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Installation-Parts
Pump
Pump Expansion
Pump
Expansion Kits
Expansion
To add
add a a a third
third or or or fourth
fourth pump
To
To
add
third
fourth
includes
includes one
includes
one pump
one
pump
pump and
and associated
and
Important Safety
Safety Instructions
Important
Important
Safety
Read all warnings and instructions in this manual and in your PD2K
manual. Save these instructions.
See page 3 for model part numbers and
approvals information.
Kits
Kits
pump to to to a a a ProMix®
ProMix® PD2K,
PD2K, or or or to to to add
pump
ProMix®
PD2K,
associated parts.
associated
parts. PD2K
parts.
PD2K is is is shown
PD2K
Instructions
Instructions
PROVEN QUALITY. LEADING TECHNOLOGY.
add pumps
pumps to to to a a a PD1K
add
pumps
shown with
shown
with two
with
two kits
two
kits added.
kits
added. For
added.
332456D
PD1K Proportioner.
Proportioner. Each
Each kit kit kit
PD1K
Proportioner.
Each
For professional
For
professional use
professional
EN
use only.
use
only.
only.
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Table of Contents
Related Manuals for Graco 24R968
Summary of Contents for Graco 24R968
- Page 1 Installation-Parts Pump Pump Expansion Pump Expansion Expansion Kits Kits Kits 332456D To add add a a a third third or or or fourth fourth pump pump to to to a a a ProMix® ProMix® PD2K, PD2K, or or or to to to add add pumps pumps to to to a a a PD1K PD1K Proportioner.
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Page 2: Table Of Contents
Contents Contents Contents Related Manuals ..........2 TSL Cup Kit ..........12 Fluid Connections ........15 Models............... 3 Electrical Connections ........16 Warnings ............3 Grounding ........... 18 Complete the Installation ......19 Important Isocyanate (ISO) Information ....6 Isocyanate Conditions ........6 Repair.............. -
Page 3: Models
Description Description Maximum Maximum Fluid Working Pressure 24R968 70 cc Low Pressure Color Pump Kit 300 psi (2.068 MPa, 20.68 bar) 24R969 70 cc High Pressure Color Pump Kit 1500 psi (10.34 MPa, 103.4 bar) 24R970 35 cc Low Pressure Color or 300 psi (2.068 MPa, 20.68 bar) - Page 4 Warnings WARNING WARNING WARNING FIRE AND AND EXPLOSION EXPLOSION HAZARD HAZARD FIRE FIRE EXPLOSION HAZARD work area area can ignite or explode. To help Flammable fumes, such as solvent and paint fumes, in work work area prevent fire and explosion: •...
- Page 5 Warnings WARNING WARNING WARNING PERSONAL PROTECTIVE PROTECTIVE EQUIPMENT EQUIPMENT PERSONAL PERSONAL PROTECTIVE EQUIPMENT 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: •...
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Page 6: Important Isocyanate (Iso) Information
Important Isocyanate (ISO) Information Important Isocyanate Isocyanate (ISO) (ISO) Information Information Important Important Isocyanate (ISO) Information Keep Keep Components Keep Components A A A and Components and B B B Separate Separate Separate Isocyanates (ISO) are catalysts used in two component materials. -
Page 7: Changing Materials
Important Isocyanate (ISO) Information Changing Materials Materials Changing Changing Materials NOTICE NOTICE NOTICE Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime. • When changing materials, flush the equipment multiple times to ensure it is thoroughly clean. •... -
Page 8: Important Acid Catalyst Information
Important Acid Catalyst Information Important Acid Acid Catalyst Catalyst Information Information Important Important Acid Catalyst Information Pump Expansion Kit 26A048 is designed for acid catalysts (“acid”) currently used in two-component, wood-finishing materials. Current acids in use (with pH levels as low as 1) are more corrosive than earlier acids. More corrosion-resistant wetted materials of construction are required, and must be used without substitution, to withstand the increased corrosive properties of these acids. -
Page 9: Installation
Installation Installation Installation Installation Before Installing Installing the the Kit Before Before Installing 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. -
Page 10: Install The Frame
Installation Install Install the Install the Frame Frame Frame NOTE: NOTE: The illustration shows a resin (70cc) pump NOTE: expansion kit being installed on the left (color) side of the PD2K proportioner. The pump control module Use these steps if you want to install the kit onto the and dual grommet (11) are preassembled at the PD2K stand using frame (13). -
Page 11: Install The Wall Bracket
Installation Install Install the Install the Wall Wall Wall Bracket Bracket Bracket 3. Install the back panel/bracket assembly (B) to wall bracket (47) using six screws (15) and six nuts (18). Use these steps if you want to install the kit away from the PD2K or PD1K stand using wall bracket (47). -
Page 12: Tsl Cup Kit
Installation TSL Cup Cup Kit The cup is used for either Throat Seal Liquid (TSL) 2. Place the TSL cup (73) into the bracket (73a). 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 13 Installation 4. Catalyst Catalyst (35 Catalyst (35 cc) cc) pumps: pumps: pumps: Repeat for the lower 6. Cut the tubing (73c) to length as required. throat cartridge. 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;...
- Page 14 Installation Air Connections Connections Connections For PD2K installations: Follow the steps below. NOTE: NOTE: A 6 ft (1.83 m) length of 1/4 in. (6 mm) OD NOTE: polyethylene tubing (35) is supplied with the kit to For PD1K installations: For the first expansion supply air to the expansion pump’s solenoid manifold kit, connect the air supply tube (35) directly to the (3).
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Page 15: Fluid Connections
Installation Fluid Connections Connections Fluid Fluid Connections 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. -
Page 16: Electrical Connections
Installation Electrical Connections Connections Electrical Electrical Connections 4. Thread the cable into the electrical control box and connect to the appropriate connection port on the enhanced fluid control module. For NOTICE NOTICE NOTICE example, connect Pump 1 to P1 and Pump 2 to P2 (PD1K only);... - Page 17 Installation 5. The PD2K/PD1K fluid panel cover was previously NOTICE NOTICE NOTICE removed in Air Connections, page 14. Thread the 2–wire cable (22) through the grommet (42) Be sure to keep 48 volt cables isolated from the on the bottom of the fluid panel and up into low voltage wiring.
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Page 18: Grounding
Installation Grounding Grounding Grounding 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. -
Page 19: Complete The Installation
Installation Complete the the Installation Installation Complete Complete Installation 1. Install the cover (12) on the expansion kit, using 4. Press and navigate to System Screen 1 the screw (37) and nut (18). on the Advanced Display Module. Change the number of Color Pumps and Catalyst Pumps as needed, based on the kit installation. - Page 20 Installation 5. Go to the Pump Screens. The menu bar at the 6. The Home Screen will now show animations and top of the screen will now show separate tabs information for the added pumps. for the added pump(s) 3 and 4. Each pump has three screens.
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Page 21: Repair
Repair Repair Repair Repair Dose Valve Valve Tubing Tubing Connections Connections Dose Dose Valve Tubing Connections NOTE: 5/32 in. (4 mm) tubing connects the solenoid NOTE: NOTE: 2. On the side of the solenoid manifold are four manifold to the pump’s dosing valves. See the Pump ports with 90°... - Page 22 Repair c. Connect yellow tubing (Y) from the DOWN See the following table to understand the relationship OPEN fitting to the 90° tube fitting on the side between pump stroke and dose valve actuation. of the OUTLET DOWN dosing valve. Table Table 1 1 1 Dose Table...
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Page 23: Replace Pump Control Module
Repair Replace Pump Pump Control Control Module Module Replace Replace Pump Control Module If the pump control module needs replacement, install a new module as follows. NOTICE NOTICE NOTICE To avoid electrical component damage, remove all system power before plugging any connectors. NOTE: See the NOTE: NOTE:... -
Page 24: Electrical Schematics
Electrical Schematics Electrical Schematics Schematics Electrical Electrical Schematics Standard Standard Models Standard Models (MC1000, Models (MC1000, MC2000, (MC1000, MC2000, MC3000, MC2000, MC3000, MC3000, MC4000) MC4000) MC4000) NOTE: The electrical schematic illustrates all possible NOTE: NOTE: wiring expansions in a ProMix PD2K system; models MC1000, MC2000, and MC4000. - Page 25 Electrical Schematics CONT INU ED ON P A GE 3 CONT INU ED ON P A GE 3 UNU SED UNU SED UNU SED CABLE (121227) CABLE CABLE A WI (121227) (121001) GCA M ODULE 16T072 GA TEW A Y INTEGR A TION (24R910) GA TEWA Y...
- Page 26 Electrical Schematics GFB PRESSURE SWITCH (121323) GCA M ODULE SOL VENT FLOW SWITCH 1 (120278) EFCM FLOW RA TE ANALOG IN 1 FLOW RA TE ANALOG COM M ON 1 FLOW RA TE ANALOG IN 2 FLOW RA TE ANALOG COM M ON 2 FLOW RA TE ANALOG IN 3 (24N913) FLOW RA TE ANALOG COM M ON 3...
- Page 27 Electrical Schematics FROM CAN IS BOARD (24M 485) CABLE (15V206) 1 2 3 4 5 COLOR CHANGE M ODULE 1 M ANIFOLD M ANIFOLD (CO LORS +24VDC FLU SH 1 THRU 8) DUM P +24VDC +24VDC COLOR 1 COLOR 1 +24VDC +24VDC COLOR 2...
- Page 28 Electrical Schematics CA TAL YST CHA NGE M ODULE 6 M ANIFOLD M ANIFOLD (CA TAL YST +24VDC 3 THRU 4) DUM P FLUSH +24VDC +24VDC CA TAL YST 3 CA TAL YST 3 +24VDC +24VDC CA TAL YST 4 CA TAL YST 4 +24VDC UNU SED...
- Page 29 Electrical Schematics FROM CAN IS BOARD (24M 485) NON-HAZARDOUS LOCA TION HAZARDOUS LOCA TION 1 2 3 4 5 COLOR CHANG E M ODULE 7 M ANIFOLD M ANIFOLD (COLORS +12VDC COLOR FLUSH CA TAL YST FLUSH 33 THRU 40) +12VDC +12VDC COLOR 1...
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Page 30: Mc4002)
Electrical Schematics Dual Panel Panel Models Models (MC1002, (MC1002, MC2002, MC2002, MC4002) MC4002) Dual Dual Panel Models (MC1002, MC2002, MC4002) NOTE: NOTE: 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. - Page 31 Electrical Schematics UNUSED UNUSED UNUSED CABLE CABLE (121227) CABLE A WI (121227) (121001) 16T072 GA TEW A Y INTEGRA T ION GCA M ODULE (24R9 10) GA TEWA Y 1 2 3 4 5 1 2 3 4 5 CAN IS BOARD (NON IS) EFCM (IS)
- Page 32 Electrical Schematics AIR FLOW SWITCH 1 BLACK WHITE AIR FLOW SWITCH 2 GREEN SOL VENT FLOW SW . 1 (120278) LEFT BRKT SOL VENT FLOW SW . 2 (120278) LEFT BRKT SOL VENT FLOW SW . 3 (120278) RIGHT BRKT AIR CONTROL M ODULE (26A231) GCA M ODULE SOL VENT FLOW SW .
- Page 33 Electrical Schematics FROM CA N I S BOARD (24M 485) CABLE (15V20 6 ) 1 2 3 4 5 COLOR CHANGE MOD ULE 1 MAN IFOL D MAN IFOL D (COLORS +24VDC FLUSH 1 THRU 8) DUM P +24VDC +24VDC COL OR 1 COL OR 1 +24VDC...
- Page 34 Electrical Schematics FROM CAN IS BOARD (24M 485) CABLE (16V429) NON-HAZARDOUS LOCA TION HAZARDOUS LOCA TION 1 2 3 4 5 COLOR CHANGE M ODULE 7 M ANIFOLD M ANIFOLD (COLORS +12VDC BLACK CA TAL YST FLUSH COLOR FLUSH 33 THRU 40) +12VDC BLACK +12VDC...
- Page 35 Electrical Schematics CA TAL YST CHANGE MODUL E 6 M ANIFOLD M ANIFOLD (CA TAL YST +24VDC 3 THRU 4) DUM P FLUSH +24VD C +24VDC CA TAL YST 3 CA TAL YST 3 +24VD C +24VDC CA TAL YST 4 CA TAL YST 4 +24VD C UNUSED...
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Page 36: Pump Expansion Kit Parts
Pump Expansion Kit Parts Pump Pump Expansion Pump Expansion Expansion Kit Kit Parts Parts Parts 332456D... - Page 37 — — — PANEL, back — — — CABLE, 2–wire 24T772 MANIFOLD, solenoid 24P684 WIRE HARNESS; 24T770 KIT, fan for Kits 24R968 and 24R970 24N527 MODULE, control, 24P685 WIRE HARNESS; pump — — — for Kits 24R969, SCREW, cap, socket 24R971, and 26A048 head;...
- Page 38 Pump Expansion Kit Parts Part Part Part Description Description Description Part Part Part Description Description Description — — — 24T302 KIT, cup, TSL; PLUG, screw; 10–32; includes items to replace unused 73a-73e item 73b at TSL cup; — — — not shown BRACKET —...
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Page 39: Technical Data
Metric Pump Pump Expansion U.S. U.S. Metric Metric Maximum fluid working pressure: Kits 24R968, 24R970, 300 psi 2.1 MPa, 21 bar and 25M268 Kits 24R969, 24R971, 1500 psi 10.5 MPa, 105 bar and 26A048 Maximum working air 100 psi 0.7 MPa, 7.0 bar... - Page 40 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.