Graco ProMix PD2K Installation Manual
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Graco ProMix PD2K Installation Manual

Graco ProMix PD2K Installation Manual

Electronic proportioner
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Installation
ProMix® PD2K Electronic Proportioner
Electronic positive displacement proportioner for fast-setting two-component materials. Manual system
with Advanced Display Module. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual. Save these
instructions.
See page 3 for model part numbers and
approvals information.
PROVEN QUALITY. LEADING TECHNOLOGY.
332457H
EN

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Summary of Contents for Graco ProMix PD2K

  • Page 1 Installation ProMix® PD2K Electronic Proportioner 332457H Electronic positive displacement proportioner for fast-setting two-component materials. Manual system with Advanced Display Module. For professional use only. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. See page 3 for model part numbers and approvals information.

  • Page 2: Table Of Contents

    Contents Fluid Requirements ........31 Related Manuals ..........2 Single Color Connections ......32 Models............... 3 Color Change Connections ......32 Warnings ............6 Solvent Connections ........32 Important Isocyanate (ISO) Information ....9 TSL Cup Kit............33 Important Acid Catalyst Information ..... 11 Solvent Meter Accessory........

  • Page 3: Models

    PART NO. SERIES SERIAL MAX FLUID WPR 2.068 20.68 MFG. YR. GRACO INC. P.O. Box 1441 Minneapolis, MN MAX TEMP 50°C (122°F) 55440 U.S.A. Continued on the next page. Figure 1 Models MC1000, MC1002, & MC3000 (Low Pressure) Identification Label...
  • Page 4 90-250 ~ VOLTS 7 AMPS MAX AMPS Intrinsically safe connections 50/60 Hz for Class I, Div 1, Group D GRACO INC. Ta = 2°C to 50°C P.O. Box 1441 II (2) G Install per 16P577 Minneapolis, MN [Ex ia] IIA Gb...
  • Page 5 Models www.graco.com/patents 12 VDC FM16US0241 Intrinsically safe FM16CA0129 equipment for Class I, Div 1, II 2 G Ex ia IIA T3 Gb Group D, T3 FM13 ATEX 0026 Install per 16P577 Ta = 2°C to 50°C IECEx FMG 13.0011 Figure 6 Booth Control Identification Label Figure 7 Pump Expansion Kit (Accessory) Identification Label...

  • Page 6: Warnings

    Warnings Warnings The following warnings are for the setup, use, grounding, maintenance and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings.
  • Page 7 Warnings WARNING INTRINSIC SAFETY Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe equipment will create a hazardous condition and can cause fire, explosion, or electric shock. Follow local regulations and the following safety requirements. • Be sure your installation complies with national, state, and local codes for the installation of electrical apparatus in a Class I, Group D, Division 1 (North America) or Class I, Zones 1 and 2 (Europe) Hazardous Location, including all of the local safety fire codes (for example, NFPA 33, NEC 500 and 516, OSHA 1910.107, etc.).
  • Page 8 Warnings WARNING TOXIC FLUID OR FUMES Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed. • Read Safety Data Sheet (SDS) for handling instructions and to know the specific hazards of the fluids you are using, including the effects of long-term exposure.

  • Page 9: Important Isocyanate (Iso) Information

    Important Isocyanate (ISO) Information Important Isocyanate (ISO) Information Material Self-ignition Isocyanates (ISO) are catalysts used in two component materials. Isocyanate Conditions Some materials may become self-igniting if applied too thick. Read material manufacturer’s warnings and Safety Data Sheet (SDS). Spraying or dispensing fluids that contain Keep Components A and B Separate isocyanates creates potentially harmful mists, vapors, and atomized particulates...
  • Page 10 Important Isocyanate (ISO) Information Moisture Sensitivity of Isocyanates NOTE: The amount of film formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature. Exposure to moisture (such as humidity) will cause ISO to partially cure; forming small, hard, abrasive crystals, which become suspended in the fluid.

  • Page 11: Important Acid Catalyst Information

    Important Acid Catalyst Information Important Acid Catalyst Information The PD2K MC3000 and MC4000 Proportioner is designed for acid catalysts (“acid”) currently used in two-component, wood-finishing materials. Current acids in use (with pH levels as low as 1) are more corrosive than earlier acids.

  • Page 12: Moisture Sensitivity Of Acid Catalysts

    Important Acid Catalyst Information Moisture Sensitivity of Acid Catalysts NOTICE Acid build-up will damage the valve seals and Acid catalysts can be sensitive to atmospheric reduce the performance and life of the catalyst moisture and other contaminants. It is recommended pump.

  • Page 13: System Control Drawing 16P577

    System Control Drawing 16P577 System Control Drawing 16P577 Do not substitute or modify system components as this may impair intrinsic safety. For installation, maintenance, or operation instructions, read instruction manuals. Do not install equipment approved only for non-hazardous location in a hazardous location.
  • Page 14 CLASS 1, DIV 1, GROUP D, T3 (USA AND CANADA) CLASS 1, ZONE 1, GROUP IIA, T3 (ATEX AND IECEx) POWER IN Ta = 2 C TO 50 250 VAC MAXIMUM SUPPLY VOLTAGE BOOTH CONTROL PROMIX PD2K (24M731) ELECTRICAL ENCLOSURE FM13ATEX0026 IECEx FMG 13.0011 (24M672) INTRINSIC SAFE APPARATUS...

  • Page 15: Configuring Your System

    Configuring Your System Configuring Your System 1. Select a Base Model Choose a PD2K base model that meets your If using a mix-at-wall configuration, see Figure 10, application’s requirements. See Models, page 3 page 14. Base models include components A through F shown in the Typical Installation Drawing.
  • Page 16 Configuring Your System HAZARDOUS (CLASSIFIED) LOCATION NON-HAZARDOUS LOCATION ONLY Figure 9 Typical Installation Component Description ★ Components A through F are included with the base unit. A★ Material A (Color) Pump B★ Material B (Catalyst) Pump C★ Solvent Valve D★ Booth Control E★...
  • Page 17 Configuring Your System HAZARDOUS (CLASSIFIED) LOCATION NON-HAZARDOUS LOCATION ONLY Figure 10 Typical Installation with Remote Mix Manifold Component Description ★ Components A through F are included with the base unit. A★ Material A (Color) Pump B★ Material B (Catalyst) Pump C★...
  • Page 18 Configuring Your System HAZARDOUS (CLASSIFIED) LOCATION NON-HAZARDOUS LOCATION ONLY Figure 11 Typical Dual Panel Installation (MC1002, MC2002, MC4002) Component Description ★ Components A through F are included with the base unit. A★ Material A (Color) Pump B★ Material B (Catalyst) Pump C★...
  • Page 19 Configuring Your System Component Description Components L through T are accessories and must be ordered separately. Fluid/Air Hose Bundle (accessory) — see PD2K Installation Manual (332457) for acid-compatible hose bundles Mix Manifold (accessory) — see Mix Manifold Instruction-Parts Manual (3A2801) for acid-compatible mix manifolds Air Spray Gun (accessory) Gun Air Hose (accessory) Intrinsically Safe CAN Cable (to connect booth control to electrical control...

  • Page 20: Select Hoses

    2. Select Hoses Hose Selection Tool Use this chart to determine the proper size hose NOTE: Always use Graco hoses. bundle for your mix ratio and viscosity, then select a NOTE: Shaded areas may use hose sizes from either hose bundle for your application from the tables on of the two adjacent areas.
  • Page 21 Low Pressure Air 200 psi (1.4 MPa, 13.8 bar) Spray 24T764 50 ft (15.2 m) Fluid Whip Hoses Select a fluid whip hose from the following table. Always use Graco hoses. Application Hose Part Hose I.D. Length Material Maximum Fluid Working...

  • Page 22: Select Mixing Option

    Configuring Your System 3. Select Mixing Option The system will use either a Mix at Belt Manifold or a Wall Mounted Mix Manifold. 3a. Mix At Belt Using Mix Manifold The following mix manifold kits are available. The mixing to occur at the point of spray. See manual mix manifolds attach to the painter’s belt, allowing 3A2801 for further information.

  • Page 23: Select A Spray Gun

    Configuring Your System Table 3 . High-Pressure, Non-Circulating Remote Table 4 . High-Pressure, Circulating Remote Color Color Change Manifold Kits (1500 psi [10.34 MPa, Change Manifold Kits (1500 psi [10.34 MPa, 103.4 103.4 bar]) bar]) Number Number of Catalyst + Solvent Valves Number Number of Catalyst + Solvent Valves of Color...

  • Page 24: Select Color And Catalyst Change

    Configuring Your System 5. Select Color and Catalyst Change Kits Using the following table, choose color/catalyst change kits that meet your application’s requirements. The kits include a manifold with valves and a control module. See color change kit manual 332455 for further information.

  • Page 25: Select Pump Expansion Kits

    Configuring Your System 6. Select Pump Expansion Kits 7. Select Communication Options NOTE: These are not required for Acid systems Use the following table to choose the appropriate which only use a single catalyst, or Dual Panel kit(s) to meet your system requirements. systems which already include four pumps.

  • Page 26: General Information

    General Information Location General Information • Reference numbers and letters in parentheses in the text refer to numbers and letters in the illustrations. • Be sure all accessories are adequately sized and To prevent tipping which can cause serious injury pressure-rated to meet system requirements.

  • Page 27: Install The Display Module

    Install the Display Module Install the Display Module 1. Use the screws (11) to mount the bracket (10) for the Advanced Display Module (12) on the front of the Control Box or on the wall, as you prefer. 2. Snap the Advanced Display Module into the bracket.

  • Page 28: Install The Booth Control

    Install the Booth Control Install the Booth Control 1. Use screws (S) to mount the bracket (10) for the 2. Snap the Booth Control into the bracket. Booth Control (13) on the wall. Connect a ground 3. Connect the Booth Control to the Isolation Board wire (G) to one of the screws.

  • Page 29: Air Supply

    To reduce the risk of fire and explosion if using a Graco electrostatic gun, a shutoff valve must be installed in the gun air line to shutoff the atomizing and turbine air to the gun. Contact your Graco distributor for information on air shutoff valves for electrostatic applications.
  • Page 30 Connection Module (see manual 3A4497). Air inlet NOTE: If you are using a Graco hose bundle, connect the 4 ft (1.2 m) end of the air hose to the GFB/Air cutoff output (plugged) atomizing air outlet (159c) and the 7 ft (2.1m) end Exhaust muffler...

  • Page 31: Fluid Supply

    800 cc/minute (depending on material viscosity). tank on the pump fluid inlet lines to reduce pulsation. • Fluid supply pressure tanks, feed pumps, or Contact your Graco distributor for additional circulating systems can be used to supply fluid to information.

  • Page 32: Single Color Connections

    Fluid Supply Single Color Connections Color Change Connections NOTE: Check valves (J, L) are provided on the inlet If you are installing the color change accessory kit, and outlet manifolds of each pump. make the fluid connections as described in manual 332455.

  • Page 33: Tsl Cup Kit

    TSL Cup Kit TSL Cup Kit 2. Place the TSL cup (73) into the bracket (73a). 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.
  • Page 34 TSL Cup Kit 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). NOTE: If you are not lubricating the dosing valves, remove the unused barbed fittings (73b) from the bottom of the TSL cup (73).
  • Page 35 TSL Cup Kit ISO Oil Fill Procedure To bleed air: 1. Fill the catalyst pump TSL cup to the lower When using polyurethane coatings with isocyanate horizontal line. catalysts in high-humidity environments, use of ISO oil on the catalyst pump TSL cup is recommended 2.

  • Page 36: Solvent Meter Accessory

    Solvent Meter Accessory Electrostatic Air Hose Solvent Meter Accessory Quick Disconnect Kit To install Solvent Meter Kit 280555, see manual 24S004 308778. NOTE: Install the solvent meter downstream of the solvent cutoff switch near the base unit. NOTE: To use a quick disconnect on an existing Light Tower Accessory electrostatic air hose, order Part No.

  • Page 37: Electrical Supply

    Electrical Supply Electrical Supply Electrical Connections Electrical Schematics, page 1. Verify that electrical power at the main panel is Improper wiring may cause electric shock or other shut off. Open the Control Box cover. serious injury if work is not performed properly. All 2.

  • Page 38: Grounding

    Use grounded hoses only. Spray Gun Follow the grounding instructions in your gun manual. • Non-Electrostatic: Ground the spray gun through connection to a Graco-approved grounded fluid supply hose. • Electrostatic: Ground the spray gun through Figure 22 Ground Screw and Power Switch connection to a Graco-approved grounded air supply hose.
  • Page 39 Grounding HAZARDOUS LOCATION NON-HAZARDOUS LOCATION Figure 23 System Grounding Electrical Control Box ground screw True Earth Ground; check local code for requirements Electrical Control Box ground wire Non-Intrinsically Safe cable Color Change Module (CC) ground wires Booth Control (BC) mounting bracket Intrinsically Safe (IS) cable ground wire 332457H...
  • Page 40 Grounding Object Being Sprayed Check Resistance Follow local code. All Solvent Pails Used When Purging To ensure proper grounding, resistance between Follow local code. Use only conductive metal components and true earth ground must be less pails/containers placed on a grounded surface. Do than 1 ohm.

  • Page 41: Electrical Schematics

    Electrical Schematics Electrical Schematics Standard Models (MC1000, MC2000, MC3000, MC4000) NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix PD2K system; models MC1000, MC2000, and MC4000. Some components shown are not included with all systems. NOTE: See Optional Cables and Modules, page 53 a list of cable options.
  • Page 42 Electrical Schematics UNUSED UNUSED UNUSED CABLE (121227) CABLE CABLE GCA MODULE (121227) (121001) 16T072 GATEWAY INTEGRATION (24R910) GATEWAY 1 2 3 4 5 1 2 3 4 5 EFCM CAN IS BOARD (NON IS) (IS) (24M485) (24N913) 1 2 3 4 5 1 2 3 4 5 +12VDC GFB INTERFACE...
  • Page 43 Electrical Schematics GUN TRIGGER INPUTS GCA MODULE GFB PRESSURE SWITCH (121323) SOLVENT FLOW SWITCH 1 (120278) EFCM FLOW RATE ANALOG IN 1 FLOW RATE ANALOG COMMON 1 FLOW RATE ANALOG IN 2 FLOW RATE ANALOG COMMON 2 (24N913) FLOW RATE ANALOG IN 3 FLOW RATE ANALOG COMMON 3 FLOW RATE ANALOG IN 4 FLOW RATE ANALOG COMMON 4...
  • Page 44 Electrical Schematics FROM CAN IS BOARD (24M485) ON PAGE 2 FROM CAN IS BOARD (24M485) ON PAGE 2 CABLE (15V206) 1 2 3 4 5 COLOR CHANGE MODULE 1 MANIFOLD MANIFOLD (COLORS +12VDC FLUSH DUMP 1 THRU 8) +12VDC +12VDC COLOR 1 COLOR 1 +12VDC...
  • Page 45 Electrical Schematics CATALYST CHANGE MODULE 6 MANIFOLD MANIFOLD (CATALYST +12VDC 3 THRU 4) DUMP FLUSH +12VDC +12VDC CATALYST 3 CATALYST 3 +12VDC +12VDC CATALYST 4 CATALYST 4 +12VDC UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED...
  • Page 46 Electrical Schematics FROM CAN IS BOARD (24M485) ON PAGE 2 NON-HAZARDOUS LOCATION HAZARDOUS LOCATION 1 2 3 4 5 COLOR CHANGE MODULE 7 MANIFOLD MANIFOLD (COLORS +12VDC COLOR FLUSH CATALYST FLUSH 33 THRU 40) +12VDC +12VDC COLOR 1 CATALYST 1 +12VDC COLOR 2 +12VDC...

  • Page 47: Dual Panel Models

    Electrical Schematics Dual Panel Models (MC1002, MC2002, MC4002) NOTE:The electrical schematic illustrates all possible wiring expansions in a ProMix PD2K system; models MC1002, MC2002, and MC4002. Some components shown are not included with all systems. NOTE: See Optional Cables and Modules, page 53 a list of cable options.
  • Page 48 Electrical Schematics CONTINUED ON PAGE 3 UNUSED UNUSED UNUSED CABLE CABLE (121227) CABLE (121227) (121001) GCA MODULE GATEWAY 16T072 INTEGRATION (24R910) GATEWAY 1 2 3 4 5 1 2 3 4 5 CAN IS BOARD EFCM (NON IS) (IS) (24M485) 1 2 3 4 5 1 2 3 4 5 (24N913)
  • Page 49 Electrical Schematics AIR FLOW SWITCH 1 BLACK WHITE AIR FLOW SWITCH 2 GREEN SOLVENT FLOW SW. 1 (120278) LEFT BRKT SOLVENT FLOW SW. 2 (120278) LEFT BRKT SOLVENT FLOW SW. 3 (120278) RIGHT BRKT GCA MODULE AIR CONTROL MODULE (26A231) SOLVENT FLOW SW.
  • Page 50 Electrical Schematics FROM CAN IS BOARD (24M485) ON PAGE 2 CABLE (15V206) 1 2 3 4 5 COLOR CHANGE MODULE 1 MANIFOLD MANIFOLD (COLORS +12VDC FLUSH DUMP 1 THRU 8) +12VDC +12VDC COLOR 1 COLOR 1 +12VDC +12VDC COLOR 2 COLOR 2 +12VDC +12VDC...
  • Page 51 Electrical Schematics FROM CAN IS BOARD (24M485) ON PAGE 2 CABLE (16V429) NON-HAZARDOUS LOCATION HAZARDOUS LOCATION 1 2 3 4 5 COLOR CHANGE MODULE 7 MANIFOLD MANIFOLD (COLORS +12VDC BLACK CATALYST FLUSH COLOR FLUSH 33 THRU 40) +12VDC BLACK BLACK +12VDC COLOR 1 CATALYST 1...
  • Page 52 Electrical Schematics CATALYST CHANGE MODULE 6 MANIFOLD MANIFOLD (CATALYST +12VDC 3 THRU 4) DUMP FLUSH +12VDC +12VDC CATALYST 3 CATALYST 3 +12VDC +12VDC CATALYST 4 CATALYST 4 +12VDC UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED...

  • Page 53: Optional Cables And Modules

    Electrical Schematics Optional Cables and Modules NOTE: The total length of all cable used in the system must not exceed 150 ft (45 m). See the Electrical Schematics, page M12 CAN Cables, for Hazardous Locations 25 Pin D-SUB Cables, for Non-Hazardous Locations Only NOTE: The total length of cable used in the 16T659...

  • Page 54: Dimensions

    Dimensions Dimensions Figure 36 Figure 37 Figure 38 with ADM without 65.3 in. 14.5 in. 11.12 in. 22.5 in. 19.26 in. 2.25 in. 18.0 in. 17.26 in. 0.52 in. (1659 (368 mm) (282 mm) (572 mm) (489 mm) (57 mm) (457 mm) (438 mm) (13 mm)

  • Page 55: Notes

    Notes Notes 332457H...

  • Page 56: Technical Data

    Technical Data Technical Data Positive Displacement U.S. Metric Proportioner Maximum fluid working pressure: MC1000, MC1002, and 300 psi 2.1 MPa, 21 bar MC3000 Air Spray Systems MC2000, MC2002, 1500 psi 10.5 MPa, 105 bar MC4000, and MC4002 Air-Assisted Spray Systems Maximum working air 100 psi 0.7 MPa, 7.0 bar...
  • Page 57 Technical Data Positive Displacement Metric U.S. Proportioner Wetted parts: MC0500 and MC0502 Pumps sold separately; see selected pump manual for wetted parts information. MC1000, MC1002, 17–4PH, 303, 304 SST, Tungsten carbide (with nickel binder), MC2000, and MC2002 perfluoroelastomer; PTFE, PPS, UHMWPE MC3000, MC4000, 316 SST, 17–4PH SST, PEEK, and MC4002...
  • Page 58 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.

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