Graco 332457C User Manual
Installation
ProMix® PD2K Electronic
Proportioner
Electronic positive displacement proportioner for fast-setting two-component materials. Manual system
with Advanced Display Module. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual. Save these
instructions.
See page 3 for model part numbers
and approvals information.
332457C
EN
PROVEN QUALITY. LEADING TECHNOLOGY.
Contents
Related Manuals ................................................ 2
Models............................................................... 3
Warnings ........................................................... 5
Important Isocyanate (ISO) Information................ 8
System Control Drawing 16P577 ......................... 10
Configuring Your System .................................... 12
1. Select a Base Model ................................ 12
2. Select Hoses ........................................... 14
3. Select Mix Manifold.................................. 16
4. Select a Spray Gun.................................. 16
5. Select Color and Catalyst Change
Kits................................................ 17
6. Select Pump Expansion Kits..................... 17
General Information............................................ 18
Location............................................................. 18
Install the Display Module.................................... 19
Install the Booth Control ...................................... 20
Air Supply .......................................................... 21
Fluid Supply ....................................................... 22
Fluid Requirements...................................... 22
Single Color Connections ............................. 23
Color Change Connections........................... 23
TSL Cup Kit........................................................ 24
Solvent Meter Accessory..................................... 25
Light Tower Accessory........................................ 25
Electrostatic Air Hose Quick Disconnect Kit
24S004................................................. 25
Electrical Supply................................................. 26
Electrical Requirements................................ 26
Electrical Connections.................................. 26
Grounding .......................................................... 27
Electrical Schematics.......................................... 31
Optional Cables and Modules ....................... 37
Dimensions ........................................................ 38
Technical Data ...................................................39
Graco Standard Warranty....................................40
Related Manuals
Manual No. Description
3A2800 PD2K Proportioner Repair-Parts
Manual, Manual Systems
332562 PD2K Proportioner Operation
Manual, Manual Systems
3A2801
332339 Pump Repair-Parts Manual
Mix Manifold Instructions-Parts
Manual
Manual No. Description
332454
332455
332456 3rd and 4th Pump Kits
Color Change Valve Repair-Parts
Manual
Color Change Kits InstructionsParts Manual
Instructions-Parts Manual
2
332457C
Models
See Figs. 1–7 for component identification labels, including approval information and certification.
Models
Part No.
MC1000
MC2000
0359
Series
A
A
Maximum Air Working
Pressure
100 psi (0.7 MPa,
7.0 bar)
100 psi (0.7 MPa,
7.0 bar)
II 2 G
Maximum Fluid Working
Pressure
300 psi (2.068 MPa, 20.68 bar)
1500 psi (10.34 MPa,
103.4 bar)
Location of PD2K and
Electrical Control Box
(ECB) Labels
Figure 1 Model MC1000 (Low Pressure) Identification
Label
Figure 2 24M672 Control Box Identification Label
Continued on the next page.
332457C 3
Models
Figure 3 Model MC2000 (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 Booth Control Identification Label
Figure 7 Pump Expansion Kit (Accessory) Identification Label
4
332457C
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.
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.
• All electrical wiring must be done by a qualified electrician and comply with all local codes
and regulations.
332457C 5
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.
• Be sure your installation complies with national, state, and local codes for the installation of
electrical apparatus in a Class I, Group D, Division 1 (North America) or Class I, Zones 1
and 2 (Europe) Hazardous Location, including all of the local safety fire codes (for example,
NFPA 33, NEC 500 and 516, OSHA 1910.107, etc.).
• 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 substitute system components as this may impair intrinsic safety.
• 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.
• 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.
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, orcleaning
equipment.
6 332457C
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.
• 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.
332457C
7
Important Isocyanate (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.
8 332457C
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
332457C 9
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.
NOTES FOR SYSTEM CONTROL DRAWING 16P577 (FM13ATEX0026 SYSTEM ASSEMBLY
CERTIFICATE)
Alternate M12 CAN Cables, for Hazardous Locations
Cable Part No. Length ft (m)
16V423
16V424
16V425 6.0 (2.0)
16V426
16V427
16V428
16V429
16V430
2. The non-intrinsically safe terminals (power rail) must not be connectedtoanydevicewhichusesor
generates more than Um = 250 Vrms or dc unless it has been determined that the voltage has been
adequately isolated.
3. The electrical enclosure ground screw must be connected to a true earth ground using the supplied
ground strap (223547) or by an equivalent 10 AWG or larger isolated conductor. Resistance from the
electrical enclosure ground to the true earth ground shall not exceed 1 ohm.
4. Multiple earthing of components is allowed. Intrinsically safe apparatus provides isolation from earth to
500 Vrms.
Do not operate system with power barrier cover removed.
6. Installation should be in accordance with ANSI/ISA RP12.06.01 “Installation of Intrinsically Safe Systems
for Hazardous (Classified) Locations” and the National Electrical Code® (ANSI/NFPA 70).
2.0 (0.6)
3.0 (1.0)
10.0 (3.0)
15.0 (5.0)
25.0 (8.0)
50.0 (16.0)
100.0 (32.0)
7. Installation in Canada should be in accordance with the Canadian Electrical Code, CAS C22.1, Part I,
Appendix F.
8. For ATEX, install per EN 60079–14 and applicable local and national codes.
9. For IECEx install per IEC 60079–14 and applicable local and national codes.
10 332457C
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
250 VAC MAXIMUM SUPPLY VOLTAGE
POWER IN
PROMIX PD2K
ELECTRICAL ENCLOSURE
(24M672)
POWER
BARRIER
(248192)
COMMUNICATION
BARRIER
(24M485)
FM13ATEX0026
IECEx FMG 13.0011
ASSOCIATED APPARATUS
HAZARDOUS (CLASSIFED) 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
J4
OR
J3
CABLE (16V429)
COLOR CHANGE MODULE
(24R219, 24R220, 24R221, 24R222)
FM13ATEX0026
IECEx FMG 13.0011
INTRINSIC SAFE APPARATUS
CABLE
(16V426)
COLOR CHANGE MODULE
(24R219, 24R220, 24R221, 24R222)
FM13ATEX0026
IECEx FMG 13.0011
INTRINSIC SAFE APPARATUS
CABLE
(16V426)
BOOTH CONTROL
(24M731)
FM13ATEX0026
IECEx FMG 13.0011
INTRINSIC SAFE APPARATUS
Figure 8 System Control Drawing 16P577
332457C
11
Configuring Your System
Configuring Your System
1. Select a Base Model
Choose a PD2K base model that meets your
application’s requirements. See Models, page 3 .
Component
Fluid Pumps (A, B) The base models include two fluid pumps, one for resin and one for
Solvent Valve (C)
Booth Control (D)
Electrical Control Box (E) The electrical control box includes a barrier board, intrinsically safe
Advanced Display Module (F) The Advanced Display Module (ADM) enables the user to setup, monitor,
Description
catalyst. Install in the non-hazardous area.
Dispenses solvent to the gun during purge.
The booth control enables the user to monitor and control the system.
Install the booth control in the hazardous location, near the painter.
isolation board, 24 Vdc and 48 Vdc power supplies, Enhanced Fluid
Control Module, and Pump Control Modules. It accepts 90–250 Vac line
power and converts that power to acceptable low voltage signals used
by other system components. Install the electrical control box in the
non-hazardous area.
and control the system. Install the ADM in the non-hazardous area.
Base models include components A through F
shown in the Typical Installation Drawing. Base unit
components are described in the following table.
12
332457C
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