Graco 332455F User Manual

Instructions-Parts

Color Change K

To add optional color change function to ProMix® PD2K Electronic Proportioners. Kits include low or high pressure color/catalyst change valves and a Non-IS or IS control module. For professional use only.

Important Safety Instructions Read all warnings and instructions in this manual and in your PD2K proportioner manual. Save these instructions.

See page 4 numbers a informat

for model part

nd approvals

ion.

its

332455F

PROVEN QUALITY. LEADING TECHNOLOGY.

Related Manuals ................................................ 3

Models............................................................... 4

Non-Intrinsically Safe Kits............................. 4

Intrinsically Safe Kits.................................... 6

Warnings ........................................................... 7

Important Isocyanate (ISO) Information................ 10

Isocyanate Conditions.................................. 10

Material Self-ignition..................................... 10

Keep Components A and B Separate............ 10

Moisture Sensitivity of Isocyanates................ 10

Changing Materials ...................................... 11

Setup the Modules.............................................. 12

Setup Non-IS Control Modules...................... 12

Setup IS Control Modules............................. 15

Installa

tion..........................................................17

Mounting

Air Suppl Groundi Non-Haz Hazardo Install Install

Connec

the Color Change Control

Module........................................... 17

y.................................................... 17

ng ................................................... 17

ardous Location.............................. 18

us Location ..................................... 20

the Valve Manifolds ............................ 21

the Back Pressure Regulator (High

Pressu

t the Valve Air Lines.......................... 23

re Systems Only)..................23

Connect the Fluid Lines................................ 24

Install an Expansion Kit ................................ 28

Troubleshooting.................................................. 30

Color Change Solenoid Valves ..................... 30

Color Change Board .................................... 32

Electrical S

Repair................................................................ 41

Parts.................................................................. 44

Dimensi

Weights ............................................................. 69

Technical Data ...................................................73

Graco S

chematics.......................................... 34

Optional Ca

Replace a Color Valve.................................. 41

Replace a Solenoid...................................... 42

Replace the ColorChangeBoard Fuse........... 42

Replace the Color Change Board.................. 43

Non-IS Color Change Kits ............................ 45

IS Color Change Kits.................................... 47

Valve Manifolds ........................................... 49

Color Change Control Module Kits ................ 60

Expansion Kits............................................. 64

ons ........................................................ 66

tandard Warranty.................................... 74

bles and Modules....................... 40

332455F

Related Manuals

Manual No. Description

3A2800 PD2K Proporti

Manual, Manua

332457 PD2K Proportioner Installation

Manual, Manual Systems

332562

3A2801

PD2K Propor Manual, Man

Mix Manifold Instructions-Parts Manual

oner Repair-Parts

lSystems

tioner Operation

ual Systems

Manual No. Description

332339 Pump Repair-P

332454

332456 3rd and 4th P

Color Change Valve Repair-Parts Manual

Instructio

ns-Parts Manual

arts Manual

ump Kits

332455F 3

Models

Non-Intrinsically Safe Kits

See the modul information

Figure 1 Non-Intrinsically Safe Color Change Control Module Label

Kit No.

24R915 A 2 color or 2 catalyst

24R916 A 4 color

e identiﬁcation label for product part number, maximum air working pressure, and approval

and certiﬁcation.

Series

Kit Description Maximum Air Working Pressure

(Control Module)

Low Pres

or 4 catalyst

sure Non-Circulating Color Change Kits

100 psi (0.7 MPa, 7.0 bar) 300 psi (2.068 MPa, 20.68 bar)

Maximum Fluid Working Pressure (Valves)

24R917 A 6 color

24R918 A 8 color

24R919 A 2 color

24R920 A 4 color

921

24R

24R922 A 8 color

A6co

lor

100 psi

100 psi (0.7 MPa, 7.0 bar) 300 psi (2.068 MPa, 20.68 bar)

Low Pressure Circulating Color Change Kits

100 p

100 psi (0.7 MPa, 7.0 bar) 300 psi (2.068 MPa, 20.68 bar)

(0.7 MPa, 7.0 bar)

si (0.7 MPa, 7.0 bar)

0psi(0.7MPa,7.0bar)

300 psi

300 p

(2.068 MPa, 20.68 bar)

si (2.068 MPa, 20.68 bar)

0 psi (2.068 MPa, 20.68 bar)

332455F

Models

Kit No.

24R959 A 2 color or 2 cat

24R960 A 4 color or 4 catalyst

24R961 A 6 color

24R962 A 8 color

24T579 A

24T580 A

24R963 A 2 color

24R96

24R965 A 6 color

24R966 A 8 color

Series

Kit Descriptio

High Press

2 catalyst (acid compatible)

4 catalyst (acid compatible)

A4colo

High Pressure Non-Circulating Color Change Kits

alyst

ure Acid Compatible Non-Circulating Catalyst Change Kits

High Pr

Maximum Air Wor (Control Modul

100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar)

100 psi (0.7 M

100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar)

essure Circulating Color Change Kits

100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar)

100 ps

100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar)

i(0.7MPa,7.0bar)

king Pressure

Pa, 7.0 bar)

Maximum Fluid W Pressure (Valv

1500 psi (10.

1500 p

si (10.34 MPa, 103.4 bar)

orking

es)

34 MPa, 103.4 bar)

332455F 5

Models

Intrinsicall

See the module identiﬁcation label for product part number, maximum air working pressure, and approval information and certiﬁcation.

Figure 2 Intrinsically Safe Color Change Control Module Label

Kit No.

ySafeKits

0359

Series

II 2 G

Kit Description Maximum Air Working Pressure

(Control Module)

Low Pressure Non-Circulating Color Change Kits

Maximum Fluid Working Pressure (Valves)

24T343 A 2 color or 2 catalyst

24T344 A 4 color or 4 catalyst

24T345 A 6 color

24T346 A 8 color

Low Pressure Circulating Color Change Kits

24T347 A 2 color

24T348 A 4 color

24T349 A 6 color

24T350 A 8 color

High Pressure Non-Circulating Color Change Kits

24T351 A 2 color or 2 catalyst

24T352 A 4 color or 4 catalyst

24T353 A 6 color

24T354 A 8 color

High Pressure Circulating Color Change Kits

24T355 A 2 color

24T356 A 4 color

100 psi (0.7 MPa, 7.0 bar) 300 psi (2.068 MPa, 20.68 bar)

100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar)

24T357 A 6 color

24T358 A 8 color

100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar)

6 332455F

Warnings

The following exclamation p risks. When th Warnings. Pr the body of th

warnings are for the setup, use, grounding, maintenance and repair of this equipment. The oint symbol alerts you to a general warning and the hazard symbol refers to procedure-speciﬁc

ese symbols appear in the body of this manual or on warning labels, refer backtothese

oduct-speciﬁc hazard symbols and warnings not covered in this section may appear throughout

is manual where applicable.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable prevent ﬁr

• Use equipment only in well ventilated area.

• Eliminat plastic d

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when ﬂammable fumes are present.

•Grounda

• Use only grounded hoses.

• Hold gun ﬁrmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are antistatic or conductive.

• Stop op equipm

• Keep a working ﬁre extinguisher in the work area.

fumes, such as solvent and paint fumes, in work area can ignite or explode. To help

e and explosion:

e all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and

rop cloths (potential static arc).

ll equipment in the work area. See Grounding instructions.

eration immediately if static sparking occurs or you feel a shock, Do not use

ent until you identify and correct the problem.

332455F

ELECTRIC SHOCK HAZARD This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing or installing equipment.

• Connect only to grounded power source.

lectrical wiring must be done by a qualiﬁed electrician and comply with all local codes

•Alle

egulations.

and r

Warnings

WARNING

INTRINSIC 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.

• Besureyouri electrical a and 2 (Europ NFPA 33, NEC

• To help prevent ﬁre and explosion:

• Do not install equipment approved only for a non-hazardous location in a hazardous location. See model ID label for the intrinsic safety rating of your model.

• Do not subs

• Equipment that comes in contact with the intrinsically safe terminals must be rated for Intrinsic Safety. This includes DC voltage meters, ohmmeters, cables, and connections. Remove the unit from the hazardous area when troubleshooting.

SKIN INJECTION HAZARD

High-pressure ﬂuid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

•Donotsp

• Engage trigger lock when not spraying.

• Do not point gun at anyone or at any part of the body.

•Donotp

• Do not stop or deﬂect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop spraying/dispensing and before cleaning, checking, or servicing equipment.

•Tight

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

en all ﬂuid connections before operating the equipment.

nstallation complies with national, state, and local codes for the installation of

pparatus in a Class I, Group D, Division 1 (North America) or Class I, Zones 1

e) Hazardous Location, including all of the local safety ﬁre codes (for example,

500 and 516, OSHA 1910.107, etc.).

titute system components as this may impair intrinsic safety.

ray without tip guard and trigger guard installed.

ut your hand over the spray tip.

MOVING PARTS HAZARD Moving parts can pinch, cut or amputate ﬁngers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

ssurized equipment can start without warning. Before checking, moving, or servicing

•Pre

ipment, follow the Pressure Relief Procedure and disconnect all power sources.

equ

ICFLUIDORFUMES

TOX

ic ﬂuids or fumes can cause serious injury or death if splashed in the eyes or on skin,

Tox

aled, or swallowed.

inh

• Read MSDSs to know the speciﬁc hazards of the ﬂuids you are using.

ore hazardous ﬂuid in approved containers, and dispose of it according to applicable

•St

idelines.

• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment.

8 332455F

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 M Misuse can

• Do not operate the unit when fatigued or under the inﬂuence of drugs or alcohol.

• Do not exce system com

• Use ﬂuids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read ﬂuid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

•Turnoffa

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modiﬁcations may void agency approvals and create safety hazards.

•Makesu

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from trafﬁc areas, sharp edges, moving parts, and hot surfaces.

•Donotk

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

ISUSE HAZARD

cause death or serious injury.

ed the maximum working pressure or temperature rating of the lowest rated ponent. See Technical Data in all equipment manuals.

ll equipment and follow the Pressure Relief Procedure when equipment is not in use.

re all equipment is rated and approved for the environment in which you are using it.

ink or over bend hoses or use hoses to pull equipment.

332455F 9

Important Isocy

anate (ISO) Information

Important Iso

Isocyanates (ISO) are catalysts used in two component materials.

cyanate (ISO) Information

Isocyanate Conditions

Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates.

Read material manufacturer’s warnings and material MSDS to know speciﬁc hazards and precautions related to isocyanates.

Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufﬁcient ventilation in the work area. If sufﬁcient ventilation is not available, a supplied-air respirator is required foreveryoneintheworkarea.

To prevent contact with isocyanates, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area.

Keep Components A and B Separate

Cross-contamination can result in cured material in ﬂuid lines which could cause serious injury or damage equipment. To prevent cross-contamination:

• Never interchange component A and component Bwettedparts.

• Never use solvent on one side if it has been contaminated from the other side.

Moisture Sensitivity of Isocyanates

Exposure to moisture (such as humidity) will cause ISO to partially cure; forming small, hard, abrasive crystals, which become suspended in the ﬂuid. 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.

• Always use a sealed container with a desiccant

Material Self-ignition

Some materials may become self-igniting if applied too thick. Read material manufacturer’s warnings and material MSDS.

10 332455F

dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.

• Keep the ISO pump wet cup or reservoir (if installed) ﬁlled with appropriate lubricant. The lubricant creates a barrier between the ISO and the atmosphere.

• Use only moisture-proof hoses compatible with ISO.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Always lubricate threaded parts with an appropriate lubricant when reassembling.

NOTE: The amount of ﬁlm formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.

Important Isocy

anate (ISO) Information

Changing Mate

rials

NOTICE

Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime.

• When changi multiple ti

• Always clea ﬂushing.

• Check with chemical c

• When chang or polyur componen have amin often hav

ng materials, ﬂush the equipment

mes to ensure it is thoroughly clean.

n the ﬂuid inlet strainers after

your material manufacturer for

ompatibility.

ing between epoxies and urethanes

eas, disassemble and clean all ﬂuid

ts and change hoses. Epoxies often es on the B (hardener) side. Polyureas

eaminesontheA(resin)side.

332455F

Setup the Module

Setup the Modu

Setup Non-IS C

NOTE: The PD2K System can use up to four pumps and six color change modules in the non-hazardous area. Use the following table to understand how many color change modules are needed for the number of pumps in your system, and which module should be associated to which pump.

Table 1 . Relationship of Non-IS Color Change Control Modules to Pumps

System Pump Conﬁguration Color Change Control Modules, Colors, and Catalysts

Color

Pump(s)

1 0 1 Not Applicable

112

213

Catalyst Pump(s)

ontrol Modules

Total

Pumps

les

Module 1

(Colors

1–8)

Module 2

(Colors

9–16)

All Non-IS modules ship from the factory as Module 1 (Colors 1–8). Labels for Modules 2 through 6 areprovidedwiththemodulekit. Afﬁxthelabels according to your system conﬁguration.

Module

3(Colors

17–24)

Pump # 1 Pump # 1

Module 4

(Colors

25–30)

Catalyst

1–2

Module # 5

Pump # 2

Module

Pump # 2

Catalyst

3–4

2 0 2 Not Applicable

Pump # 1

224

314

303

404

Pump # 1

Pump#3

Pump # 2

Pump # 3

Pump # 4

Module

Pump # 2

Module # 5

Pump # 2

Not Applicable

Module

Pump # 4

332455F

Setup the Module

Conﬁgure each module according to its designated number, as follows:

NOTICE

To avoid damaging the circuit boards, wear Part No. 112190 grounding strap on your wrist and ground appropriately.

To avoid elec system power

1. Remove elec

2. Open the col S4, S5, and S switches a

3. For each module, set the switches to ON or OFF, as shown in the following table.

trical component damage, remove all

before plugging any connectors.

trical power from the system.

or change module. Locate switches

6 on the control module board. The

re shipped in the OFF position.

Non-IS Control Module Switch Settings

Control

S6 S5 S4

Module

Module 1

Module 2

Module 3

Module 4

Module 5

Module 6

OFF

4. Use the following ﬁgure and tables to determine the solenoid valve assigned to each valve in the valve manifold.

NOTE: There can be only one solvent valve and one dump valve per pump.

Inlet Manifold Outlet Manifold

Figure 3 Non-IS Control Module

332455F 13

Setup the Module

Non-IS Control Module 1

Inlet Manifol

Solenoid

Inlet Manifold Outlet Manifold

Solenoid

Valve

Solvent

Color 1

Color 2

Color 3

Color 4

Color 5

Color 6

Color 7

Color 8

Non-IS Control Module 2

Valve

(Solvent)*

Color 9

Color 10

Color 11

Color 12

Color 13

Color 14

Color 15

Outlet Manifo

Solenoid

1Dump

Solenoid

Valve

Color 1

Color 2

Color 3

Color 4

Color 5

Color 6

Color 7

Color 8

Valve

(Dump)*

Color 9

Color 10

Color 11

Color 12

Color 13

Color 14

Color 15

Non-IS Control Module 4

Inlet Manifol

Solenoid

8 Not Used 8 Not Used

9NotUse

Inlet Manifold Outlet Manifold

Solenoid

6 Not Used 6 Not Used

8 Not Used 8 Not Used

Valve

(Solvent)*

Color 25

Color 26

Color 27

Color 28

Color 29

Color 30

Non-IS Control Module 5

Valve

(Solvent)*

Catalyst 1

Catalyst 2

Catalyst 3

Catalyst 4

Not Used

Outlet Manifo

Solenoid

9NotUse

Solenoid

Valve

(Dump)*

Color 25

Color 26

Color 27

Color 28

Color 29

Color 30

Valve

(Dump)*

Catalyst 1

Catalyst 2

Catalyst 3

Catalyst 4

Not Used

Inlet Manifold Outlet Manifold

Solenoid

* There should be only one solvent valve and one dump valve per pump.

Color 16

Non-IS Control Module 3

Valve

(Solvent)*

Color 17

Color 18

Color 19

Color 20

Color 21

Color 22

Color 23

Color 24

Solenoid

Color 16

Valve

(Dump)*

Color 17

Color 18

Color 19

Color 20

Color 21

Color 22

Color 23

Color 24

9 Not Used 9 Not Used

Non-IS Control Module 6

Inlet Manifold Outlet Manifold

Solenoid

4 Not Used 4 Not Used

6 Not Used 6 Not Used

8 Not Used 8 Not Used

9 Not Used 9 Not Used

Valve

(Solvent)*

Catalyst 3

Catalyst 4

Not Used

Solenoid

Valve

(Dump)*

Catalyst 3

Catalyst 4

Not Used

332455F

Setup the Module

Setup IS Contr

ol Modules

NOTE: Two color change control modules may be installed in the hazardous area. The modules are labeled 7 or 8. An alternate label is provided with the module kit for Module 8 (Colors 13–30). Afﬁx the label according to your system conﬁguration.

Conﬁgure eac number, as f

h module according to its designated

ollows:

NOTICE

To avoid dam No. 112190 ground app

To avoid electrical component damage, remove all system power before plugging any connectors.

1. Remove electrical power from the system.

2. Open the color change module. Locate switches S4, S5, and S6 on the control module board. The switches may be shipped in the OFF position.

aging the circuit boards, wear Part

grounding strap on your wrist and

ropriately.

3. For each module, set the switches to ON or OFF, as shown in the following table.

IS Control Mod

Control

ule Switch Settings

S6 S5 S4

Module

Module 7

Module 8

OFF

4. Use the following ﬁgure and tables to determine the solenoid valve assigned to each valve in the valve manifold.

Figure 4 IS Control Module

332455F 15

Setup the Module

Solenoid

IS Control Module 7

Valve

Color Solvent

Color 1

Color 2

Color 3

Color 4

Color 5

Color 6

Color 7

Color 8

Solenoid

Valve

Catalyst Solvent

Catalyst 1

Catalyst 2

Catalyst 3

Catalyst 4

Color 9

Color 10

Color 11

Color 1

Inlet Manifol

Solenoid

IS Control Module 8

Valve

Color 13

Color 14

Color 15

Color 16

Color 17

Color 18

Color 19

Color 2

Color 21

Solenoid

Outlet Manifo

Valve

Color 22

Color 23

Color 24

Color 25

Color 26

Color 27

Color 28

Color 2

Color 30

16 332455F

Installation

• To avoid electric shock, turn off power at the main circuit breaker before opening the enclosure.

Installation

3. Using the equipment as a template, mark the mounting holes on the wall at a convenient height for the operator and so the equipment is easily accessible for maintenance.

4. Drill mounting holes in the wall. Install anchors as needed.

• All electrical wiring must be done by a qualiﬁed electrician and comply with all local codes and regulations.

• Do not substitute or modify system components as this may impair intrinsic safety.

• 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.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized ﬂuid, such as skin injection, splashing ﬂuid and moving parts, follow the Pressure Relief Procedure in the PD2K Operation Manual before installing the kit.

Mounting the Color Change Control Module

1. See Dimensions, page 66.

2. Ensure that the wall and mounting hardware are strong enough to support the weight of the equipment, ﬂuid, hoses, and stress cause during operation.

5. Bolt the equipment securely.

Air Supply

Connect a clean and dry air supply to the color change control module air inlet ﬁtting (317); the ﬁtting is for 1/4 in. (6 mm) OD tubing. Use a 5 micron ﬁlter. Regulate the air pressure to 85–100 psi (0.6–0.7 MPa, 6.0–7.0 bar).

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.

Connect a ground wire from the color change module to a true earth ground.

Intrinsically safe color change modules located in the hazardous area must be connected to a true earth ground in the hazardous area.

332455F

Installation

Non-Hazardous Location

NOTE: Non-IS c control for th change valves in the system, be installed

1. Mount the ﬁrst non-IS color control module as described in Mounting the Color Change Control

Module, page 17.

2. Connect the 5–pin CAN cable (109) to J7 on the color control module (108).

Figure 5 Cable Connector J7 at Non-IS Color Control Module

olor change control modules provide

e pump’s inlet and outlet color/catalyst

. Depending on the number of valves

as many as six control modules may

in the non-hazardous location.

NOTICE

To avoid damaging the circuit boards, wear Part No. 112190 grounding strap on your wrist and ground appropriately.

of the previou next control m

8. Replace the co box before tur

Figure 6 Cable Connection at PD2K Electrical Control Box

s color control module to J7 of the

odule.

ver of the PD2K electrical control

ning on power to the system.

To avoi remove conne

3. Remove electrical power from the system.

4. Remove the cover from the PD2K electrical control box.

5. Install the supplied 2–cable grommet (110) on the cable (109) and secure the grommet to the side of the electrical control box.

6. Connect the cable (109) to J2 on the non-IS side of the isolation board inside the electrical control box. See Electrical Schematics, page 34 for a list of M12 CAN cables for use in a non-hazardous area.

7. To install additional color control modules (six maximum), mount the module(s) as described in Mounting the Color Change Control Module,

page 17. Connect a 5–pin CAN cable from J11

d electrical component damage,

all system power before plugging any

ctors.

Figure 7 Detail of Isolation Board Cable Connections

18 332455F

Notes

Installation

332455F 19

Installation

Hazardous Location

NOTE: IS color control for co hazardous loc modules may be See IS Color C alistofmodu hazardous lo

change control modules provide

lor/catalyst change valves located in the

ation. A maximum of two IS control

installed in the hazardous location.

hange Control Modules, page 62 for

les approved for installation in a

cation.

NOTICE

To avoid dam No. 112190 g ground appr

To avoid electrical component damage, remove all system power before plugging any connectors.

Only approved cables may be used in the hazardous location. Hazardous location cables are marked with a light blue ﬂag next to each connector. See Optional Cables and Modules, page 40 for a list of M12 CAN cables for use in a hazardous area.

1. Remove electrical power from the system.

2. Mount the ﬁrst color control module as described in Mounting the Color Change Control Module,

page 17.

aging the circuit boards, wear Part

rounding strap on your wrist and

opriately.

3. Connect the ha on the color co

Figure 9 Cable Connectors J7 and J11 at IS Color Control Module

4. Remove the cover from the PD2K electrical control box. Install the grommet (G) on the supplied cable (C1) and secure the grommet to the side of the electrical control box. Locate J4ontheISsideoftheisolationboardinthe electrical control box. Connect the cable (C1) to J4. See Electrical Schematics, page 34.

zardous location cable (C1) to J7

ntrol module (108).

Figure 10 Detail of Isolation Board Cable Connections

Figure 8 Intrinsically Safe Cable Connections

20 332455F

Installation

5. Mount a second color control module as described in Mounting the Color Change

Control Module, page 17. Connect the supplied

hazardous location cable (C2) from J11 on the ﬁrst color control module to J7 on the second module.

6. Replace the cover of the PD2K electrical control box before turning on power to the system.

Install the

NOTE: Always label the color connections to prevent cross-connections. Label the inlet manifold, outlet manifold, and each color valve with its assigned color. The solvent and dump valves should be furthest from the manifold stack primary inlet or outlet.

1. Install a m with four For stabi (103) to t

Valve Manifolds

ounting bracket (101) on the PD2K

screws (103). High pressure systems:

lity, be sure to fasten the bottom screws

he pump bracket.

2. Install the inlet and outlet valve manifolds (102) on the mounting bracket (101) with four screws (104), washers (105), and nuts (106).

NOTE: On low pressure systems, the supplied bracket (101) will accommodate a manifold with 16 valve positions (14 colors). On high pressure systems, the supplied bracket (101) will accommodate a manifold with 14 valve positions (12 colors). A larger valve stack will require a customer supplied/sourced bracket.

3. Repeat for the opposite side of the PD2K.

4. Connect the air lines from the solenoids to the valves. See Connect the Valve Air Lines, page 23.

NOTE: On high pressure systems, see

Install the Back Pressure Regulator (High Pressure Systems Only), page 23.

5. Connect the ﬂuid supply lines to the valves. See

Connect the Fluid Lines, page 24.

332455F

Figure 11 Install the Valve Manifolds

Installation

Notes

332455F

Install the Back Pressure Regulator (High Pressure Systems Only)

NOTE: The back pressure regulator is required on high pressure systems to prevent the system’s feed pumps from overdriving the dosing pumps during color change pump ﬂush and color ﬁll operations. Adjust the back pressure during the dump process to be approximately 75% of the supply pressure from the feed pumps, but never more than 300 psi (2.1 MPa, 21 bar) less than the supply pressure.

Install the back pressure regulator (120) and attaching hardware at the dump valve of the outlet manifold stack.

1. Screw the t the outlet

ee (122) onto the dump valve ﬁtting of

manifold stack.

Installation

Figure 12 Install Back Pressure Regulator at Dump Valve of Outlet Stack

2. Assemble t pressure assembly

3. Install t tee (122)

4. Connect facing n

5. Connect

Connect

regulator (120). Screw the regulator

he gauge (123) in the open port of the

a 1/4 npt(f) dump line to the downward

ipple (121).

the ﬂuid supply lines to the valves. See

the Fluid Lines, page 24.

he two nipples (121) to the back

Connect the Valve Air Lines

into the tee (122) as shown.

1. Connect 5/32 in. (4 mm) OD air tubes from the inlet solenoids to the air inlets of each inlet valve, using the label inside the color control module as a guide. See Setup the Modules, page 12.

2. Repeat for the outlet valves.

332455F 23

+ 51 hidden pages

Graco 332455F User Manual

Contents

Related Manuals

Models

Non-Intrinsically Safe Kits

Warnings

Isocyanate Conditions

Keep Components A and B Separate

Moisture Sensitivity of Isocyanates

Material Self-ignition

Table 1 . Relationship of Non-IS Color Change Control Modules to Pumps

Installation

Mounting the Color Change Control Module

Air Supply

Grounding

Non-Hazardous Location

Notes

Hazardous Location

Notes

Install the Back Pressure Regulator (High Pressure Systems Only)

Connect the Valve Air Lines