Graco ProMix PD2K Installation Manual
  1. Manuals
  2. Brands
  3. Graco Manuals
  4. Industrial Equipment
  5. ProMix PD2K
  6. Installation manual

Graco ProMix PD2K Installation Manual

Electronic proportioner
Hide thumbs Also See for ProMix PD2K:
Table of Contents

Advertisement

Quick Links

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

Advertisement

Table of Contents
loading

Related Manuals for Graco ProMix PD2K

Summary of Contents for Graco ProMix PD2K

  • Page 1 Installation ProMix® ProMix® ProMix® PD2K PD2K Electronic PD2K Electronic Proportioner Electronic Proportioner Proportioner 332457M Electronic positive positive displacement displacement proportioner proportioner for for fast fast- - - setting setting two two- - - component component materials. materials. Manual Manual system system Electronic Electronic...

  • Page 2: Table Of Contents

    Contents Contents Contents Related Manuals ..........2 Air Supply ............32 Models............... 3 Fluid Supply ............34 Fluid Requirements ........34 Warnings ............6 Single Color Connections ......35 Important Isocyanate (ISO) Information ....9 Color Change Connections......35 Important Acid Catalyst Information ..... 11 Solvent Connections ........

  • Page 3: Models

    Models Models Models Models See Figs. 1–7 for component identification labels, including approval information and certification. Part No. Maximum Air Air Working Working Maximum Fluid Fluid Working Working Part Part Series Series Series Maximum Maximum Working Maximum Maximum Fluid Working Location Location Location of of of PD2K...
  • Page 4 Models Figure 2 24M672 & 26A188 Control Box Identification Label Figure 3 Models MC2000, MC2002, MC4000, and MC4002 (High Pressure) Identification Label Figure 4 Non-Intrinsically Safe Color Change Control (Accessory) Identification Label Figure 5 Intrinsically Safe Color Change Control Continued on the next page. (Accessory) Identification Label Figure 6 Booth Control Identification Label 332457M...
  • Page 5 Models Figure 7 Pump Expansion Kit (Accessory) Identification Label 332457M...

  • Page 6: Warnings

    Warnings 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 WARNING WARNING INTRINSIC INTRINSIC INTRINSIC SAFETY SAFETY 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. •...
  • Page 8 Warnings WARNING WARNING WARNING TOXIC TOXIC TOXIC FLUID FLUID FLUID OR OR FUMES FUMES 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 Isocyanate (ISO) (ISO) Information Information Important Important Isocyanate (ISO) Information Material Material Self Material Self - - - ignition Self ignition ignition Isocyanates (ISO) are catalysts used in two component materials. Isocyanate Isocyanate Isocyanate Conditions Conditions Conditions Some materials may become self-igniting if applied...
  • Page 10 Important Isocyanate (ISO) Information Moisture Sensitivity Sensitivity of of of Isocyanates Isocyanates Moisture Moisture Sensitivity Isocyanates NOTE: The amount of film formation and rate of NOTE: NOTE: 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;...

  • Page 11: Important Acid Catalyst Information

    Important Acid Catalyst Information Important Acid Acid Catalyst Catalyst Information Information Important 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: System Control Drawing 16P577

    System Control Drawing 16P577 System Control Control Drawing Drawing 16P577 16P577 System 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 13 System Control Drawing 16P577 NON- - - HAZARDOUS HAZARDOUS LOCATION LOCATION ONLY ONLY HAZARDOUS (CLASSIFIED) (CLASSIFIED) LOCATION LOCATION HAZARDOUS LOCATION ONLY HAZARDOUS HAZARDOUS (CLASSIFIED) LOCATION Class 1, Div 1, Group D, T3 (USA and Canada) Class 1, Zone 1, Group IIA, T3 (ATEX and IECEx) Ta = 2°C to 50°C HAZARDOUS (CLASSIFED) LOCA TION NON-HAZARDOUS LOCA TION ONL Y...

  • Page 14: Configuring Your System

    Configuring Your System Configuring Your Your System System Configuring Configuring Your System 1. 1. 1. Select Select a a a Base Base Model Model Select Base Model Choose a ProMix PD base model that meets your If using a mix-at-wall configuration, see Figure 10 application’s requirements.
  • Page 15 Configuring Your System HAZARDOUS (CLASSIFIED) (CLASSIFIED) LOCATION LOCATION NON- - - HAZARDOUS HAZARDOUS LOCATION LOCATION ONLY ONLY HAZARDOUS HAZARDOUS (CLASSIFIED) LOCATION HAZARDOUS LOCATION ONLY Figure 9 Typical Installation Component Component Component Description Description Description ★ ★ ★ Components Components A A A through through F F F are are included included with...
  • Page 16 Configuring Your System HAZARDOUS (CLASSIFIED) (CLASSIFIED) LOCATION LOCATION NON- - - HAZARDOUS HAZARDOUS LOCATION LOCATION ONLY ONLY HAZARDOUS HAZARDOUS (CLASSIFIED) LOCATION HAZARDOUS LOCATION ONLY Figure 10 Typical Installation with Remote Mix Manifold Component Component Component Description Description Description ★ ★ ★ Components Components A A A through through F F F are are included...
  • Page 17 Configuring Your System HAZARDOUS (CLASSIFIED) (CLASSIFIED) LOCATION LOCATION NON- - - HAZARDOUS HAZARDOUS LOCATION LOCATION ONLY ONLY HAZARDOUS HAZARDOUS (CLASSIFIED) LOCATION HAZARDOUS LOCATION ONLY Figure 11 Typical Dual Panel Installation (MC1002, MC2002, MC4002) Component Component Component Description Description Description ★ ★ ★ Components Components A A A through through F F F are are included...
  • Page 18 Configuring Your System Component Description Component Component Description Description Components Components L L L through Components through T T T are through are accessories accessories accessories and and must must must be be ordered ordered ordered separately. separately. separately. Fluid/Air Hose Bundle (accessory) — see PD2K Installation Manual (332457) for acid-compatible hose bundles Mix Manifold (accessory) —...
  • Page 19 Configuring Your System HAZARDOUS (CLASSIFIED) (CLASSIFIED) LOCATION LOCATION NON- - - HAZARDOUS HAZARDOUS LOCATION LOCATION ONLY ONLY HAZARDOUS HAZARDOUS (CLASSIFIED) LOCATION HAZARDOUS LOCATION ONLY Figure 12 Typical PD3K+ Installation (MC1000, MC2000, MC3000, MC4000) Component Component Component Description Description Description ★ ★ ★ Components Components A A A through Components through...
  • Page 20 Configuring Your System Component Description Component Component Description Description Gun Air Hose (accessory) Intrinsically Safe CAN Cable (to connect booth control to electrical control box) Gun Fluid Hose (accessory) Remote Color Change Valves Remote Catalyst Change Valves 332457M...

  • Page 21: Select Hoses

    When sizing results differ, select the larger recommended A lines, and the smaller recommended NOTE: NOTE: Always use Graco hoses. NOTE: B and C side hoses. NOTE: Shaded areas may use hose sizes from either NOTE: NOTE: of the two adjacent areas.
  • Page 22 Configuring Your System Additional Considerations Considerations for for PD3K+ PD3K+ Systems Systems Additional Additional Considerations PD3K+ Systems – A and C materials combined first, and then B added (solvent reduction for resin for viscosity Step 1: 1: 1: Determine Determine hardware hardware requirements requirements Step...
  • Page 23 24T764 50 ft (15.2 m) Fluid Whip Whip Hoses Hoses Fluid Fluid Whip Hoses Select a fluid whip hose from the following table. Always use Graco hoses. Application Hose Part Part Hose I.D. I.D. Length Material Maximum Fluid Fluid Working...

  • Page 24: Select Mixing Option

    Configuring Your System 3. 3. 3. Select Select Mixing Mixing Option Option Select Mixing Option combination of manifold types, and/or a Three-port Wall Mounted Manifold. A Mix-at-Belt Manifold may only be used for the final mixing stage because it The system will use either a Mix-at-Belt Manifold or requires user interaction to go between spray and a Wall Mounted Mix Manifold.

  • Page 25: Select A Spray Gun

    Configuring Your System 4. 4. 4. Select Select a a a Spray Spray Gun Select Spray Spray Spray Guns Spray Guns Guns Select a spray gun from the following table. Application Maximum Fluid Fluid Working Working Application Application Gun Model Model Model Gun Manual...

  • Page 26: Manifold Kits

    Configuring Your System 6. 6. 6. Select Select Color Color and and Catalyst Catalyst Change Change Manifold Manifold Kits Kits Select Color Catalyst Change Manifold Kits Using the following tables, choose color/catalyst manifold with valves. See the Color Change Kits and change control manifold kits that meet your Color Change and Remote Mix Manifold Kits manuals application’s requirements.
  • Page 27 Configuring Your System Table 2 2 2 High High Pressure Pressure Color/Catalyst Color/Catalyst Change Change Manifold Manifold Table Table High Pressure Color/Catalyst Change Manifold Kit Part Part No. Kit Description Description Kit Part Part No. Kit Description Description Part Description Part Description High...

  • Page 28: Select Pump Expansion Kits

    70cc pump 10. Upgrade Upgrade Kit Upgrade 24R971 High pressure catalyst 35cc pump The following kit includes software and parts to upgrade a ProMix PD2K to PD3K+. Kit Part Part No. Kit Description Description Part Description 26C416 PD3K+ Upgrade Kit...

  • Page 29: General Information

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

  • Page 30: Install The Display Module

    Install the Display Module Install the the Display Display Module Module Install Install 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.

  • Page 31: Install The Booth Control

    Install the Booth Control Upgrade Software Software for for ProMix ProMix PD3K+ PD3K+ Install the the Booth Booth Control Control Upgrade Upgrade Software ProMix PD3K+ Install Install Booth Control System System System 1. Use screws (S) to mount the bracket (10) for the If upgrading your ProMix PD system to a PD3K+, Booth Control (13) on the wall.

  • Page 32: 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 33 Figure 20 Air Manifold Connections NOTE: NOTE: NOTE: If you are using a Graco hose bundle, connect the 4 ft (1.2 m) end of the air hose to the atomizing air outlet (159c) and the 7 ft (2.1m) end of the air hose to the gun. If there is more than...

  • Page 34: Fluid Supply

    If necessary, install pressure regulators or a surge to 800 cc/minute (depending on material viscosity). tank on the pump fluid inlet lines to reduce pulsation. Contact your Graco distributor for additional • Fluid supply pressure tanks, feed pumps, or information.

  • Page 35: Single Color Connections

    Fluid Supply Single Color Color Connections Connections Color Change Change Connections Connections Single Single Color Connections Color Color Change Connections If you are installing the color change accessory kit, NOTE: NOTE: Check valves (J, L) are provided on the inlet NOTE: make the fluid connections as described in manual and outlet manifolds of each pump.
  • Page 36 Fluid Supply For PD3K+ PD3K+ Systems Systems PD3K+ Systems Solvent Flow Switch 1: EFCM Connector J6 Component A Remote Pins 11-12 Solvent connections for a PD3K+ system using Solvent mix-at-belt manifolds will be the same as shown above for the PD2K system. However, the wiring Solvent Flow Switch 2: EFCM Connector J7 of the solvent flow switch needs to be moved from...

  • Page 37: Tsl Cup Kit

    TSL Cup Kit 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 38 TSL Cup Kit NOTE: If you are not lubricating the dosing Repeat for the lower throat cartridge. NOTE: NOTE: 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.

  • Page 39: Highly-Reactive/Moisture-Sensitive Iso Catalyst Pd2K Pumps

    TSL. The ISO oil will present a barrier NOTE: NOTE: NOTE: Graco recommends this alternate TSL (Throat that will prevent catalyst hardening from contact with Seal Liquid) plumbing installation only on Catalyst moisture. When performing the first fill of a cup with...
  • Page 40 TSL Cup Kit Additional Maintenance Maintenance and and Precautions Precautions 2. Connect the tubing (73c1) from the barbed fitting Additional Additional Maintenance Precautions (73b) on the lower throat cartridge to one of The TSL fluid in the TSL reservoir must be replaced the barbed fittings (73b) on the upper throat more frequently when the alternate TSL plumbing cartridge.* * * Connect tubing (73c2) from the other...

  • Page 41: Solvent Meter Accessory

    Solvent Meter Accessory Solvent Meter Meter Accessory Accessory Electrostatic Air Air Hose Hose Solvent Solvent Meter Accessory Electrostatic Electrostatic Hose Quick Quick Disconnect Quick Disconnect Disconnect Kit To install Solvent Meter Kit 280555, see manual 24S004 24S004 24S004 308778. NOTE: NOTE: Install the solvent meter downstream of the NOTE: solvent cutoff switch near the base unit.

  • Page 42: Electrical Supply

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

  • Page 43: Grounding

    Spray Follow the grounding instructions in your gun manual. • Non-Electrostatic: Non-Electrostatic: Non-Electrostatic: Ground the spray gun through connection to a Graco-approved grounded fluid supply hose. • Electrostatic: Electrostatic: Electrostatic: Ground the spray gun through connection to a Graco-approved grounded air supply hose.
  • Page 44 Grounding HAZARDOUS LOCATION LOCATION NON- - - HAZARDOUS HAZARDOUS LOCATION LOCATION HAZARDOUS HAZARDOUS LOCATION HAZARDOUS LOCATION Figure 26 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...
  • Page 45 Grounding Object Being Being Sprayed Sprayed Check Resistance Resistance Object Object Being Sprayed Check Check Resistance Follow local code. All Solvent Solvent Pails Pails Used Used When When Purging Purging Solvent Pails Used When Purging To ensure proper grounding, resistance between Follow local code.

  • Page 46: Electrical Schematics

    MC2000, MC3000, MC4000) NOTE: NOTE: 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 NOTE: NOTE: Optional Cables and Modules, page 58 a list of cable options.
  • Page 47 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 GA TEWA Y 16T072 INTEGR A TION (24R910) GA TEW A Y 1 2 3 4 5...
  • Page 48 Electrical Schematics Figure 29 Electrical Schematic, Sheet 2, Part 2 CONTINUED ON THE NEXT PAGE 332457M...
  • Page 49 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 DUM P 1 THRU 8) +24VDC +24VDC COLOR 1 COLOR 1 +24VDC +24VDC COLOR 2...
  • Page 50 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 51 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...

  • Page 52: Dual Panel Models

    MC2002, MC3002, 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. NOTE: NOTE: NOTE: See Optional Cables and Modules, page 58 a list of cable options.
  • Page 53 Electrical Schematics UNUSED UNUSED UNUSED CABLE (121227) CABLE 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 54 Electrical Schematics BLACK AIR FLOW SWITCH 1 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 55 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 DUM P 1 THRU 8) +24VDC +24VDC COL OR 1 COL OR 1 +24VDC...
  • Page 56 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 BLACK +12VDC CA TAL YST FLUSH COLOR FLUSH 33 THRU 40) BLACK +12VDC +12VDC...
  • Page 57 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...

  • Page 58: Optional Cables And Modules

    Electrical Schematics Optional Cables Cables and and Modules Modules Optional Optional Cables Modules NOTE: NOTE: 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 CAN Cables, Cables, for Cables,...

  • Page 59: Dimensions

    Dimensions Dimensions Dimensions Dimensions Figure 39 Figure 40 Figure 41 A A A B B B C C C D D D E E E F F F G G G H H H with ADM without with with without without 65.3 in.

  • Page 60: Technical Data

    Technical Data Technical Data Data Technical Technical Data Positive Positive Displacement Positive Displacement Displacement U.S. Metric Metric Metric U.S. U.S. Proportioner Proportioner 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...
  • Page 61 Technical Data Positive Displacement Displacement Metric Positive Positive Displacement U.S. U.S. U.S. Metric Metric Proportioner Proportioner 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;...
  • Page 62 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.

Table of Contents