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

OD x 20 ft (cut to length required)

2

4

1

3

12

254

255

256

269

270

273

273a

273b

273c

273d

273e

274

— — —

223547

— — —

— — —

16V429

24T302

— — —

24U617

— — —

— — —

— — —

121907

TUBE, nylon, red; for control air to turn valves off;

5/32 in. (4 mm) OD x 20 ft (cut to length required)

GROUND WIRE

12

1

SCREW, cap, socket head;

1/4–20 x 3/4 in.

(19 mm)

2

GROMMET, cable 2

1 CABLE, CAN, intrinsically safe,

5 pin; for booth control; fbe; 50 ft

(15 m)

KIT, cup, TSL; includes items

73a-73e

BRACKET

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

TUBE, polyurethane; 1/4 in. (6 mm) OD; 10 ft (3.05 m); cut to fit

PLUG, screw;

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

GASKET; for item

73d; not shown

NIPPLE, pipe; 1/4 npt

2

2

2

2

8

8

1

Items marked — — — are not available separately.

66 332709H

Parts

332709H 67

Parts

101

— — —

ENCLOSURE

102

— — —

PANEL, back

103 24T769 POWER SUPPLY; 48

104

— — —

Vdc; 10 A; 480 W

WASHER, lock; no. 6

105 — — —

SPACER, standoff

106 255786 BOARD, barrier; includes item 106a

106a 15D979 FUSE; 400 mA, quick acting

107 — — —

COVER, barrier

108

— — —

109

— — —

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

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

(10 mm)

2

3

1

2

1

1

1

3

3

1

110

— — —

BRACKET, board

111 24M485 BOARD, isolation, IS

112 16U725 SWITCH, selector, 2 position

113

— — —

DUCT, wire

114 — — —

COVER, duct

115 16V446 FILTER , line; 10A

116

— — —

BLOCK, terminal

117

— — —

COVER, enclosure

118

— — —

GROMMET

119 — — —

LIGHT

120 16T660 POWER SUPPLY; 24

Vdc, 4 A, 96 W

1

2

4

1

1

1

1

2

2

1

1

68 332709H

Parts

121 — — —

CONNECTOR, bar, ground

122 — — —

SCREW, ground; M5 x

123

— — —

0.8

NUT, hex, flange head;

124

— — —

1/4–20

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

125

126

— — —

— — —

(19 mm)

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

(10 mm)

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

(19 mm)

127

— — —

128

— — —

FITTING, connector;

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

SCREW, machine, pan

129

— — — head; 8–32 x 0.25 in. (6 mm)

SCREW, machine, binding head; 6–32 x

0.25 in. (6 mm)

130 121003 CABLE, CAN; fbe; 3.0

131

— — — m

MANIFOLD, air

1

3

4

4

2

3

1

8

4

1

1

132 24N527 MODULE, control, pump

133 16P243 CABLE, splitter

134

— — —

MUFFLER

137

— — —

PLUG, pipe; 1/8 npt(f)

2

1

1

4

138

— — —

STRAIN RELIEF, cord 4

139a 24U601 MODULE, control, enhanced fluid includes

16X039 TOKEN; latest version of software

139b 26A298 MODULE, control enhanced fluid includes

17N631 TOKEN; latest version of software

139c 26D119 MODULE, control enhanced fluid includes

25C283 TOKEN; latest version of software

1

1

1

140

141

— — —

— — —

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

(13 mm)

SCREW, cap, socket

2

2 head; 8–32 x 0.625 in.

(16 mm)

142

— — —

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

(6 mm)

10

143 — — —

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

8

(38 mm)

144▲ 172953 LABEL, ground symbol 1

145 — — —

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

147▲ 15W598 LABEL, warning

4

1

148

150

151

152

153

— — —

HARNESS, CAN isolation, power (not shown)

16T072 ADAPTER, CAN cable,

IS to non-IS

121227 CABLE, CAN; fbe; 0.6

— — — m

HARNESS, 3–wire

— — —

HARNESS, 2–wire

1

1

1

1

1

154

155

16T659 CABLE, D-SUB, 25 pin,

— — —

2.5 ft

SCREW, self sealing

2

2

163

168

169

170

— — —

— — —

NUT, hex, self-locking;

1/4–20

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

(8 mm)

173▲ 15W776 LABEL, warning,

176

- — — electrical shock

WASHER, flat

177

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

50 ft. 15.25 m)

16U600

- — —

LABEL, isolation board

WASHER, #10, sst

1

1

4

4

1

2

1

Items marked — — — are not available separately.

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

332709H 69

Parts

70 332709H

Parts

270

277*

285

286

287

288

289

281*

— — —

290

292

401

402

403

404

405

406

406a

— — —

— — —

— — —

— — —

26A189

— — —

— — —

255786

15D979

16V429

— — —

— — —

— — —

— — —

— — —

— — —

CABLE, CAN, I.S.; fbe; 50 ft. 15.25 m)

BRACKET, mount, modbus (included with CGM Installation

Kits)

SCREW, pan, #8–32

(included with CGM

Installation Kits)

MANIFOLD, air

1

1

4

1

PLUG, pipe; 1/8 npt(f) 4

MUFFLER, sintered; 1

1/8 in.

SCREW, self-sealing 4

1 FITTING, connector;

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

SCREW, machine, pan head

WASHER, lock, #6

2

ENCLOSURE

PANEL, back

1

1

1

POWER SUPPLY; 1

48 Vdc; 10 A; 480 W

WASHER, lock; no. 6 3

SPACER, standoff 3

BOARD, barrier; includes item 106a

FUSE; 400 mA, quick acting

1

2

332709H

407

408

409

410

411

412

413

414

415

416

417

418

419

420

421

422

423

424

— — —

24M485

16U725

— — —

— — —

16V446

— — —

— — —

— — —

— — —

16T660

— — —

— — —

— — —

— — —

— — —

— — —

— — —

COVER, barrier

SCREW, machine, pan head; 6–32 x 1.5

in. (38 mm)

SCREW, machine, pan head; 6–32 x

0.375 in. (10 mm)

BRACKET, board

3

2

BOARD, isolation, IS 1

SWITCH, selector, 2 position

DUCT, wire

1

1

COVER, duct 2

FILTER , line; 10A

BLOCK, terminal

1

1

1

2

COVER, enclosure

GROMMET

LIGHT

POWER SUPPLY;

24 Vdc, 4 A, 96 W

CONNECTOR, bar, ground

SCREW, ground; M5 x 0.8

NUT, hex, flange head; 1/4–20

SCREW, flanged, hex head; 1/4–20 x

0.75 in. (19 mm)

1

3

4

4

1

2

4

1

71

Parts

425

426

427

428

429

430

431

432

433

434

435

436

437

438

439a

439b

439c

440

— — —

— — —

— — —

— — —

— — —

121003

— — —

24N527

16P243

— — —

121324

— — —

— — —

— — —

24U601

26A298

26D119

— — —

SCREW, machine, pan head; 10–24 x

0.375 in. (10 mm)

SCREW, machine, pan head; 10–32 x

0.75 in. (19 mm)

FITTING, connector;

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

SCREW, machine, pan head; 8–32 x

0.25 in. (6 mm)

SCREW, machine, binding head; 6–32 x

0.25 in. (6 mm)

CABLE, CAN; fbe;

3.0 m

MANIFOLD, air

MODULE, control, pump

CABLE, splitter

MUFFLER

VALVE, solenoid;

3–way

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

PLUG, pipe; 1/8 npt(m)

STRAIN RELIEF, cord

MODULE, control, enhanced fluid includes 16X039

TOKEN; latest version of software

MODULE, control enhanced fluid includes 17N631

TOKEN; latest version of software

MODULE, control enhanced fluid includes 25C283

TOKEN; latest version of software

SCREW, machine, pan head; 1/4–20 x

0.5 in. (13 mm)

2

3

1

8

4

1

1

1

1

3

1

1

2

4

1

1

1

2

441

442

443

444▲

445

447▲

448

450

451

452

453

454

455

459

459a

459b

459c

463

468▲

469

470

473▲

— — —

— — —

— — —

172953

— — —

15W598

— — —

16T072

121227

— — —

— — —

16T659

— — —

15T632

104641

111763

113029

16V429

16U600

— — —

— — —

15W776

SCREW, cap, socket head; 8–32 x 0.625

in. (16 mm)

SCREW, machine, pan head; 10–32 x

0.25 in. (6 mm)

SCREW, machine, pan head; 10–32 x

1.5 in. (38 mm)

LABEL, ground symbol

CLAMP; for 3/8 in.

(10 mm) OD cable

LABEL, warning

2

10

8

1

4

HARNESS, CAN isolation, power (not shown)

ADAPTER, CAN cable, IS to non-IS

CABLE, CAN; fbe;

0.6 m

HARNESS, 3–wire

HARNESS, 2–wire

ELBOW; 1/4 npt

(mbe)

NIPPLE; 1/4 npt

CABLE, CAN, I.S.; fbe; 50 ft. 15.25 m)

LABEL, isolation board

NUT, hex, self-locking; 1/4–20

SCREW, machine, pan head; 8–32 x

0.312 in. (8 mm)

LABEL, warning

1

1

CABLE, D-SUB, 25 pin, 2.5 ft

2

SCREW, self sealing 2

1 KIT, air flow switch; includes items

159a-159c

FITTING, bulkhead 1

1

1

1

1

4

4

1

1

1

1

1

Items marked — — — are not available separately.

* Bracket (277) and Screws (281) included with CGM Installation Kits. See Manual 334494.

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

72 332709H

Parts

Ref Part

301

302 — — —

303

304

305

307

308

— — —

— — —

115671

16P812

114151

114263

PLATE

MANIFOLD

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

in. (10 mm)

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

VALVE, solenoid

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

5/32 in. (4 mm) OD tube

FITTING, straight;

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

(4 mm) OD tube

MUFFLER

1

1

4

1

2

4

4

2 309 C06061

Items marked — — — are not available separately.

332709H 73

Technical Specifications

Maximum fluid working pressure:

AC0500 and AC0502 Systems with Low-Pressure Pumps

AC0500 and AC0502 Systems with High-Pressure Pumps

AC1000 and AC1002 Air

Spray Systems

AC2000 and AC2002

Air-Assisted Spray Systems

Maximum working air pressure:

Air supply:

Air filter inlet size:

Air filtration for air logic

(user-supplied):

Air filtration for atomizing air

(user-supplied):

Mixing ratio range:

Fluids handled:

300 psi

1500 psi

300 psi

1500 psi

100 psi

85–100 psi

3/8 npt(f)

2.1 MPa, 21 bar

10.5 MPa, 105 bar

2.1 MPa, 21 bar

10.5 MPa, 105 bar

0.7 MPa, 7.0 bar

0.6–0.7 MPa, 6.0–7.0 bar)

5 micron (minimum) filtration required; clean and dry air

30 micron (minimum) filtration required; clean and dry air

Viscosity range of fluid:

Fluid filtration (user-supplied):

Maximum fluid flow:

Fluid outlet size:

External power supply requirements:

0.1:1 — 50:1, ±1% one or two component:

• solvent and waterborne paints

• polyurethanes

• epoxies

• moisture sensitive isocyanates

20–5000 centipoise

100 mesh minimum

800 cc/minute (depending on material viscosity)

1/4 npt(m)

90 - 250 Vac, 50/60 Hz, 7 amps maximum draw

15 amp maximum circuit breaker required

Operating temperature range:

Storage temperature range:

Weight of base model

(approximate):

8 to 14 AWG power supply wire gauge

36 to 122°F

-4 to 158°F

195 lb

2 to 50°C

-20 to 70°C

88 kg

Sound data:

Wetted parts:

Less than 75 dB(A)

AC0500 and AC0502 Pumps sold separately; see selected pump manual for wetted parts information.

AC1000, AC1002, AC2000, and AC2002

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

74 332709H

California Proposition 65

332709H 75

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

IMPLIED,

OF

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

AND

MATERIALS 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.

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

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

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

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

Original Instructions. This manual contains English. MM 332709 www.graco.com

Revision H, November 2022

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