Graco ProMix PD2K Installation Manual
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Graco ProMix PD2K Installation Manual

Graco ProMix PD2K Installation Manual

Proportioner for automatic spray applications
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Installation
ProMix® PD2K
PD2K Proportioner
ProMix®
ProMix®
PD2K
Automatic
Automatic
Automatic Spray
Spray Applications
Spray
Electronic positive
positive displacement
displacement proportioner
Electronic
Electronic
positive
displacement
system
system with
system
with Advanced
with
Advanced Display
Advanced
Important
Important Safety
Important
Safety Instructions
Safety
Read all warnings and instructions in this manual and in your
operation, repair, and associated component manuals. Save
instructions.
instructions.
instructions.
See page 3 for model part numbers and
approvals information.
Proportioner for
Proportioner
Applications
Applications
proportioner for
proportioner
Display Module.
Display
Module. For
Module.
For professional
For
professional use
professional
Instructions
Instructions
PROVEN QUALITY. LEADING TECHNOLOGY.
for
for
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
332458M
materials. Automatic
Automatic
materials.
Automatic
EN

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Summary of Contents for Graco ProMix PD2K

  • Page 1 Installation ProMix® PD2K PD2K Proportioner Proportioner for ProMix® ProMix® PD2K Proportioner Automatic Automatic Automatic Spray Spray Applications Spray Applications Applications 332458M Electronic positive positive displacement displacement proportioner proportioner for for fast fast- - - setting setting two two- - - component component materials.

  • Page 2: Table Of Contents

    Dimensions ............54 Air Supply ............28 Technical Specifications........55 Fluid Supply ............29 California Proposition 65 ........55 Related Manuals Manuals Related Related Manuals Current manuals are available at www.graco.com. Manual Manual Manual No. Description Description Description Manual Manual No. Manual...

  • 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 and 26A188 Control Box Identification Label Figure 3 Model AC2000 and AC2002 Identification Label Figure 4 Model AC0500 and AC0502 Identification Label 332458M...
  • Page 5 Models 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 PART NO. DATE / SERIES RECOGNIZED COMPONENT SERIAL NO. 4003764 12-30 VDC Conforms to UL STD 508 4 AMP MAX...

  • 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 symbols refer to procedure-specific risks. When these symbols appear in the body of this manual, 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.
  • 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: 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 12 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 NON -HAZA R DOUS LOCA TION ONL Y HAZARDOUS (CLASSIFED) LOCA TION...

  • Page 13: Configure Your System

    Configure Your System Configure Your Your System System Configure Configure 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 application’s requirements. See Models, page 3 Base models include components A through F shown in the Typical Installation drawing on the next page.
  • Page 14 Configure 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 Description Component Component Component Description Description ★ ★ ★ Components Components A A A through Components through F F F are through...
  • Page 15 Configure 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 (AC1002 and AC2002 only) Description Component Component Component Description Description ★...
  • Page 16 Configure Your System NON- - - HAZARDOUS HAZARDOUS LOCATION LOCATION ONLY ONLY HAZARDOUS (CLASSIFIED) (CLASSIFIED) LOCATION LOCATION HAZARDOUS LOCATION ONLY HAZARDOUS HAZARDOUS (CLASSIFIED) LOCATION Figure 12 Typical PD3K+ Installation (AC1000 and AC2000) Component Component Component Description Description Description ★ ★ ★ Components Components A A A through through F F F are are included...
  • Page 17 Configure Your System Component Description Component Component Description Description Gun Fluid Hose (accessory) Remote Color Change Valves Remote Catalyst Change Valves W★ Material W Pump 332458M...

  • Page 18: Select Hoses

    When sizing results differ, select the larger recommended A lines, and the smaller recommended NOTE: NOTE: NOTE: Always use Graco hoses. B and C side hoses. NOTE: Shaded areas may use hose sizes from either NOTE: NOTE: of the two adjacent areas.
  • Page 19 Configure 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 20: Select Remote Mix Manifold

    Configure Your System 1/4 in. in. in. (6 (6 (6 mm) mm) ID ID ID Hoses Hoses Hoses Application Application Application Material Material Material Pressure Pressure Pressure Maximum Maximum Fluid Maximum Fluid Working Fluid Working Working Length Length Length Pressure Pressure Pressure 15 ft ft ft...

  • Page 21: Select A Spray Gun

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

  • Page 22: Control Module Kits

    Configure Your System 5. 5. 5. Select Select Color Color and and Catalyst Catalyst Change Change 6. 6. 6. Select Select Color Color and and Catalyst Catalyst Change Change Select Color Catalyst Change Select Color Catalyst Change Control Module Module Kits Kits Manifold Kits Kits...
  • Page 23 Configure Your System Kit Part Part No. Kit Description Description Kit Part Part No. Kit Description Description Part Description Part Description 26A273 11 valve manifold 24T659 14 valve manifold 26A275 12 valve manifold 24T660 15 valve manifold 25A605 13 valve manifold 24T661 16 valve manifold 26A277...

  • Page 24: Select Pump Expansion Kits

    Description Description 25D980 PD2K Maintenance Tool Kit 10. Upgrade Upgrade Kit Upgrade 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 332458M...

  • Page 25: 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 26: 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 Item Item Item Description Description Description the Advanced Display Module (12) on the front of Battery Cover the Control Box or on the wall.

  • Page 27: System

    Install the Display Module Upgrade Software Software for for ProMix ProMix PD3K+ PD3K+ Upgrade Upgrade Software ProMix PD3K+ 3. Insert and press token (T) firmly into slot. System System System NOTE: There is no preferred orientation of the NOTE: NOTE: token.

  • Page 28: Air Supply

    Use bleed-type shutoff valves. 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 29: Fluid Supply

    Contact your Graco distributor for additional information. • Materials can be transferred from their original containers or from a central paint recirculating line.

  • Page 30: Single Color Connections

    Fluid Supply Single Color Color Connections Connections Color Change Change Connections Connections Single Single Color Connections Color Color Change Connections NOTE: NOTE: NOTE: Check valves (J, L) are provided on the inlet If you are installing the color change accessory kit, (K) and outlet (H) manifolds of each pump.

  • Page 31: Dual Panel Solvent Connections

    Fluid Supply Dual Panel Panel Solvent Solvent Connections Connections PD3K+ Solvent Solvent Connections Connections Dual Dual Panel Solvent Connections PD3K+ PD3K+ Solvent Connections 1. Connect the solvent supply line for the resin for 1. Connect the solvent supply line for component A Mix Unit #1 to the inlet fitting (17) for solvent flow to inlet fitting (17) for solvent flow switch 1 (FS1).

  • Page 32: 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 33 TSL Cup Kit 4. Repeat for the lower throat cartridge. 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.

  • Page 34: Highly-Reactive/Moisture-Sensitive Iso Catalyst Pd2K Pumps

    TSL cup is recommended instead of TSL. The ISO oil will present a barrier NOTE: NOTE: Graco recommends this alternate TSL (Throat NOTE: that will prevent catalyst hardening from contact with Seal Liquid) plumbing installation only on Catalyst moisture.
  • Page 35 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 36: Solvent Meter Accessory

    Solvent Meter Accessory Solvent Meter Meter Accessory Accessory Light Tower Tower Accessory Accessory Solvent Solvent Meter Accessory Light Light Tower Accessory To install Solvent Meter Kit 280555, see manual To install Light Tower Kit 24K337, see manual 3A1906. 308778. NOTE: NOTE: NOTE: Install the solvent meter downstream of the solvent cutoff switch near the base unit.

  • Page 37: 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 38 Electrical Supply Field Field Field Bus Bus Connections Connections Connections 2. Remove the nut on fitting (F). 3. Remove the fitting far enough to allow If used, connect the ethernet cable to the CGM as disassembly of the fitting and to open the applicable.

  • Page 39: Grounding

    Supply Container Container Fluid Fluid Supply Container Non-Electrostatic: Ground the spray gun through • Non-Electrostatic: Non-Electrostatic: connection to a Graco-approved grounded fluid Follow local code. supply hose. Electrostatic: Ground the spray gun through • Electrostatic: Electrostatic: Color Color Color Change...
  • Page 40 Grounding HAZARDOUS LOCATION LOCATION NON- - - HAZARDOUS HAZARDOUS LOCATION LOCATION HAZARDOUS HAZARDOUS LOCATION HAZARDOUS LOCATION Figure 24 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 Remote Mix Control Module ground...

  • Page 41: Electrical Schematics

    Models (AC1000 AC2000) NOTE: The electrical schematic illustrates all possible NOTE: NOTE: wiring expansions in a ProMix PD2K system; models AC1000 and AC2000. Some components shown are not included with all systems. NOTE: See NOTE: NOTE: Optional Cables and Modules, page 53 a list of cable options.
  • Page 42 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 CABLE (121227) CABLE A WI (121227) (121001) GCA M ODULE 16T072 GA TEWA Y INTEGR A TION (24R910) GA TEW A Y 1 2 3 4 5...
  • Page 43 Electrical Schematics Figure 27 Electrical Schematic, Sheet 2, Part 2 CONTINUED ON THE NEXT PAGE 332458M...
  • Page 44 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 45 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 46 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 47: Ac2002)

    AC2002) AC2002) AC2002) NOTE: NOTE: NOTE:The electrical schematic illustrates all possible wiring expansions in a ProMix PD2K system; models AC1002 and AC2002. Some components shown are not included with all systems. NOTE: See NOTE: NOTE: Optional Cables and Modules, page 53 a list of cable options.
  • Page 48 Electrical Schematics UNUSED UNUSED UNUSED CABLE (121227) CABLE CABLE A WI (121227) (121001) GA TEW A Y 16T072 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 49 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 50 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 51 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 COLOR FLUSH CA TAL YST FLUSH 33 THRU 40) BLACK +12VDC +12VDC...
  • Page 52 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 53: Optional Cables And Modules

    Optional Cables and Modules Optional Cables Cables and Optional Optional Cables Modules Modules Modules NOTE: The total length of all cable used in the system must not exceed 150 ft (45 m). See the NOTE: NOTE: Electrical Schematics, page M12 CAN CAN Cables, Cables, for for Hazardous...

  • Page 54: Dimensions

    Dimensions Dimensions Dimensions Dimensions Figure 38 Figure 37 Figure 39 A A A B B B C C C D D D E E E F F F G G G H H H J J J with without with with without without...

  • Page 55: Technical Specifications

    Technical Specifications Technical Specifications Specifications Technical Technical Specifications Positive Displacement Displacement Proportioner Proportioner U.S. Metric Positive Positive Displacement Proportioner U.S. U.S. Metric Metric Maximum fluid working pressure: 300 psi 2.1 MPa, 21 bar AC1000 and AC1002 Air Spray Systems 1500 psi 10.5 MPa, 105 bar AC2000 and AC2002 Air-Assisted Spray Systems...
  • Page 56 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 manual is also suitable for:

Ac0500Ac1000Ac2000Ac2002Ac0502Ac1002 ... Show all

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