Graco 332456B User Manual

Installation-Parts

Pump Expansion Kits

To add a third or fourth pump to a ProMix® PD2K Proportioner. Each kit includes one pump and
associated parts. PD2K is shown with two kits added. For professional use only.

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

See page 3 for model part numbers
and approvals information.

332456B

EN

PROVEN QUALITY. LEADING TECHNOLOGY.

Contents

Related Manuals ................................................ 2

Models............................................................... 3

Warnings ........................................................... 4

Important Isocyanate (ISO) Information................ 6

Isocyanate Conditions.................................. 6

Material Self-ignition..................................... 6

Keep Components A and B Separate............ 6

Moisture Sensitivity of Isocyanates................ 6

Changing Materials...................................... 7

Installation.......................................................... 8

Before Installing the Kit................................. 8

Install the Frame.......................................... 8

TSL Cup Kit................................................. 10

Related Manuals

Manual No. Description

3A2800 PD2K Proportioner Repair-Parts

Manual, Manual Systems

332457 PD2K Proportioner Installation

Manual

332562

PD2K Proportioner Operation
Manual, Manual Systems

Fluid Connections ........................................ 12

Electrical Connections.................................. 13

Grounding ................................................... 15

Complete the Installation.............................. 16

Repair................................................................ 18

Dose Valve Tubing Connections ................... 18

Replace Pump Control Module ..................... 20

Electrical Schematics.......................................... 21

Pump Expansion Kit Parts................................... 27

Technical Data ...................................................31

Graco Standard Warranty.................................... 32

Manual No. Description

332339 Pump Repair-Parts Manual

332454 Color Change Valve Repair-Parts

Manual

332455

Color Change Kits Instructions­Parts Manual

3A2801

Mix Manifold Instructions-Parts
Manual

2

332456B

Models

Models

KitPartNo.

24R968 A 70 cc Low Pressure Color Pump Kit 300 psi (2.068 MPa, 20.68 bar)

24R969 A

24R970 A

24R971 A

Figure 1 . Pump Expansion Kit Identification Label

Series

70 cc High Pressure Color

35 cc Low Pressure Color or

35 cc High Pressure Color or

Description Maximum Fluid Working Pressure

1500 psi (10.34 MPa, 103.4 bar)

Pump Kit

300 psi (2.068 MPa, 20.68 bar)

Catalyst Pump Kit

1500 psi (10.34 MPa, 103.4 bar)

Catalyst Pump Kit

332456B 3

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.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help
prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and
plastic drop cloths (potential static arc).

• 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.

• Ground all equipment in the work area. See Grounding instructions.

• 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 operation immediately if static sparking occurs or you feel a shock, Do not use
equipment until you identify and correct the problem.

• Keep a working fire extinguisher in the work area.

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.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

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

• Do not put your hand over the spray tip.

• 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.

• Tighten all fluid connections before operating the equipment.

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

4

332456B

Warnings

WARNING

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.

• Pressurized equipment can start without warning. Before checking, moving, or servicing
equipment, follow the Pressure Relief Procedure and disconnect all power sources.

TOXIC FLUID OR FUMES
Toxic fluids or fumes can cause serious injury or death if splashed in the eyesoronskin,
inhaled, or swallowed.

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

• Store hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.

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

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.

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

• Do not exceed the maximum working pressure or temperature rating of the lowest rated
system component. See Technical Data in all equipment manuals.

• 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.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• 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.

• Make sure all equipment is rated and approved for the environment in which youareusingit.

• 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.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

332456B 5

Important Isocy anate (ISO) Information

Important Isocyanate (ISO) Information

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

Isocyanat

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
for everyone in the work area.

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.

e Conditions

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
B wetted parts.

• 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

e materials may become self-igniting if applied

Som

thick. Read material manufacturer’s warnings

too

d material MSDS.

an

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.

6 332456B

Changing Materials

NOTICE

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

• When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.

• Always clean the fluid inlet strainers after
flushing.

• Check with your material manufacturer for
chemical compatibility.

• When changing between epoxies and urethanes
or polyureas, disassemble and clean all fluid
components and change hoses. Epoxies often
have amines on the B (hardener) side. Polyureas
often have amines on the A (resin) side.

Important Isocyanate (ISO) Information

332456B

7

Installation

Installation

Before Installing the Kit

• 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.

• 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.

Follow the Pressure Relief Procedure in
your PD2K manual whenever you see this
symbol.

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 your system manual
when you stop spraying and before cleaning,
checking, or servicing the equipment.

Install the Frame

1. Follow the steps in

Before Installing the Kit, page 8 .

2. Install the frame (13) to the upright of the PD2K
stand (A) using three screws (16) and nuts (18).

3. Install the back panel/bracket assembly (B) in the
outermost position on the frame (13), to allow
clearance for the color change manifold (C).
Fasten the panel to the frame (13) using four
screws (15) and nuts (18). Install the top screws
from the front and the bottom screws from the
back.

NOTE: The illustration shows a resin (70cc) pump
expansion kit being installed on the left (color) side
of the PD2K proportioner. The pump control module
and dual grommet (11) are preassembled at the
factory so the cable (8) is facing to the right, allowing
easier access to connections inside the PD2K
electrical control box (D).

Install a catalyst (35cc) pump expansion kit on the
right side of the proportioner, with the pump control
module and dual grommet (11) preassembled in the
opposite direction so the cable (8) is facing to the left.

1. Flush the system as explained in your PD2K
Operation Manual. Follow the Pressure Relief
Procedure in your PD2K manual.

2. Close the main air shutoff valve on the air supply
line.

3. Remove electrical power from the system.

8 332456B

Installation

Figure 2 Install the Frame and Pump

332456B 9

Installation

TSL Cup Kit

Throat Seal Liquid (TSL) lubricates the pump throat
packings and dosing valves. The TSL Cup Kit
supplies TSL to the upper and lower throat cartridges
of the pump, and to the four pump dosing valves.

NOTE: TSL must be ordered separately. Order Part
No. 206995, 1 quart (0.95 liter).

1. Slide the kit mounting bracket onto any side of
the pump’s hex nut.

2. Place the TSL cup (73) into the bracket (73a).

NOTE: The pump’s upper throat cartridge has
three ports (two are plugged). Install the barbed
fitting (73b) in the port closest to the TSL cup, by
moving a plug if necessary.

3. Check that the o-ring is in place on the barbed
fitting (73b). Apply low strength thread adhesive
and install the fitting in the upper throat cartridge
port.

NOTE: If you are not lubricating the dosing
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.

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.

7. Fill the cup with TSL.

4. Repeat for the lower throat cartridge.

5. If you are lubricating the dosing valves, remove
the plug and gasket from the valve port 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.

Figure 3 Install TSL Cup Kit

10 332456B