Repair-Parts ProMix® PD2K Proportioner for Automatic Spray Applications 332709B Electronic positive displacement proportioner for fast-setting two-component materials. System for automatic dispense, with Advanced Display Modules. For professional use only. Important Safety Instructions Read all warnings and instructions in this manual and in your installation, operation, and associated component manuals. Save these instructions. See page 3 for model part numbers and approvals information.
Contents Models............................................................... 3 Optional Cables and Modules ....................... 33 Related Manuals ................................................ 5 Repair................................................................ 34 Before Servicing .......................................... 34 Pressure Relief Procedure............................ 35 Repairing the Advanced Display Module (ADM) ............................................
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 332709B
Related Manuals Related Manuals Current manuals are available at www.graco.com. Manual No. Description Manual No.
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.
Troubleshooting Troubleshooting NOTE: Check all possible remedies before disassembling the system. System Troubleshooting Problem Cause Solution Unit will not operate. Inadequate power supply. See Technical Data, page 61. Power switch is off. Turn switch on. Main power is shut off. Turn main power switch on. Exhausted fluid supply. Refill and reprime pump. Clogged fluid outlet line, valves, etc. Clear. Fluid dried on piston rod. Disassemble and clean pump. See pump manual.
Troubleshooting Error Code Troubleshooting System errors alert you of a problem and help prevent off-ratio spraying. There are three types: Advisory, Deviation, and Alarm. An Advisory records an event in the system, and will clear itself after 60 seconds. A Deviation records an error in the system but does not shut down the equipment. The deviation must be acknowledged by the user. NOTE: When an error occurs be sure to determine the code before resetting it.
Troubleshooting Code Type Description Problem Cause Solution B9S0 Advisory Volume Rollover Solvent Current Batch counter for solvent rolled over. The totalizer has reached maximum capable value and started over at zero. n/a B9SX Advisory Volume Rollover Solvent Lifetime Grand total counter for solvent rolled over. The totalizer has reached maximum capable value and started over at zero. n/a CAC# Alarm Comm. Error Color Change # System does not detect the Color Change Module #.
Troubleshooting Code Type Description Problem Cause Solution CDDX Alarm Duplicate Fluid Module System sees two or more identical Enhanced Fluid Control Modules EFCM). More than one EFCM is connected in the system. Check the system and remove the extra EFCM. DA0# Alarm Exceeded Max Flow Pump # Pump was driven to its maximum allowed speed. System has a leak or open valve that is allowing unrestricted flow. Inspect system for leaks. Pump is cavitating, cycling without restriction.
Troubleshooting Code Type Description Problem Cause Solution DG0# Alarm No Stall Down Pump # Pump failed the stall test; did not stall on the downstroke. Valve failure, seal failure, worn rod or cylinder. Replace inlet and outlet valve and seal for down stroke. Replace piston and throat seals. Replace rod and cylinder as necessary. DH0# Alarm No Stall Pump # Pump failed the stall test; did not stall on either the upstroke or the downstroke. Valve failure, seal failure, worn rod or cylinder.
Troubleshooting Code Type Description Problem Cause Solution EF0# Alarm Timeout Startup Pump # Pump tried but was not able to move to the home position within a specified amount of time. Pump dose valves did not actuate. Verify air pressure to solenoid valves. Verify the valves are actuating. Motor could not drive pumps and linear actuator. Verify motor is driving the pump. Pump stroke length is shortened by mechanical system tolerance.
Troubleshooting Code Type Description Problem Cause Solution EQU2 Record USB Sys. Settings Uploaded Settings were uploaded from USB drive. User installed USB device in ADM USB port. n/a EQU3 Record USB Custom Lang. Downloaded Custom Language was downloaded to USB drive. User installed USB device in ADM USB port. n/a EQU4 Record USB Custom Lang. Uploaded Custom Language was uploaded from USB drive. User installed USB device in ADM USB port.
Troubleshooting Code Type Description Problem Cause Solution F7D# Alarm Flow Detected Pump # The pump flow exceeded 20 cc/min flow coming into Idle mode. There is a leak in the system or the gun was open when the system went into Idle mode. Verify there are no leaks in the system. Make sure the air flow switch is actuating properly. Do not trigger the gun without atomizing air. F7S1 Alarm Flow Detected Solvent Gun One of the solvent flow switches is indicating unexpected solvent flow.
Troubleshooting Code Type Description Problem P3F# Deviation Pressure High Inlet Pump # The inlet pressure on pump # is greater than the user-entered deviation limit. Decrease inlet pressure. P4D# Alarm Pressure High Outlet Pump # The outlet pressure on pump # is greater than the user entered alarm limit. Relieve system pressure. P4F# Alarm Pressure High Inlet Pump # The inlet pressure on pump # is greater than the user-entered alarm limit. Decrease inlet pressure. P6D# Alarm Press.
Troubleshooting Code Type Description Problem Cause Solution QPD1 Deviation Potlife Expired Potlife time has expired before the system has moved the required amount of material (potlife volume) through the mixed material line. Purge process was not completed. Make sure purge process is completed. Solvent supply shut off or empty. Verify solvent supply is available and on, supply valves are open. The system timed out before the mix fill cycle loaded the gun with mixed material.
Troubleshooting Maintenance Error Codes Perform the required maintenance if the following codes occur. Code Type Name Description END# Record Calibration Pump # A calibration test was run on the pump. ENS0 Record Calibration Solvent Meter A calibration test was run on the solvent meter. ENT# Record Calibration Stall Test Pump # A stall test was completed successfully on pump #. MAD# Advisory Maint. Outlet Pump # Maintenance is due on pump. MAT# Advisory Maint.
Troubleshooting Power Barrier Board Diagnostics Figure 7 Power Barrier Board Table 1 . Power Barrier Board Diagnostics ID Component or Indicator Function D4 LED (green) IS Power D5 LED (green) Power F3 Fuse, 400 mA, 250 V F4 Fuse, 400 mA, 250 V If either F3 or F4 is blown, there is no power to the IS location. D4 is out.
Troubleshooting Isolation Board Diagnostics Figure 8 Isolation Board Table 2 .
Troubleshooting Enhanced Fluid Control Module (EFCM) Diagnostics Figure 9 Enhanced Fluid Control Module Table 3 .
Troubleshooting Pump Module Diagnostics Figure 10 Pump Module Table 4 .
Troubleshooting Advanced Display Module Diagnostics Figure 11 Advanced Display Module Table 5 .
Notes Notes 26 332709B
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 33 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
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 27. 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.
Repair Repair Before Servicing 1. Flush the system as explained in your PD2K Operation Manual if service time may exceed pot life time. Follow the Pressure Relief Procedure, page 35 before servicing fluid components. 2. Close the main air shutoff valve on the air supply line. 3. Shut off the power switch (P) at the electrical control box. • Servicing the electrical control box exposes you to high voltage. To avoid electric shock, turn off power at the main circuit breaker before opening the enclosure.
Repair Pressure Relief Procedure • Loosen the fitting completely. With Color Change Follow the Pressure Relief Procedure whenever you see this symbol. NOTE: The following procedure relieves all fluid and air pressure in the system. 1. Turn off the supply pumps. Open the drain valve on the supply line fluid filter to relieve pressure in the supply lines. Do this for each color. This equipment stays pressurized until pressure is manually relieved.
Repair Repairing the Advanced Display Module (ADM) Replace the ADM To replace the Advanced Display Module, disconnect the cable from the module and remove the module from the bracket. Install the new module on the bracket and attach the cable. 3. Remove blue key token. 4. Insert and press black upgrade token (T) firmly into slot. NOTE: There is no preferred orientation of the token. Figure 21 Insert Token 5. Turn the power switch back on.
Repair Replace the Battery A lithium battery maintains the ADM clock when the power is not connected. Sparking can occur when changing the battery. Replace the battery only in a non-hazardous location, away from flammable fluid or fumes. 1. Turn off the PD2K power switch. 2. Remove the rear access panel. Figure 22 Remove Battery Panel 3. Remove the old battery and replace with a new CR2032 battery. 4. Replace the rear access panel. 5. Turn the power switch on. 6.
Repair Servicing the Control Box Replacing the Isolation Board 4. Remove the screws (128) holding the isolation board (111) to the barrier cover (107). Remove the isolation board. 5. Install the new isolation board, using the screws (128). NOTICE 6. Install the brackets (110). Reconnect the cables to the positions as noted above. To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately. 7.
Repair Figure 24 Detail of Isolation Board Cable Connections 332709B 39
Repair Replacing the Barrier Board NOTICE To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately. To avoid electrical component damage, remove all system power before plugging any connectors. 1. Follow the steps in Before Servicing, page 34. 2. Loosen the screws (124) and remove the enclosure cover (117). 3.
Repair Replacing the Barrier Board Fuses NOTICE To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately. To avoid electrical component damage, remove all system power before plugging any connectors. 1. Follow steps 1–4 under Replacing the Barrier Board, page 40. 2. Remove the fuse (F3 or F4) from its fuseholder. 3. Snap the new fuse (Graco PN 15D979) into the fuseholder. 4.
Repair Replacing the 24 Vdc Power Supply 7. Reinstall the cover (117) and tighten the screws (124). 8. Turn on power at the main circuit breaker. NOTICE To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately. 9. Turn on the control box power switch.
Repair Replacing the 48 Vdc Pump Power Supply 7. Reinstall the cover (117) and tighten the screws (124). 8. Turn on power at the main circuit breaker. NOTICE To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately. 9. Turn on the control box power switch. Press to turn pump power on. NOTE: The 48V green LED on each of the pump control modules (132) will light when operating.
Repair Replacing a Pump Control Module 7. Turn on power at the main circuit breaker. 8. Turn on the control box power switch. Check that the 48V green LED and the 24V green LED on each of the pump control modules (132) are on. NOTICE To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately. NOTE: If the pumps do not work, recheck the wiring. 9. Reinstall the cover (117) and tighten the screws (124).
Repair Replacing a Communication Gateway Module 6. Turn on the control box power switch. Check that the three status indicator lights are green. 7. Reinstall the cover (117) and tighten the screws (124). NOTICE To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately. To avoid electrical component damage, remove all system power before plugging any connectors. 1. Follow the steps in Before Servicing, page 34. 2.
Repair Replacing the Line Filter NOTICE To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately. To avoid electrical component damage, remove all system power before plugging any connectors. 1. Follow the steps in Before Servicing, page 34. 2. Loosen the screws (124) and remove the enclosure cover (117). Figure 31 Replacing the Line Filter 3. Note the position of the line filter input and output wires.
Repair Replacing the Power Switch NOTICE Failure to follow the electrical schematic could result in damage to the electrical components. NOTICE To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately. 7. Reinstall the cover (117) and tighten the screws (124). 8. Turn on power at the main circuit breaker. To avoid electrical component damage, remove all system power before plugging any connectors. 1.
Repair Servicing the Fluid Section Removing a Pump 7. Loosen the jam nuts holding the pump to the mounting bracket (4). Remove the pump. 8. See manual 332339 to repair the pump. Installing a Pump 1. Slide the pump into the mounting bracket (4). Tighten the jam nuts to secure. 2. Install the pump bracket (7) and screws (15). 1. Follow the steps in Before Servicing, page 34. 3. Connect the fluid inlet and outlet lines to the pump manifolds (IN, OUT). 2.
Repair Replacing a Solenoid NOTICE To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately. To avoid electrical component damage, remove all system power before plugging any connectors. 1. Follow the steps in Before Servicing, page 34. 2. Remove the screws (56) holding the cover (8) to the front of the unit. 3. Loosen the screws (124) and remove the enclosure cover (117). 4.
Repair Replacing a Fan NOTICE To avoid damaging the circuit boards when servicing the control box, wear Part No. 112190 grounding strap on your wrist and ground appropriately. To avoid electrical component damage, remove all system power before plugging any connectors. 1. Follow the steps in Before Servicing, page 34. 2. Remove the screws (56) holding the cover (8) to the front of the unit. 3. Loosen the screws (124) and remove the enclosure cover (117). 4.
Repair Figure 35 Replacing a Fan 332709B 51
Repair Replacing a Solvent Flow Switch 1. Follow the steps in Before Servicing, page 34. 2. Remove the screws (56) holding the cover (8) to the front of the unit. 3. Disconnect the solvent flow switch wires from J6 pins 11–12 (Switch 1) or J7 pins 9–10 (Switch 2) on the EFCM. See Electrical Schematics, page 27. 4. Disconnect the solvent lines. 5. Unscrew the adapter (45) from the solvent flow switch (19). 6. Unscrew the solvent flow switch from the elbow (18). 7. Remove the solvent flow switch (159). 8.
Notes Notes 332709B 53
Parts Parts Proportioner Parts Part No. AC1000 Low Pressure Proportioner Part No.
Parts Part No. AC1000 Low Pressure Proportioner Part No.
Parts Part Description Qty GROUND WIRE 1 56 223547 ——— 2 69 ——— SCREW, cap, socket head; 1/4–20 x 3/4 in. (19 mm) GROMMET, cable 70 16V429 1 73 24T302 73a ——— CABLE, CAN, intrinsically safe, 5 pin; for booth control; fbe; 50 ft (15 m) KIT, cup, TSL; includes items 73a-73e BRACKET 73b 24U617 73c ——— 73d ——— 73e ——— 74 166421 Description Qty 30 Part ——— WASHER; 3/8 40 Ref 55 31 ——— 4 32 ——— SCREW, cap, hex head; 3/8–16 x 2.75 in.
Parts Control Box Parts Electrical Control Box 332709B 57
Parts Electrical Control Box (continued) 110 Part ——— BRACKET, board 2 111 24M485 BOARD, isolation, IS 1 1 112 16U725 1 3 113 ——— SWITCH, selector, 2 position DUCT, wire SPACER, standoff 3 114 ——— COVER, duct 2 BOARD, barrier; includes item 106a FUSE; 400 mA, quick acting COVER, barrier 1 115 FILTER , line; 10A 1 116 16V446 ——— BLOCK, terminal 1 117 ——— COVER, enclosure 1 1 118 ——— GROMMET 2 SCREW, machine, pan head; 6–32 x 1.5 in.
Parts Description Qty Ref Part Description Qty CONNECTOR, bar, ground SCREW, ground; M5 x 0.8 NUT, hex, flange head; 1/4–20 SCREW, flanged, hex head; 1/4–20 x 0.75 in. (19 mm) SCREW, machine, pan head; 10–24 x 0.375 in. (10 mm) SCREW, machine, pan head; 10–32 x 0.75 in. (19 mm) FITTING, connector; 1/8 npt(m) x 1/4 in. (6 mm) OD tube SCREW, machine, pan head; 8–32 x 0.25 in. (6 mm) SCREW, machine, binding head; 6–32 x 0.25 in. (6 mm) CABLE, CAN; fbe; 3.
Parts Solenoid Manifold Parts Part No. 24T772 Solenoid Manifold Description Qty 301 Part ——— PLATE 1 302 ——— MANIFOLD 1 303 ——— 4 304 115671 305 16P812 SCREW, cap, socket head; 1/4–20 x 0.375 in. (10 mm) CONNECTOR; 1/8 npt(m) x 1/4 in. (6 mm) OD tube VALVE, solenoid 307 114151 308 114263 309 C06061 Ref FITTING, elbow, swivel; 1/8 npt(m) x 5/32 in. (4 mm) OD tube FITTING, straight; 1/8 npt(m) x 5/32 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.
