Installation. Graco 332456D, Pump Expansion Kits, 25M268

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Installation. Graco 332456D, Pump Expansion Kits, 25M268 | Manualzz

Installation

• 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.

Follow the Pressure Relief Procedure in your PD2K manual whenever you see this symbol.

1.

Flush the system as explained in your PD2K

Operation Manual. Follow the Pressure Relief

Procedure in your PD2K manual.

2.

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

3.

Remove electrical power from the system.

directly on the PD2K stand, or mounted onto a wall.

Install using the steps in

Install the Frame, page 10

or the steps in

Install the Wall Bracket, page 11

.

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 when you stop spraying and before cleaning, checking, or servicing the equipment.

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Installation

Use these steps if you want to install the kit onto the

PD2K stand using frame (13).

1.

Follow the steps in

Before Installing the Kit, page 9 .

2.

Install the frame (13) to the upright of the PD2K stand (A) using three screws (16) and nuts (18).

3.

Install the back panel/bracket assembly (B) in the outermost position on the frame (13), to allow clearance for the color change manifold (C).

Fasten the panel to the frame (13) using four screws (15) and nuts (18). Install the top screws from the front and the bottom screws from the back.

expansion kit being installed on the left (color) side of the PD2K proportioner. The pump control module and dual grommet (11) are preassembled at the factory so the cable (8) is facing to the right, allowing easier access to connections inside the PD2K electrical control box (D).

Install a catalyst (35cc) pump expansion kit on the right side of the proportioner, with the pump control module and dual grommet (11) preassembled in the opposite direction so the cable (8) is facing to the left.

Figure 2 Install the Frame and Pump

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Use these steps if you want to install the kit away from the PD2K or PD1K stand using wall bracket (47).

1.

Follow the steps in

Before Installing the Kit, page 9 .

2.

Install wall bracket (47) to a wall or other suitable vertical surface using four screws or bolts (user provided).

Installation

3.

Install the back panel/bracket assembly (B) to wall bracket (47) using six screws (15) and six nuts (18).

pump expansion kit being installed on the left

(color) side of the PD1K proportioner. The pump control module and dual grommet (11) are preassembled at the factory so the cable (8) is facing to the right, allowing easier access to connections inside the PD1K electrical control box (D).

Install a catalyst (35cc) pump expansion kit on the right side of the proportioner, with the pump control module and dual grommet (11) preassembled in the opposite direction so the cable (8) is facing to the left.

Figure 3 Install the Wall Bracket and Pump

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Installation

The cup is used for either Throat Seal Liquid (TSL) or ISO oil. These liquids prevent exposure of air or moisture with the resin or catalyst at the pump throat packings and dosing valves. The PD2K Proportioner includes two TSL Cup Kits, one for each pump. The cups supply TSL to the upper throat cartridge of the color (70 cc) pump, to the upper and lower throat cartridges of the catalyst (35 cc) pump, and to the four pump dosing valves. When using isocyanate catalysts, the cup attached to the catalyst side of the

PD2K Proportioner is used to supply ISO oil to the upper and lower throat cartridges of the catalyst (35 cc) pump and the catalyst dosing valves.

For TSL, order Part No. 206995, one quart (0.95

liter). For ISO oil, order Part No. 217374, one pint

(0.48 liter).

1.

Slide the kit mounting bracket onto any side of the pump’s hex nut.

2.

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

permanent black marker to mark a horizontal line on the front of the cup approximately half way between the top and bottom of the cup. Mark a second horizontal line approximately 1/4 in. (3 mm) above the first line. Shining a strong light towards these lines will provide a shadow that will be visible from inside the TSL cup.

Figure 4 Install TSL Cup Kit three ports (two are plugged). Move a plug (73d) if necessary so the barbed fitting (73b) can be put in the port closest to the TSL cup.

3.

Check that the o-ring is in place on the barbed fitting (73b). Apply low strength thread adhesive and install the fitting in the upper throat cartridge port. Be sure the other two ports are plugged

(73d).

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4.

Catalyst (35 throat cartridge.

5.

If you are lubricating the dosing valves, remove the plug (73d) and gasket from the valve port (V) closest to the TSL cup.

facing position. This will allow liquid to flow into the valve while allowing air to rise out of the valve.

Check that the o-ring is in place on the barbed fitting (73b). Apply low strength thread adhesive and install the fitting in the valve port (V).

air port (W).

Installation

6.

Cut the tubing (73c) to length as required.

Connect the TSL cup fittings to the fittings on the pump and valves. TSL is gravity-fed from the cup to the pump and valves; position the fittings and tubing to prevent kinks and enable the TSL to flow freely down to the valve and air to rise up and out of the valve.

7.

Fill the cup to the level of the lower black horizontal line with either TSL or ISO oil, as appropriate for the resin and catalyst materials being used.

color (70 cc) pump, be sure the lower u-cup seal is installed in the lower throat cartridge.

checked daily. Fluid levels should remain static for an extended period of time. Rising or falling fluid levels in a TSL cup can be an indication of a condition which needs immediate attention. Refer to the troubleshooting steps in the repair manual for guidance.

When using polyurethane coatings with isocyanate catalysts in high-humidity environments, use of ISO oil on the catalyst pump TSL cup is recommended instead of TSL. The ISO oil will present a barrier that will prevent catalyst hardening from contact with moisture. When performing the first fill of a cup with

ISO oil, it will be necessary to bleed the air out of the feed line.

the two horizontal lines at, and slightly above, the vertical center of the front of the cup before filling.

To bleed air:

1.

Fill the catalyst pump TSL cup to the lower horizontal line.

2.

Remove one plug (73d) from the upper throat cartridge and allow air in that area to flow until no air is being expelled. Replace the plug.

3.

Repeat step 2 at the lower throat cartridge.

4.

Use absorbent rags to clean up excess ISO oil that escaped from the plug holes.

5.

Replenish the ISO oil level in the TSL cup to the lower horizontal line.

valves, remove the unused barbed fittings (73b) from the bottom of the TSL cup (73). Apply low strength thread adhesive and install the plugs and gaskets supplied with the kit.

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Installation

For PD2K installations: Follow the steps below.

For PD1K installations: For the first expansion kit, connect the air supply tube (35) directly to the electrical control box (Z). For the second through fourth expansion kits, follow steps 2–4 below.

polyethylene tubing (35) is supplied with the kit to supply air to the expansion pump’s solenoid manifold

(3).

1.

See the PD2K Repair-Parts Manual. Remove the

PD2K fluid panel cover to expose the air supply tubing to the two existing solenoid manifolds.

2.

Cut the air supply tubing upstream of the Y-fitting.

3.

Install the Y-fitting (36) supplied in the kit as shown, to restore the air supply to the two existing solenoid manifolds.

4.

Connect the supplied 1/4 in. (6 mm) OD tubing

(35) between the open branch of the Y-fitting

(36) and the air inlet of the solenoid manifold (3).

This supplies air to the expansion pump solenoid manifold, as shown in the detail of the illustration.

a second splice in the main solenoid air supply line and plumb as explained above.

Figure 5 Air Connection for PD1K First Expansion Kit

Figure 6 Supplying Air to the Expansion Pump

Solenoid Manifold

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1.

Connect a 1/4 npt(f) fluid hose from the fluid source to the pump’s fluid inlet fitting (S).

2.

Connect a 1/4 npt(f) fluid outlet hose from the pump’s fluid outlet fitting (R) to the gun’s fluid supply.

Installation

Figure 7 Pump Fluid Connections

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Installation

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

NOTE:

Electrical Schematics, page 24 .

1.

Verify that electrical power is removed from the system.

2.

Remove the cover from the PD2K/PD1K electrical control box.

3.

Remove the knockout (K) from the side of the electrical control box.

4.

Thread the cable into the electrical control box and connect to the appropriate connection port on the enhanced fluid control module. For example, connect Pump 1 to P1 and Pump 2 to

P2 (PD1K only); Pump 3 to P3, Pump 4 to P4, and so on.

Figure 8 Install Grommet in Electrical Control

Box

Figure 9 Enhanced Fluid Control Module

Connection Points

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Be sure to keep 48 volt cables isolated from the low voltage wiring. All 48 VDC wiring must use the right-hand wireway (X) inside the electrical control box. Use grommet (Y) marked in Figure

9 to install the Pump Expansion Kit wiring.

Installation

5.

The PD2K/PD1K fluid panel cover was previously removed in

Air Connections, page 14 . Thread

the 2–wire cable (22) through the grommet (42) on the bottom of the fluid panel and up into the electrical box through an existing grommet and the wireway. Connect the cable (22) to the appropriate terminals on the top of the 48 VDC power supply: P1 for Pump 1 and P2 for Pump

2 (PD1K only); P3 for Pump 3, P4 for Pump 4.

Connect the red wire to + terminal, black wire to

- terminal.

Figure 10 48 VDC Grommet and Wireway

Figure 11 48 VDC Power Supply Connection

Points

6.

Install the dual grommet (11, shipped loose) on the free end of the D-SUB cable (8).

7.

Fasten the grommet (11) to the side of the electrical control box, using two screws (31).

8.

Reinstall the covers on the PD2K electrical control box and on the fluid panel.

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Installation

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

1.

Verify that the PD2K base unit is properly grounded. See the PD2K installation manual for complete grounding instructions.

2.

Ground the expansion kit pump(s) as follows: a.

If grounded by taking a resistance reading from the ground screw (7) on the added pump kit’s back panel (2) to the system’s true earth ground. Resistance must be less than 1 ohm.

b.

If the the ground screw (7) on the added pump kit’s back panel (2). Connect the other end of the that the main PD2K unit is connected to.

Verify that the added pump is grounded by taking a resistance reading from the ground screw (7) on the added pump kit’s back panel (2) to the system’s true earth ground.

Resistance must be less than 1 ohm.

Figure 12 Grounding the Pump Expansion Kit

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1.

Install the cover (12) on the expansion kit, using the screw (37) and nut (18).

Installation

4.

Press and navigate to System Screen 1 on the Advanced Display Module. Change the number of Color Pumps and Catalyst Pumps as needed, based on the kit installation.

Figure 13 Install Expansion Kit Cover (Frame)

Figure 15 System Screen 1

Figure 14 Install Expansion Kit Cover (Wall

Mount)

2.

Restore electrical power to the PD2K/PD1K.

3.

Turn on the control box power switch.

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Installation

5.

Go to the Pump Screens. The menu bar at the top of the screen will now show separate tabs for the added pump(s) 3 and 4. Each pump has three screens. Enter the required information, as explained in the PD2K Operation Manual.

Pump Size on Pump Screen 1 and transducer calibration data “Outlet Offset Factor” and “Outlet

Sensitivity Factor” on Pump Screen 2 (see your

PD2K Operation Manual). Also, create a recipe using the new material number, which can be found on Pump Screen 1 under Available Colors

(or Catalysts).

6.

The Home Screen will now show animations and information for the added pumps.

Figure 18 PD2K Home Screen (Advanced

Display Module)

7.

See the PD2K Operation Manual to return the system to service.

Figure 16 Third (Color) Pump Screen

Figure 17 Fourth (Catalyst) Pump Screen

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