Installation ProMix® PD2K Proportioner for Automatic Spray Applications 332458B Electronic positive displacement proportioner for fast-setting two-component materials. Automatic system with Advanced Display Module. For professional use only. Important Safety Instructions Read all warnings and instructions in this manual and in your operation, repair, and associated component manuals. Save these instructions. See page 3 for model part numbers and approvals information. PROVEN QUALITY.
Contents Warnings ........................................................... 5 Fluid Supply ....................................................... 21 Fluid Requirements ...................................... 21 Single Color Connections ............................. 22 Color Change Connections ........................... 22 Important Isocyanate (ISO) Information ................ 8 TSL Cup Kit........................................................ 23 System Control Drawing 16P577 .....................
Models Models See Figs. 1–7 for component identification labels, including approval information and certification. Part No. Series Maximum Air Working Pressure Maximum Fluid Working Pressure AC1000 A 100 psi (0.7 MPa, 7.0 bar) 300 psi (2.068 MPa, 20.68 bar) AC2000 A 100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.
Models Figure 3 Model AC2000 (High Pressure) Identification Label Figure 4 Non-Intrinsically Safe Color Change Control (Accessory) Identification Label Figure 5 Intrinsically Safe Color Change Control (Accessory) Identification Label Figure 6 Pump Expansion Kit (Accessory) Identification Label 4 332458B
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. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
Warnings INTRINSIC SAFETY WARNING 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.
Warnings WARNING 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: • Protective eyewear, and hearing protection. • Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer. EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury.
Important Isocyanate (ISO) Information Important Isocyanate (ISO) Information Isocyanates (ISO) are catalysts used in two component materials. Isocyanate Conditions Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. NOTICE Partially cured ISO will reduce performance and the life of all wetted parts. Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates.
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. See the identification label for the intrinsic safety rating for your model.
System Control Drawing 16P577 NON-HAZARDOUS LOCATION ONLY 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-HAZARDOUS LOCATION ONLY POWER IN 250 VAC MAXIMUM SUPPLY VOLTAGE HAZARDOUS (CLASSIFED) LOCATION CLASS 1, DIV 1, GROUP D, T3 (USA AND CANADA) CLASS 1, ZONE 1, GROUP IIA, T3 (ATEX AND IECEx) Ta = 2ºC TO 50ºC PROMIX PD2K ELECTRICAL ENCLOSURE (24M672) POWER BARRIER (248192) CABLE (16V426) FM13ATEX0026 IECE
Configure Your System Configure Your System 1. Select a Base Model Choose a PD2K base model that meets your application’s requirements. See Models, page 3 . Base unit components are described in the following table. Base models include components A through F shown in the Typical Installation drawing on the next page. Component Description Fluid Pumps (A, B) The base models include two fluid pumps, one for resin and one for catalyst. Install in the non-hazardous area.
Configure Your System HAZARDOUS (CLASSIFIED) LOCATION NON-HAZARDOUS LOCATION ONLY Figure 8 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 Flow Switch D★ Electrical Control Box E★ Advanced Display Module F★ CAN Communication Cable Components G through K are included in optional color change kits.
Configure Your System 2. Select Hoses Hose Selection Tool Use this chart to determine the proper size hoses for your mix ratio and viscosity., then select hoses for your application. NOTE: Shaded areas may use hose sizes from either of the two adjacent areas. NOTE: Always use Graco hoses. Recommended Hose Sizes (internal diameter) for A and B 20 - 50 18 3/8ʺ A 1/8ʺ B 16 14 3/8ʺ A 1/4ʺ B 12 Mix Ratio (X:1) 10 8 1/4ʺ A 1/4ʺ B 6 4 2 0 10:1 Thick Resin (A) 1/4ʺ A 3/8ʺ B 7.5:1 5:1 2.5:1 1:1 1:2.
Configure Your System 1/4 in. (6 mm) ID Hoses Application Material MoistureLok Catalyst Nylon Resin Nylon Maximum Fluid Working Pressure Length 15 ft (4.6 m) 25 ft (7.6 m) 50 ft (15.2 m) High and Low 2000 psi (13.8 MPa, 138 bar) 947078 24T134 24T135 Low 225 psi (1.6 MPa, 16 bar) 17C967 24T266 24T267 High 4100 psi (28.3 MPa, 283 bar) 238825 239107 239111 Low 225 psi (1.6 MPa, 16 bar) 17C967 24T266 24T267 High 4100 psi (28.
Configure Your System 4. Select Non- IS Color and Catalyst Change Kits Using the following table, choose the non-IS color/catalyst change kits that meet your application’s requirements. The kits include a manifold with valves and a control module for installation in the non-hazardous area. See color change kit manual 333282 for further information. Table 1 . Low Pressure Color/Catalyst Change Kits (300 psi [2.068 MPa, 20.68 bar]) Kit Part No. Kit Description Table 2 .
Configure Your System 5. Select IS Remote Color Change Kits IS remote color change manifold kits include a manifold with valves and a control module, which may be installed in the hazardous area. The remote color change manifold kit must have the same number of color valves and catalyst valves as the color/catalyst change kit you selected in the previous step. The remote color change manifolds attach to the robot arm or wall, allowing mixing to occur close to the point of spray.
Configure Your System Table 6 . High-Pressure, Circulating Remote Color Change Manifold Kits (1500 psi [10.34 MPa, 103.4 bar]) Number of Color + Solvent Valves Number of Catalyst + Solvent Valves 1 24V369 2 24V370 24V389 4 24V371 24V390 24V402 6 24V372 24V391 24V403 8 24V373 24V392 24V404 12 24V374 24V393 24V405 13–18 24V375 13–24 24V376 13–30 24V377 1 4 2 6. Select Pump Expansion Kits The following table lists available kits to add a third or fourth pump to your system.
General Information General Information 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 pressure-rated to meet system requirements. • To protect the screens from paints and solvents, clear-plastic protective shields (10 per pack) are available. Order Part No. 197902 for the Advanced Display Module. Clean the screens with a dry cloth if necessary.
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. 2. Snap the Advanced Display Module into the bracket. Figure 10 Advanced Display Module Connection Ports Item Description J Battery Cover K Model Number L USB Drive Interface M CAN Cable Connection N ADM Status LEDs P Accessory Cable Connection R Token Access Cover Figure 9 Install Display Module 3.
Air Supply Air Supply Air Requirements This air supplies gun atomizing air. The air flow switch detects air flow to the gun and signals the controller when the gun is being triggered. • Compressed air supply pressure: 85-100 psi (0.6–0.7 MPa, 6.0-7.0 bar). NOTE: If there is more than one gun (for example, a separate gun for each color), the atomizing air outlet (159c) must be branched to each gun. For ease of maintenance, install a ball valve at all air line tees.
Fluid Supply Fluid Supply Fluid Requirements • To reduce the risk of equipment overpressurization and rupture which can cause injury, including skin injection, do not exceed the pressure rating of the lowest rated system component. See the identification label for the maximum working pressure of the equipment. • To reduce the risk of injury, including skin injection, you must install a shutoff valve between each fluid supply line and the mix manifold.
Fluid Supply Single Color Connections Color Change Connections NOTE: Check valves (J, L) are provided on the inlet (K) and outlet (H) manifolds of each pump. If you are installing the color change accessory kit, make the fluid connections as described in manual 333282. 1. Connect the color supply line to the pump fluid inlet fitting (S). 2. Connect the color outlet line to the pump fluid outlet fitting (R). 3. Make the same connections on the catalyst side.
TSL Cup Kit TSL Cup Kit Throat Seal Liquid (TSL) lubricates the pump throat packings and dosing valves. The PD2K Proportioner includes two TSL Cup Kits, one for each pump. The kits 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. NOTE: TSL must be ordered separately. Order Part No. 206995, 1 quart (0.95 liter).
Solvent Meter Accessory 5. If you are lubricating the dosing valves, remove the plug (73d) and gasket from the valve port (V) closest to the TSL cup. 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). NOTE: Do not confuse the valve port (V) with the air port (W). Solvent Meter Accessory To install Solvent Meter Kit 280555, see manual 308778.
Electrical Supply Electrical Supply Electrical Connections See Electrical Schematics, page 29. Improper wiring may cause electric shock or other serious injury if work is not performed properly. All electrical wiring must be completed by a qualified electrician and comply with all local codes and regulations. Electrical Requirements Enclose all cables routed in the spray booth and high traffic areas in conduit to prevent damage from paint, solvent, and traffic.
Grounding Grounding See illustration on next page. Fluid Supply Container Follow local code. Color Change Module 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. Electrical Control Box The electrical control box has two ground points. Both connections must be made.
Grounding HAZARDOUS LOCATION NON-HAZARDOUS LOCATION Figure 16 System Grounding Key 1 Electrical Control Box ground screw 2 Electrical Control Box ground wire 3 Color Change Module (CC) ground wires 4 Intrinsically Safe (IS) cable 332458B 5 True Earth Ground; check local code for requirements 6 Non-Intrinsically Safe cable 7 Remote Mix Control Module ground wire 27
Grounding Object Being Sprayed Check Resistance Follow local code. Solvent Reservoir or Purge Station Follow local code. Use only a conductive solvent reservoir or purge station placed on a grounded surface. Do not place the solvent reservoir or purge station on a nonconductive surface, such as paper or cardboard, which interrupts the grounding continuity. 28 To ensure proper grounding and reduce risk of fire and explosion, resistance between components and true earth ground must be less than 1 ohm.
Electrical Schematics Electrical Schematics NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix PD2K system. Some components shown are not included with all systems. NOTE: See Optional Cables and Modules, page 35 for a list of cable options. CABLE 16H078 AWI GATEWAY (24R910) UP DOWN FLOW SENSOR (120278) OR G3000 METER (239716, 258718 16M510, 16M519) PUMP INLET TRANSDUCER (16P289, 16P290) PUMP OUTLET TRANSDUCER (16P289, 16P290) PUMP V/P FOR FLUID REG.
Electrical Schematics CONTINUED ON PAGE 3 CONTINUED ON PAGE 3 2 3 CABLE (15V206) 1 2 3 4 5 8 3 1 2 3 4 5 6 7 8 9 10 11 12 5 (121001) GCA MODULE EFCM (24N913) 5 3 12345 SOLVENT CUTOFF (121324) PWR (RED) SIG (WHITE) COM (BLACK) SHIELD/GRN SOLVENT +12VDC COM UNUSED UNUSED +12VDC COM +12VDC COM UNUSED 1 RED WIRE (065161) GROUND BAR BLACK WIRE (065159) 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 METER (258718) 4 25 PIN D-SUB CABLE (16T659) 24V POWER SUPPLY (16T660
Electrical Schematics GUN TRIGGER INPUTS SIG COM SIG COM SIG COM SIG COM SIG COM SIG COM 7 1 2 3 4 5 6 7 8 9 10 11 12 FLOW RATE ANALOG IN 1 FLOW RATE ANALOG COMMON 1 FLOW RATE ANALOG IN 2 FLOW RATE ANALOG COMMON 2 FLOW RATE ANALOG IN 3 FLOW RATE ANALOG COMMON 3 FLOW RATE ANALOG IN 4 FLOW RATE ANALOG COMMON 4 SIG SOLVENT FLOW SWITCH 2 (120278) COM SIG SAFETY INTERLOCK SWITCH COM 9 1 2 3 4 5 6 GCA MODULE EFCM (24N913) 3 4 LIGHT TOWER (15X472) 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Electrical Schematics FROM CAN IS BOARD (24M485) ON PAGE 2 FROM CAN IS BOARD (24M485) ON PAGE 2 2 CABLE (15V206) MANIFOLD FLUSH COLOR 1 COLOR 2 COLOR 3 COLOR 4 COLOR 5 COLOR 6 COLOR 7 COLOR 8 12 34 5 COLOR CHANGE MODULE 1 (COLORS 1 THRU 8) +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 J8 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 J15 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 J14 J9 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC J16 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC 6 5 4 3
Electrical Schematics MANIFOLD FLUSH CATALYST 3 CATALYST 4 CATALYST CHANGE MODULE 6 (CATALYST 3 THRU 4) +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 J8 UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED 1 2 3 4 5 6 J15 UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED 1 2 3 4 5 6 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC J16 6 5 4 3 2 1 UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED J10 6 5 4 3 2 1 UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED J9 6 J14 MANIFOLD DUMP CATALYST 3 CATALYST 4 2 CABLE (15V206)
Electrical Schematics FROM CAN IS BOARD (24M485) ON PAGE 2 NON-HAZARDOUS LOCATION HAZARDOUS LOCATION MANIFOLD COLOR FLUSH COLOR 1 COLOR 2 COLOR 3 COLOR 4 COLOR 5 COLOR 6 COLOR 7 COLOR 8 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 12 34 5 COLOR CHANGE MODULE 7 (COLORS 33 THRU 40) J8 J9 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC J16 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC 6 5 4 3 2 1 COM +12VDC
Optional Cables and Modules 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 29. M12 CAN Cables, for Hazardous Locations NOTE: The total length of cable used in the hazardous location must not exceed 120 ft (36 m). Cable Part No. Length ft (m) 16V423 2.0 (0.6) 16V424 3.0 (1.0) 16V425 6.0 (2.0) 16V426 10.0 (3.0) 16V427 15.0 (5.0) 16V428 25.0 (8.0) 16V429 50.0 (16.0) 16V430 100.0 (32.
Dimensions Dimensions Figure 24 Figure 23 Figure 25 B A 58.20 in. (1478 mm) 36 with ADM without ADM 14.5 in. (368 mm) 11.12 in. (282 mm) C D E F G H J 22.0 in. (559 mm) 19.26 in. (489 mm) 2.0 in. (51 mm) 18.0 in. (457 mm) 17.26 in. (438 mm) 0.52 in.
Technical Data Technical Data Positive Displacement Proportioner U.S. Metric AC1000 Air Spray Systems 300 psi 2.1 MPa, 21 bar AC2000 Air-Assisted Spray Systems 1500 psi 10.5 MPa, 105 bar 100 psi 0.7 MPa, 7.0 bar 85–100 psi 0.6–0.7 MPa, 6.0–7.
Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. 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.
