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
Configuring Your System
HAZARDOUS (CLASSIFIED) LOCATION NON-HAZARDOUS LOCATION ONLY
Figure 9 Typical Installation
Component
★ Components A through F are included with the base unit.
A★
B★
C★ Solvent Valve
D★
E★
F★ Advanced Display Module
Components G through K are included in optional color change kits.
G Color Change Valves (accessory)
H
J
K
Components L through S are accessories and must be ordered separately.
L
M
Description
Material A (Color) Pump
Material B (Catalyst) Pump
Control
Booth
Electrical Control Box
lor Change Module (accessory)
Co
Catalyst Change Valves (accessory)
Catalyst Change Module (accessory)
Fluid/Air Hose Bundle (accessory)
Mix Manifold (accessory)
N Air Spray Gun (accessory)
P
R
S Gun Fluid Hose (accessory)
Gun Air Hose (accessory)
Intrinsically Safe CAN Cable (to connect booth control to electrical control box)
332457C 13
Configuring Your System
2. Select Hoses
Hose Selection Tool
Use this chart to determine the proper size hose
bundle for your mix ratio and viscosity, then select a
hose bundle for your application from the tables on
the following page.
LOW PRESSURE SYSTEM, 0–300 psi (0–2.1 MPa, 0–21 bar)
Recommended Hose Sizes (internal diameter) for A and B
20 - 50
18
16
14
12
10
3/8ʺ A
1/8ʺ B
Mix
Ratio
8
(X:1)
6
NOTE: Always use Graco hoses.
NOTE: Shaded areas may use hose sizes from either
of the two adjacent areas.
3/8ʺ A
1/4ʺ B
1/4ʺ A
1/4ʺ B
4
2
0
10:1 7.5:1 5:1 2.5:1 1:1 1:2.5 1:5 1:7.5 1:10
Thick Resin (A)
Thin Catalyst (B)
Equal Viscosities
Viscosity Ratio (Resin [A] : Catalyst [B]
1/4ʺ A
3/8ʺ B
Thin Resin (A)
Thick Catalyst (B)
14
332457C
1/4 in. (6 mm) ID Hose Bundles
Select a hose bundle from the following table. Always use Graco hoses.
Configuring Your System
Application Hose Bundle
Part No.
Low Pressure
Conventional Air
Spray
Low Pressur
Electrosta
Spray*
High Pressure
Conventional
Air-Assisted Spray
High Pressure
Electrostatic
Air-Assisted Spray*
* To use a quick disconnect on an existing electrostatic air hose, see
Electrostatic Air Hose Quick Disconnect Kit 24S004, page 25.
3/8 in. (10 mm) ID Fluid Hoses
If 3/8 in. (10 mm) fluid hose is required for your application, order one of the following to replace the 1/4 in.
hose in your hose bundle. Always use Graco hoses.
e
tic Air
24T140
24T141
24T138
24T139
24T247
24T248
24T245 25 ft (7.6 m)
24T246
Length Material Maximum
Fluid Working
Pressure
25 ft (7.6 m)
50 ft (15.2 m)
25 ft (7.6 m)
50 ft (15.2 m)
25 ft (7.6 m)
50 ft (15.2 m)
50 ft (15.2 m)
Nylon (A side and Solvent),
Moisture Guard (B side), Air Hose
Nylon (A side and Solvent),
Moisture Guard (B side),
Grounded Air Hose with left-hand
thread
Nylon (A side and Solvent),
Moisture Guard (B side), Air Hose
Nylon (A side and Solvent),
Moisture Guard (B side),
Grounded Air Hose with left-hand
thread
225 psi (1.6
MPa, 16 bar)
225 psi (1.6
MPa, 16 bar)
2000 psi (13.8
MPa, 138 bar)
2000 psi (13.8
MPa, 138 bar)
Application Hose Part No. Length Material Maximum Fluid Working Pressure
Low Pressure Air
Spray
Fluid Whip Hoses
Select a fluid whip hose from the following table. Always use Graco hoses.
Application Hose Part No. Hose I.D. Length Material Maximum Fluid
Low Pressure
High Pressure
24T763
24T764
24N641
24N305 0.25 in. (6 mm) 6 ft (1.8 m) Nylon 225 psi (1.6 MPa,
24N641
24N348
25 ft (7.6 m)
50 ft (15.2 m)
0.125 in. (3 mm) 6 ft (1.8 m)
0.125 in. (3 mm) 6 ft (1.8 m)
0.25 in. (6 mm) 6 ft (1.8 m)
Nylon
200 psi (1.4 MPa, 13.8 bar)
Working Pressure
Nylon
Nylon
PTFE
3200 psi (22 MPa,
220 bar)
16 bar)
3200 psi (22 MPa,
220 bar)
3000 psi (20.7 MPa,
207 bar)
332457C 15
Configuring Your System
3. Select Mix Manifold
The following mix manifold kits are available. The
mix manifolds attach to the painter’s belt, allowing
mixing to occur at the point of spray. See manual
3A2801 for further information.
Mix
Manifold
24R991Low pressure mix
24R992High pressure mix
24T273 High pressure
Description Maximum Fluid
Working Pressure
300 psi (2.1 MPa,
manifold
manifold
mix manifold, for
acid-compatible
materials
21 bar)
1500 psi (10.5
MPa, 105 bar)
1500 psi (10.5
MPa, 105 bar)
4. Select a Spray Gun
Spray Guns
Select a spray gun from the following table.
Application
Conventional Air Spray AirPro 312414 300 psi (2.1 MPa, 21 bar)
Gun Model Gun Manual No.
Maximum Fluid Working
Pressure
Electrostatic Air Spray
Conventional
Air-Assisted Spray
ctrostatic Air-Assisted
Ele
ay
Spr
Pro Xp 3A2494
G15
ProXpAA 3A2495
3A0149
100 psi (0.7 MPa, 7 bar)
1500 psi (10.5 MPa, 105
bar)
3000 psi (21 MPa, 210
bar)
16 332457C
Configuring Your System
5. Select Color and Catalyst Change Kits
Using the following table, choose color/catalyst change kits that meet your application’s requirements. The
kits include a manifold with valves and a control module. See color change kit manual 332455 for further
information.
Table 1 . Low Pressure Color/Catalyst Change Kits (300 psi [2.068 MPa, 20.68 bar])
KitPartNo. KitDescription
Low Pressure Non-Circulating Kits
24R915 2coloror2catalyst
change valves
24R916 4coloror4catalyst
change valves
24R917 6 color change valves
24R918 8 color change valves
Low Pressure Circulating Kits
24R919 2coloror2catalyst
change valves
24R920 4coloror4catalyst
change valves
24R921 6 color change valves
24R922 8 color change valves
Table 2 . High Pressure Color/Catalyst Change Kits (1500 psi [10.34 MPa, 103.4 bar])
KitPartNo. KitDescription
High Pressure Non-Circulating Kits
24R959 2coloror2catalyst
change valves
24R960 4coloror4catalyst
change valves
24R961 6 color change valves
24R962 8 color change valves
High Pressure Acid-Compatible Non-
Circulating Kits
24T579 2 catalyst change valves
24T580 4 catalyst change valves
High Pressure Circulating Kits
24R963 2coloror2catalyst
change valves
24R964 4coloror4catalyst
change valves
6. Select Pump Expansion Kits
The following table lists available kits to add a third
or fourth pump to your system. Each kit includes
one pump, a pump control module, solenoid, frame,
mounting bracket, and cabling. See pump expansion
kit manual 332456 for further information.
24R965 6 color change valves
24R966 8 color change valves
KitPartNo. KitDescription
Low Pressure Pumps (300 psi [2.068
MPa, 20.68 bar])
R968
24
24R970 Low pressure catalyst
High Pressure Pumps (1500 psi [10.34
MPa, 103.4 bar])
24R969 High pressure resin
24R971 High pressure catalyst
w pressure resin 70cc
Lo
mp
pu
35cc pump
70cc pump
35cc pump
332457C
17
General Information
General Information
• 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 and Part No. 15M483 for the
Booth Control. Clean the screens with a dry cloth if
necessary.
Location
To prevent tipping which can cause serious injury
and equipment damage, the mounting stand
must be securely anchored to the floor or to an
appropriate base. The stand is not intended for
free-standing use or wall mounting.
Mounting the PD2K Base Unit:
• Mount the PD2K in a non-hazardous location.
• Ensure that the mounting surface and mounting
hardware are strong enough to support the weight
of the equipment, fluid, hoses, and stress caused
during operation.
• Donotmounttoawall.
• Secure the stand to the floor with 1/2 in. (13 mm)
bolts which engage at least 6 in. (152 mm) into
the floor to prevent the unit from tipping. See
Dimensions, page 38.
• There must be sufficient space on all sides of
the equipment for installation, operator access,
maintenance, and air circulation. The fans at the
back of the unit require a minimum of 6 in. (152
mm) clearance from the closest surface to ensure
adequate air circulation.
Mounting the Booth Control:
Install the booth control in a hazardous area at a
convenient location for the operator to view and
operate. See Install the Booth Control, page 20.
18 332457C
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, as you prefer.
2. Snap the Advanced Display Module into the
bracket.
Install the Display Module
Figure 11 Advanced Display Module Connection
Ports
Item Description
J Battery Cover
K Model Number
Figure 10 Install Display Module
3. Connect one end of the 5 ft (1.5 m) CAN cable
(provided) to the Advanced Display Module
(M). The other end of the cable comes from the
factory connected to the Enhanced Fluid Control
Module (EFCM).
NOTE: For a list of alternate cable lengths, see
Electrical Schematics, page 31. The total length of
all cable used in the system must not exceed 150
ft (45 m).
L
M
N
P Accessory Cable
R
USB Drive Interface
CAN Cable Connection
ADM Status LEDs
Connection
Token Access Cover
332457C 19
Install the Booth Control
Install the Booth Control
1. Use screws (S) to mount the bracket (10) for the
Booth Control (13) on the wall. Connect a ground
wire (G) to one of the screws. Connect the other
end of the ground wire to a true earth ground.
Figure 12 Ground the Booth Control Bracket
2. Snap the Booth Control into the bracket.
3. Connect the Booth Control to the Isolation Board
in the Electrical Control Box, using the 50 ft (15.2
m) intrinsically safe CAN cable (163).
NOTE: For a list of alternate cable lengths, see
Electrical Schematics, page 31. The total length
of cable used in the hazardous location must not
exceed 120 ft (36 m). The total length of all cable
used in the system must not exceed 150 ft (45 m).
Figure 13 Install the Booth Control
20 332457C
Air Supply
Air Supply
Air Requirements
• Compressed air supply pressure: 85-100 psi
(0.6–0.7 MPa, 6.0-7.0 bar).
• Air hoses: use grounded hoses that are correctly
sized for your system.
Trapped air can cause a pump or dispense
valve to cycle unexpectedly, which could result
in serious injury from splashing or moving parts.
Usebleed-typeshutoffvalves.
• Air regulator and bleed-type shutoff valve: include
in each air line to fluid supply equipment. Install
an additional shutoff valve upstream of all air line
accessories to isolate them for servicing.
To reduce the risk of fire and explosion if using
a Graco electrostatic gun, a shutoff valve must
be installed in the gun air line to shutoff the
atomizing and turbine air to the gun. Contact
your Graco distributor for information on air
shutoff valves for electrostatic applications.
switch detects air flow to the gun and signals the
controller when the gun is being triggered.
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.
Figure 14 Connect Atomizing Air
• Air line filter: to filter oil and water out of the air
supply and help avoid paint contamination and
clogged solenoids. See Technical Data, page 39 for
air filtration requirements.
Air Connections
1. Tighten all system air and fluid line connections
as they may have loosened during shipment.
2. Connect the main air supply line to the main air
inlet (136). This air line supplies the solenoids,
valves, and pumps. Do not use this line to supply
the gun’s atomizing air.
3. Connect a separate, dedicated, clean air supply
line to the air inlet (159a) of the air flow switch.
This air supplies gun atomizing air. The air flow
332457C
Figure 15 Air Manifold Connections
Key
Connection
A Air inlet
C GFB/Air cutoff output
M
S Solvent cutoff output
Description
(plugged)
Exhaust muffler
21
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. Use the valves to shut off fluid during
maintenance and service.
Models are available to operate air spray (300 psi) or
air-assisted (1500 psi) systems with a capacity of up
to 800 cc/minute (depending on material viscosity).
• Fluid supply pressure tanks, feed pumps, or
circulatingsystemscanbeusedtosupplyfluidto
the system.
• Materials can be transferred from their original
containers or from a central paint recirculating line.
• Install a 100 mesh (minimum) fluid filter in the fluid
supply line, with a drain valve.
NOTE: The fluid supply must be free of pressure
spikes, which are commonly caused by pump stroke
changeover. Read the supply pressure on the gauge
(P). Supply pressure must be as close as possible
to the pressure setpoint:
• For low pressure systems, ± 100 psi (0.7 MPa, 7
bar) of setpoint.
• For high pressure systems, ± 300 psi (2.1 MPa,
21 bar) of setpoint.
If necessary, install pressure regulators or a surge
tank on the pump fluid inlet lines to reduce pulsation.
Contact your Graco distributor for additional
information.
22
332457C
Fluid Supply
Single Color Connections
NOTE: Check valves (J, L) are provided on the inlet
and outlet manifolds of each pump.
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.
NOTE: For isocyanate catalyst materials, moisture
resistant hose is required to supply fluid to the system
and also as a fluid line between the pump and the
mix manifold.
Color Change Connections
If you are installing the color change accessory kit,
make the fluid connections as described in manual
332455.
Figure 16 Pump Inlet and Outlet Connections
332457C 23
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 and lower throat
cartridges of each 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 17 Install TSL Cup Kit
24
332457C
Solvent Meter Accessory
Solvent Meter Accessory
To install Solvent Meter Kit 280555, see manual
308778.
NOTE: Install the solvent meter downstream of the
solvent cutoff switch near the base unit.
Light Tower Accessory
To install Light Tower Kit 24K337, see manual
3A1906.
Electrostatic Air Hose Quick Disconnect Kit 24S004
NOTE: To use a quick disconnect on an existing
electrostatic air hose, order Part No. 24S004 Kit. You
will also need to order Part No. 24U059 Electrostatic
Air Whip Hose (6 ft) [1.8 m].
Install the kit as follows.
1. Connect the quick disconnect (QD) to the existing
electrostatic air hose (P). The quick disconnect is
a 1/4 npsm(m) left-hand thread.
2. Screw the female end of adapter fitting (QF) onto
the quick disconnect (QD).
3. Screw the 24U059 Electrostatic Air Whip Hose
(WH) onto the male end of the adapter fitting
(QF).
NOTE: Make the following ground connections
to ensure air hose grounding continuity in the
electrostatic system.
4. Connect the ground wire (PG) of the existing
electrostatic air hose (P) to a true earth ground.
5. Connect the whip hose ground wire (WG) to
the green ground lug (GND) of the mix manifold
(M). Connect a ground wire (MG) from the mix
manifold ground lug to a true earth ground.
Figure 18 Electrostatic Air Hose Quick Disconnect Kit
332457C 25
Electrical Supply
Electrical Supply
Electrical Connections
See Electrical Schematics, page 31.
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.
The unit operates with 90-250 VAC, 50/60 Hz input
power, with a maximum of 7 A current draw. The
power supply circuit must be protected with a 15 A
maximum circuit breaker.
• A power supply cord compatible to your local
power configuration is not included. Wire gauge
size must be 8-14 AWG.
• The input power access port is 22.4 mm (0.88
in.) in diameter. A strain relief is provided which
accepts a cord diameter of 0.157–0.354 in. (4–9
mm). If another cord size is used, a user-supplied,
appropriate size strain relief must be installed.
1. Verify that electrical power at the main panel is
shut off. Open the Control Box cover.
2. Thread the electrical cord wires through the
strain relief (S).
3. Connect the wires (L, N, G) securely to the
corresponding terminals of the terminal block (T),
as shown.
4. Tighten the strain relief nut securely.
5. Close the Control Box. Restore power.
6. Follow instructions in Grounding, page 27.
Wire Key
Wire Description
L Line Power
N Neutral
G Ground
Figure 19 Control Box Electrical Connection
26 332457C
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.
Grounding
Booth Control
The booth control is grounded through intrinsically
safe cable connections to the electrical control box.
Attachaseparategroundwiretothe
booth control mounting bracket. See
Install the Booth Control, page 20.
Color Change Module
Electrical Control Box
The electrical control box has two ground points.
Both connections must be made.
• Connectthegroundwire(Y)tothegroundscrew
on the electrical control box. Connect the clamp
endtoatrueearthground.
• The power supply must be grounded according to
local codes. Connect the power supply ground
wire to the Ground terminal in the electrical control
box. See Electrical Connections, page 26.
Figure 20 Ground Screw and Power Switch
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.
Feed Pumps or Pressure Pots
Connect a ground wire and clamp from a true earth
ground to the pumps or pots. See pump or pressure
pot manual.
Air and Fluid Hoses
Use grounded hoses only.
Spray Gun
Follow the grounding instructions in your gun manual.
• Non-Electrostatic: Ground the spray gun through
connection to a Graco-approved grounded fluid
supply hose.
Fluid Supply Container
Follow local code.
332457C
• Electrostatic: Ground the spray gun through
connection to a Graco-approved grounded air
supply hose. Connect the air hose ground wire to
a true earth ground.
27
Grounding
HAZARDOUS LOCATION NON-HAZARDOUS LOCATION
Figure 21 System Grounding
Key
1
2 Electrical Control Box ground wire
3
4
Electrical Control Box ground screw
lor Change Module (CC) ground
Co
res
wi
Intrinsically Safe (IS) cable
5
6 Non-Intrinsically Safe cable
7
True Earth Ground; check local code
for requirements
oth Control (BC) mounting bracket
Bo
ound wire
gr
28 332457C
Grounding
Object Being Sprayed
Follow local code.
All Solvent Pails Used When Purging
Follow local code. Use only conductive metal
pails/containers placed on a grounded surface. Do
not place the pail/container on a nonconductive
surface, such as paper or cardboard, which interrupts
the grounding continuity.
Check Resistance
To ensure proper grounding, resistance between
components and true earth ground must be less
than 1 ohm.
332457C 29
Notes
Notes
30 332457C
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 37 for
a list of cable options.
Electrical Schematics
RELAY
(16U820)
16W159
BREAKOUT MODULE PUMP 2
BREAKOUT MODULE PUMP 4
POWER MODULE
(24R257)
16W159
(24N527)
(24N527)
(24P658)
ENCODER AND MOTOR
(16P036, 16P037)
WIRE HARNESS
(24P684, 24P685)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
PUMP V/P FOR
FLUID REG.
UP
DOWN
(16P812)
SOLENOID
MAC SERIES 46
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
(24P658)
ENCODER AND MOTOR
(16P036, 16P037)
WIRE HARNESS
(24P684, 24P685)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
PUMP V/P FOR
FLUID REG.
UP
DOWN
(16P812)
SOLENOID
MAC SERIES 46
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
POWER IN
FAN
FAN
2 POSITION
SWITCH
(16U725)
CABLE
16T658
LINE FILTER
(16V446)
CABLE
16H078
TERMINAL BLOCK
(114095)
(24N527)
BREAKOUT MODULE PUMP 1
(24N527)
BREAKOUT MODULE PUMP 3
24V
POWER
SUPPLY
(16T660)
48V-10A POWER SUPPLY
TERMINAL BLOCKS WITH FUSES
16W159
FAN
(24P658)
ENCODER AND MOTOR
(16P036, 16P037)
WIRE HARNESS
(24P684, 24P685)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
PUMP V/P FOR
FLUID REG.
UP
DOWN
(16P812)
SOLENOID
MAC SERIES 46
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
FAN
(24P658)
ENCODER AND MOTOR
(16P036, 16P037)
WIRE HARNESS
(24P684, 24P685)
PUMP INLET
TRANSDUCER
(16P289, 16P290)
PUMP OUTLET
TRANSDUCER
(16P289, 16P290)
PUMP V/P FOR
FLUID REG.
UP
DOWN
(16P812)
SOLENOID
MAC SERIES 46
FLOW SENSOR
(120278)
OR G3000 METER
(239716, 258718
16M510, 16M519)
Figure 22 Electrical Schematic, Sheet 1
16W159
SPLITTER
(16P243)
4
CABLE (15V206)
2
IS BOARD
(24M485)
BARRIER
BOARD
(248192)
CABLE (16T659)
CABLE (16T659)
CABLE (16T659)
CABLE (16T659)
COMMUNICATION
MODULE
(24R910)
3
CABLE
COMMUNICATION
MODULE
(24R910)
CABLE
(121227)
3
16T072
CAN
CABLE
(16T280)
065161, 065159
5
(121227)
5
CABLE
3
(121227)
6
(24N935)
MODULE 1
COLOR CHANGE
CABLE
2
(15V206)
GCA
MODULE
EFCM
(24N913)
FLOW RATE ANALOG IN
FLOW RATE ANALOG IN
1
CABLE (16V429)
2
CABLE
(15V206)
6
(24N935)
MODULE 2
COLOR CHANGE
FLOW RATE ANALOG IN
FLOW RATE ANALOG IN
2
CABLE
(15V206)
6
6
6
(24N935)
(24N935)
MODULE 3
COLOR CHANGE
COLOR CHANGE
CABLE
2
(15V206)
GUN TRIGGER INPUTS
119159
119159
119159
119159
SOLENOID (121324)
PRESSURE SWITCH
(121323)
SOLVENT FLOW SWITCH (120278)
SOLVENT METER (258718)
3
ADVANCED
CABLE
DISPLAY MODULE
(121003)
(24E451)
CABLE
1
(24N935)
MODULE 4
MODULE 5
CATALYST CHANGE
CABLE
2
(15V206)
COLOR CHANGE MODULE 7
(24R219)
COLOR CHANGE MODULE 8
(24R219)
(16V426)
BOOTH CONTROL (24M731)
HAZARDOUS LOCATION
NON-HAZARDOUS LOCATION
6
(24N935)
MODULE 6
CATALYST CHANGE
GFB
INTERFACES
LIGHT
TOWER
(15X472)
CABLE
1
(16V426)
7
7
332457C 31
Electrical Schematics
POWER
SUPPLY
(16T660)
L (BROWN)
N03 N03
2 POSITION
SWITCH
(16U725)
N04 N04
CABLE
(16T658)
L N
LINE
FILTER
(16V446)
L GRND N
CABLE
(16H078)
L N GRND
TERMINAL
BLOCK
(114095)
L N GRND
24V
GRND (GRN/YEL)
N (BLUE)
CABLE (16V429)
1
SPLITTER
(16P243)
2
345
1
UNUSED
UNUSED
UNUSED
13 A1(+) A2(-)
RELAY
14
N L GRND
48V-10A
POWER SUPPLY
(16U820)
+ -
+ - + - + - + -
F4
F3
F2
F1
+ - + - + - + -
DETAIL A, LOW PRESSURE
PUMPS (24M706, 24M714)
BREAKOUT MODULE
(24N527)
2
1 2 3 4 5 1 2 3 4
WIRE HARNESS
(24P684)
CONTINUED ON PAGE 3
2
CABLE
(15V206)
1 2 3 4 5
CAN IS BOARD
2
(NON IS)
4
(24M485)
1 2 3 4 5
1
UNUSED
2
3
RED WIRE (065161)
BLACK WIRE (065159)
(24R257)
POWER MODULE
3
CABLE (121227)
3
16T072
1 2 3 4 5
1
1
2
2
3
3
4
4
5
5
1
(IS)
BARRIER
(248192)
CABLE
BOARD
1 2 3 4 5
(16T280)
1 2 3
3
UNUSED
UNUSED
5
COMM MODULE (24R910)
INTERFACE
SOLVENT CUTOFF
SOLVENT
METER
(258718)
GROUND BAR
BREAKOUT MODULE PUMP 1 (24N527)
3
2
1 2 3 4 5 1 2 3 4
ENCODER/MOTOR
AND
WIRE HARNESS
PUMP 1
SEE DETAIL A OR B
DRAIN/FOIL
4
1 2 3 4 5 1 2 3 4 5 1 2
PUMP 1
(16P289 OR 16P290)
INLET TRANSDUCER
TWISTED PAIR CABLE (16W159)
DETAIL B, HIGH PRESSURE
PUMPS (24M707, 24M715)
1 2 3 4 5 1 2 3 4
CABLE
1
2
3
4
5
(121227)
3
5
COMM MODULE (24R910)
GFB
PWR (RED)
SIG (WHITE)
COM (BLACK)
SHIELD/GRN
6
5
1 2 3 4
PUMP 1
PUMP 1
(16P289 OR 16P290)
V/P FOR FLUID REG.
OUTLET TRANSDUCER
MANIFOLD
BREAKOUT MODULE
(24N527)
2
WIRE HARNESS
(24P685)
UNUSED
UNUSED
UNUSED
CABLE
1
2
3
4
5
(121227)
3
+12VDC
COM
UNUSED
UNUSED
+12VDC
COM
+12VDC
COM
UNUSED
1
7
3 4
COM
COM
+24VDC
+24VDC
UP
DOWN
PUMP 1
PUMP 1
(16P812 QTY 2)
MAC SERIES 46
3
5
4
3
10
2
1
1
2
3
8
4
5
1
2
3
4
5
6
5
7
8
9
10
11
12
25 PIN D-SUB CABLE
(16T659)
1 2 3 4
5 6 7 8
PWR (RED)
SIG (WHITE)
COM (BLACK)
SHIELD/GRN
G3000
METER
PUMP 1
(EITHER, 239716,
258718,16M510,
OR 16M519)
GRND
SCREW
DRAIN/FOIL
GCA MODULE
12
4
252423222120191817161413121110 15987654321
BREAKOUT MODULE PUMP 2 (24N527)
2
1 2 3 4 5 1 2 3 4
+48V
+48V
COM
COM
ENCODER/MOTOR
AND
WIRE HARNESS
PUMP 2
SEE DETAIL A OR B
(24P658)
FAN PUMP 1
CONTINUED ON PAGE 3
EFCM
(24N913)
252423222120191817161413121110 15987654321 252423222120191817161413121110 15987654321
3
1 2 3 4 5 1 2 3 4 5 1 2
TWISTED PAIR CABLE (16W159)
4
PUMP 2
(16P289 OR 16P290)
INLET TRANSDUCER
5
PUMP 2
OUTLET TRANSDUCER
6
1 2 3 4
PUMP 2
(16P289 OR 16P290)
V/P FOR FLUID REG.
25 PIN
(16T659)
D-SUB CABLE
4
1
3 4
COM
COM
+24VDC
+24VDC
UP
DOWN
PUMP 2
PUMP 2
MANIFOLD
(16P812 QTY 2)
MAC SERIES 46
7
5 6 7 8
G3000
METER
PUMP 2
(EITHER, 239716,
258718,16M510,
OR 16M519)
PWR (RED)
SIG (WHITE)
COM (BLACK)
SCREW
88
1 2 3 4
+48V
COM
SHIELD/GRN
GRND
+48V
FAN PUMP 2
252423222120191817161413121110 15987654321
COM
(24P658)
DRAIN/FOIL
UNUSED UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED UNUSED
UNUSED
UNUSED UNUSED
POWER IN
UNUSED
UNUSED
UNUSED
DRAIN/FOIL
1 2 3 4 5 6 7 8 9
PUMP ENCODER AND MOTOR
MOTOR
MOUNTING
SCREW
UNUSED UNUSED
11
10
(16P037)
UNUSED
12
UNUSED
UNUSED
UNUSED
1 2 3 4 5 6 7 8 9
UNUSED UNUSED UNUSED
10
UNUSED
MOTOR
MOUNTING
SCREW
1 2
1 2 3 4 5 6 7 8 9
PUMP ENCODER AND MOTOR
(16P036)
12
11
10
1 2 3 4 5 6 7 8 9
UNUSED
10
Figure 23 Electrical Schematic, Sheet 2, Part 1
CONTINUED ON THE NEXT PAGE
32 332457C
GUN TRIGGER INPUTS
SIG
1
COM
2
SIG
3
COM
4
SIG
5
COM
6
6
7
SIG
8
COM
9
SIG
10
COM
11
SIG
12
1
2
3
4
5
6
7
7
8
9
10
11
12
1
2
3
9
4
5
COM
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
UNUSED
UNUSED
UNUSED
UNUSED
CABLE
(121003)
3
GCA MODULE
EFCM
(24N913)
34
252423222120191817161413121110 15987654321 252423222120191817161413121110 15987654321
119159
GFB PRESSURE SWITCH (121323)
SOLVENT FLOW SWITCH (120278)
1
ADVANCED
2
DISPLAY MODULE
3
4
(24E451)
5
Electrical Schematics
1
2
3
4
5
LIGHT
TOWER
(15X472)
25 PIN
(16T659)
D-SUB CABLE
4
5
PUMP 3
(16P289 OR 16P290)
OUTLET TRANSDUCER
252423222120191817161413121110 15987654321
6
1 2 3 4
PUMP 3
V/P FOR FLUID REG.
3 4
COM
+24VDC
+24VDC
UP
PUMP 3
PUMP 3
MANIFOLD
MAC SERIES 46
DOWN
(16P812 QTY 2)
7
COM
5 6 7 8
G3000
METER
PUMP 3
(EITHER, 239716,
258718,16M510,
OR 16M519)
1
BREAKOUT MODULE PUMP 3 (24N527)
3
2
1 2 3 4 5 1 2 3 4 1 2 3 4 5 1 2 3 4
ENCODER/MOTOR
AND
WIRE HARNESS
PUMP 3
SEE DETAIL A OR B
4
1 2 3 4 5 1 2 3 4 5 1 2
PUMP 3
(16P289 OR 16P290)
INLET TRANSDUCER
TWISTED PAIR CABLE (16W159)
Figure 24 Electrical Schematic, Sheet 2, Part 2
CONTINUED ON THE NEXT PAGE
PWR (RED)
SIG (WHITE)
COM (BLACK)
SHIELD/GRN
GRND
SCREW
25 PIN D-SUB CABLE
(16T659)
8
COM
+48V
FAN PUM P 3
2
COM
(24P658)
1 2 3 4
+48V
4
ENCODER/MOTOR
AND
WIRE HARNESS
PUMP 4
SEE DETAIL A OR B
5
PUMP 4
(16P289 OR 16P290)
OUTLET TRANSDUCER
252423222120191817161413121110 15987654321
6
1 2 3 4
PUMP 4
V/P FOR FLUID REG.
3 4
COM
+24VDC
+24VDC
UP
PUMP 4
PUMP 4
MANIFOLD
(16P812 QTY 2)
MAC SERIES 46
7
COM
DOWN
1
BREAKOUT MODULE PUMP 4 (24N527)
3
4
1 2 3 4 5 1 2 3 4 5 1 2 1 2 3 4
PUMP 4
(16P289 OR 16P290)
INLET TRANSDUCER
TWISTED PAIR CABLE (16W159)
5 6 7 8
PWR (RED)
SIG (WHITE)
G3000
METER
PUMP 4
(EITHER, 239716,
258718,16M510,
OR 16M519)
+48V
COM (BLACK)
SHIELD/GRN
GRND
SCREW
COM
8
+48V
COM
(24P658)
FAN PUM P 4
332457C 33
Electrical Schematics
FLUSH
COLOR 1
COLOR 2
COLOR 3
COLOR 4
COLOR 5
COLOR 6
COLOR 7
COLOR 8
*FLUSH
COLOR 9
COLOR 10
COLOR 11
COLOR 12
COLOR 13
COLOR 14
COLOR 15
COLOR 16
CABLE (15V206)
2
MANIFOLD
MANIFOLD
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
2
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
FROM CAN IS BOARD (24M485) ON PAGE 2
2
345
1
COLOR
CHANGE
MODULE 1
J8
J15
J14
1
(COLORS
1 THRU 8)
2
6
345
J16
J10
1
+12VDC
2
COM
3
+12VDC
J9
4
COM
5
+12VDC
6
COM
1
+12VDC
2
COM
3
+12VDC
4
COM
5
+12VDC
6
COM
1
+12VDC
2
COM
3
+12VDC
4
COM
5
+12VDC
6
COM
CABLE
J8
J15
J14
2
345
1
COLOR
CHANGE
MODULE 2
(COLORS
9 THRU 16)
6
2
345
1
J16
J10
(15V206)
J9
1
+12VDC
2
COM
3
+12VDC
4
COM
5
+12VDC
6
COM
1
+12VDC
2
COM
3
+12VDC
4
COM
5
+12VDC
6
COM
1
+12VDC
2
COM
3
+12VDC
4
COM
5
+12VDC
6
COM
MANIFOLD
MANIFOLD
DUMP
COLOR 1
COLOR 2
COLOR 3
COLOR 4
COLOR 5
COLOR 6
COLOR 7
COLOR 8
DUMP*
COLOR 9
COLOR 10
COLOR 11
COLOR 12
COLOR 13
COLOR 14
COLOR 15
COLOR 16
FLUSH
CATALYST 1
CATALYST 2
CATALYST 3
CATALYST 4
FROM CAN IS BOARD (24M485) ON PAGE 2
MANIFOLD
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
1
2
3
J15
4
5
6
1
2
3
J14
4
5
6
CATALYST
CHANGE
MODULE 5
(CATALYST
1 THRU 4)
J8
2
1
6
345
J16
J10
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
MANIFOLD
DUMP
CATALYST 1
CATALYST 2
CATALYST 3
CATALYST 4
1
2
3
J9
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
2
CABLE
MANIFOLD
*FLUSH
COLOR 17
COLOR 18
COLOR 19
COLOR 20
COLOR 21
COLOR 22
COLOR 23
COLOR 24
ure 25 Electrical Schematic, Sheet 3
Fig
+12VDC
+12VDC
+12VDC
+12VDC
+12VDC
+12VDC
+12VDC
+12VDC
+12VDC
COM
COM
COM
COM
COM
COM
COM
COM
COM
1
2
3
4
J8
5
6
1
2
3
J15
4
5
6
1
2
3
J14
4
5
6
17 THRU 24)
5
2
345
1
COLOR
CHANGE
MODULE 3
(COLORS
6
2
4
3
J9
J16
J10
1
(15V206)
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
* May be unused in some configurations.
CONTINUED ON THE NEXT PAGE
MANIFOLD
DUMP*
COLOR 17
COLOR 18
COLOR 19
COLOR 20
COLOR 21
COLOR 22
COLOR 23
COLOR 24
2
COLOR 25
COLOR 26
COLOR 27
COLOR 28
COLOR 29
COLOR 30
CABLE (15V206)
*FLUSH
MANIFOLD
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
UNUSED
UNUSED
UNUSED
UNUSED
22
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
CABLE
2
1
COLOR
CHANGE
MODULE 4
(COLORS
25 THRU 32)
J8
J15
J14
2
1
345
6
J16
345
J10
J9
(15V206)
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
UNUSED
UNUSED
UNUSED
UNUSED
MANIFOLD
DUMP*
COLOR 25
COLOR 26
COLOR 27
COLOR 28
COLOR 29
COLOR 30
34 332457C
FLUSH
CATALYST 3
CATALYST 4
FLUSH
CATALYST 1
CATALYST 2
MANIFOLD
MANIFOLD
+12VDC
COM
+12VDC
COM
+12VDC
COM
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
+12VDC
COM
+12VDC
COM
+12VDC
COM
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
22
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
CATALYST
CHANGE
MODULE 6
(CATALYST
3 THRU 4)
J8
J15
J14
2
1
CABLE
5
4
CATALYST
CHANGE
MODULE 5
(CATALYST
1 THRU 2)
J8
J15
J14
2
1
6
345
2
3
6
345
J9
J16
J10
1
J9
J16
J10
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
(15V206)
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
+12VDC
COM
+12VDC
COM
+12VDC
COM
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
+12VDC
COM
+12VDC
COM
+12VDC
COM
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
Electrical Schematics
MANIFOLD
DUMP
CATALYST 3
CATALYST 4
MANIFOLD
DUMP
CATALYST 1
CATALYST 2
Figure 26 Electrical Schematic, Sheet 3, Alternate
Configuration for Catalyst Change Control
CONTINUED ON THE NEXT PAGE
2
CABLE
25 THRU 32)
2
345
1
COLOR
CHANGE
MODULE 4
(COLORS
(15V206)
332457C 35
Electrical Schematics
FROM CAN IS BOARD (24M485) ON PAGE 2
COLOR FLUSH
COLOR 1
COLOR 2
COLOR 3
COLOR 4
COLOR 5
COLOR 6
COLOR 7
COLOR 8
COLOR 13
COLOR 14
COLOR 15
COLOR 16
COLOR 17
COLOR 18
COLOR 19
COLOR 20
COLOR 21
MANIFOLD
MANIFOLD
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
1
2
3
4
J8
5
6
1
2
3
J15
4
5
6
1
2
3
4
J14
5
6
1
1
2
3
J8
4
5
6
1
2
3
J15
4
5
6
1
2
3
J14
4
5
6
2
345
1
COLOR
CHANGE
MODULE 7
(COLORS
33 THRU 40)
7
2
345
1
CABLE
2
345
1
COLOR
CHANGE
MODULE 8
(COLORS
41 THRU 48)
7
5
2
3
4
J9
J16
J10
J9
J16
J10
1
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
(16V426)
1
2
3
4
5
6
1
2
3
4
5
6
1
2
3
4
5
6
NON-HAZARDOUS LOCATION
HAZARDOUS LOCATION
MANIFOLD
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
MANIFOLD
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
+12VDC
COM
CATALYST FLUSH
CATALYST 1
CATALYST 2
CATALYST 3
CATALYST 4
COLOR 9
COLOR 10
COLOR 11
COLOR 12
COLOR 22
COLOR 23
COLOR 24
COLOR 25
COLOR 26
COLOR 27
COLOR 28
COLOR 29
COLOR 30
1
CABLE
5
BOOTH CONTROL
3
4
(24M731)
2
(16V426)
1
Figure 27 Electrical Schematic, Sheet 3, Hazardous
Location
36 332457C
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 31.
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
16V425
16V426
16V427
16V428
16V429 50.0 (16.0)
16V430
M12 CAN Cables, for Non-Hazardous
Locations Only
15U531
15U532
15V205
15V206 10.0 (3.0)
3.0 (1.0)
6.0 (2.0)
10.0 (3.0)
15.0 (5.0)
25.0 (8.0)
100.0 (32.0)
2.0 (0.6)
3.0 (1.0)
6.0 (2.0)
CAN Cables, for Non-Hazardous
Locations Only
Cable Part No. Length ft (m)
125306
123422
121000 1.6 (0.5)
121227
121001
121002
121003
120952
121201 20.0 (6.0)
121004
121228
25 Pin D-SUB Cables, for Non-Hazardous
Locations Only
16T659
16V659
1.0 (0.3)
1.3 (0.4)
2.0 (0.6)
3.0 (1.0)
5.0 (1.5)
10.0 (3.0)
13.0 (4.0)
25.0 (8.0)
50.0 (15.0)
2.5 (0.8)
6.0 (1.8)
15V207
15V208
15U533
15V213
Alternates for Communication Module
24R910, for Non-Hazardous Locations Only
Module Part No. Module Part No.
15V759 15V761
15V760 15V762
15.0 (5.0)
25.0 (8.0)
50.0 (16.0)
100.0 (32.0)
Alternates for Color Change Modules
by Part Number (Factory Configuration), for
Non-Hazardous Locations Only
Module Part No. Description
24T557 2 color/2 catalyst
24T558 4 color/4 catalyst
24T559 6 color/6 catalyst
24T560 8 color/8 catalyst
Alternates for Color Change Modules
by Part Number (Factory Configuration), for
Hazardous Locations Only
24T571 2 color/2 catalyst
24T572 4 color/2 catalyst
24T573 6 color/2 catalyst
24T574 8 color/2 catalyst
332457C 37
Dimensions
Dimensions
Figure 28
A
58.20 in.
(1478
mm)
B
with ADM without
ADM
14.5 in.
(368 mm)
11.12 in.
(282 mm)
C
22.0 in.
(559 mm)
Figure 29
Figure 30
DEF
19.26 in.
(489 mm)
2.0 in.
(51 mm)
18.0 in.
(457 mm)
G
17.26 in.
(438 mm)
H
0.52 in.
(13 mm)
38 332457C
Technical Data
Technical Data
Positive Displacement
Proportioner
Maximum fluid working
pressure:
MC1000 Air Spray
Systems
MC2000 Air-Assisted
Spray Systems
Maximum working air
pressure:
Air supply: 85–100 psi
Air filter inlet size: 3/8 npt(f)
Air filtration for air logic
(user-supplied):
Air filtration for atomizing
air (user-supplied):
Mixing ratio range:
Fluids handled:
one or two component:
• solvent and waterborne paints
• polyurethanes
U.S.
300 psi 2.1 MPa, 21 bar
1500 psi 10.5 MPa, 105 bar
100 psi 0.7 MPa, 7.0 bar
5 micron (minimum) filtration required; clean and dry air
30 micron (minimum) filtration required; clean and dry air
0.1:1 — 50:1, ±1%
Metric
0.6–0.7 MPa, 6.0–7.0 bar)
• epoxies
• acid catalyzed varnishes
• moisture sensitive isocyanates
Viscosity range of fluid:
Fluid filtration
(user-supplied):
Maximum fluid flow: 800 cc/minute (depending on material viscosity)
Fluid outlet size:
External power supply
requirements:
Operating temperature
range:
Storage temperature
range:
Weight (approximate):
Sound data: Less than 75 dB(A)
Wetted parts:
90 - 250 Vac, 50/60 Hz, 7 amps maximum draw
15 amp maximum circuit breaker required
8 to 14 AWG power supply wire gauge
36 to 122°F 2 to 50°C
—4 to 158°F —20 to 70°C
195 lb 88 kg
17–4PH, 303, 304 SST, Tungsten carbide (with nickel binder),
perfluoroelastomer; PTFE, PPS, UHMWPE
20–5000 centipoise
100meshminimum
1/4 npt(m)
332457C 39
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. This warranty applies only when the equipment is installed, operated and maintained in accordance
with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction,
damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper
maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco
be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures,
accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation,
operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized
Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace
free of charge any defective parts. The equipment will be returned to the original purchaser transportation
prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be
made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS
FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The
buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost
profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available.
Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT,
MATERIALS OR COMPONENTS SOL
manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of
their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of
these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco
supplying equipment hereunder, or the furn
hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices
and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be
drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en
Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou
en rapport, directement ou indirectement, avec les procédures concernées.
D BUT NOT MANUFACTURED BY GRACO. These items sold, but not
ishing, performance, or use of any products or other goods sold
Graco Information
For the latest information about Graco products, visit www.graco.com.
To place an order, contact your Graco Distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
For patent information, see www.graco.com/patents.
Original Instructions. This manual contains English. MM 332457
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2013, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revised November 2013
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