Graco 332458B User Manual

Installation

ProMix® PD2K Pr

Automatic Spr

Electronic positive displacement proportioner for fast-setting two-component materials. Automatic system with Advanced Display Module. For professional use only.

Important Safety Instructions Read all warnings and instructions in this manual and in your operation, repair, and associated component manuals. Save these instructions.

See page 3 approvals information.

for model part numbers and

ay Applications

oportioner for

332458B

PROVEN QUALITY. LEADING TECHNOLOGY.

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

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

Warnings ........................................................... 5

Important Isocyanate (ISO) Information................ 8

System Control Drawing 16P577 ......................... 9

Conﬁgure Yo

1. Select a B

2. Select Ho

3. Select a

4. Select N

5. Select I

6. Select P

General Information............................................ 18

Location............................................................. 18

Install t

Air Supply .......................................................... 20

ur System....................................... 11

ase Model ................................ 11

ses ........................................... 13

Spray Gun.................................. 14

on- IS Color and Catalyst

Change Kit

S Remote Color Change

Kits................................................ 16

ump Expansion Kits..................... 17

he Display Module.................................... 19

s ................................... 15

Fluid Supply ....................................................... 21

Fluid Requirements...................................... 21

Single Color Connections ............................. 22

Color Change Connections........................... 22

TSL Cup Kit........................................................ 23

Solvent Mete

Light Tower Accessory........................................ 24

Electrical Supply................................................. 25

Electrical Requirements................................ 25

Electrical Connections.................................. 25

Grounding

Electrical Schematics.......................................... 29

Optional Cables and Modules.............................. 35

Dimensio

Technical Data ...................................................37

Graco Standard Warranty.................................... 38

r Accessory..................................... 24

.......................................................... 26

ns ........................................................ 36

Related Manuals

Current manuals are available at www.graco.com.

Manual No. Description

332709 PD2K Proportioner Repair-Parts

Manual, Automatic Systems

3325

332339 Pump Repair-Parts Manual

PD2K Proportioner Operation Manual, Automatic Systems

Manua

332454

3332

332456 3rd and 4th Pump Kits

lNo.

iption

Descr

Color Change Valve Repair-Parts Manual

Color Change Kits InstructionsParts Manual

Instructions-Parts Manual

332458B

Models

SeeFigs.1–7f

Part No.

AC1000

AC2000

0359

or component identiﬁcation labels, including approval information and certiﬁcation.

Series

Maximum Air Wo

Pressure

100 psi (0.7

7.0 bar)

100 psi (0.7 MPa,

7.0 bar)

MPa,

II 2 G

rking

Maximum Fluid

Pressure

300 psi (2.0

1500 psi (10.34 MPa,

68 MPa, 20.68 bar)

103.4 bar)

Working

Location of PD2K and

Electrical Control Box

(ECB) Labels

Figure 1 Model AC1000 (Low Pressure) Identiﬁcation Label

Figure 2 24M672 Control Box Identiﬁcation Label

Continued on the next page.

332458B 3

Models

Figure 3 Model AC2000 (High Pressure) Identiﬁcation Label

Figure 4 Non-Intrinsically Safe Color Change Control (Accessory) Identiﬁcation Label

Figure 5 Intrinsically Safe Color Change Control (Accessory) Identiﬁcation Label

Figure 6 Pump Expansion Kit (Accessory) Identiﬁcation Label

332458B

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 EX

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).

•Keepwork

• 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.

•Useonly

• 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.

• Keepaw

PLOSION HAZARD

area free of debris, including solvent, rags and gasoline.

grounded hoses.

orking 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

• Connect only to grounded power source.

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

332458B 5

off and disconnect power at main switch before disconnecting any cables and before

icing or installing equipment.

serv

and regulations.

Warnings

WARNING

INTRINSIC SAFETY

Intrinsical equipment wi Follow local

• 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.).

•Tohelpprev

• Equipment Safety. T unit from

SKIN INJECTION HAZARD

High-pr skin. Th immedia

• Do not point dispensing device 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 dispensing and before cleaning, checking, or servicing equipment.

•Tight

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

ly safe equipment that is installed improperly or connected to non-intrinsically safe

ll create a hazardous condition and can cause ﬁre, explosion, or electric shock.

regulations and the following safety requirements.

ent 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.

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

essure ﬂuid from dispensing device, hose leaks, or ruptured components will pierce

is may look like just a cut, but it is a serious injury that can result in amputation. Get

te surgical treatment.

ut your hand over the ﬂuid outlet.

en all ﬂuid connections before operating the equipment.

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.

•Pres

TOX Tox inh

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

•St

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

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

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

equi

ICFLUIDORFUMES

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

aled, or swallowed.

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

idelines.

equipment.

6 332458B

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:

•Protectivee

• 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.

•Useﬂuids in all equ informat

• 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 eq manufac

• 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.

•Useequ

• 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.

•Keepc

• Comply with all applicable safety regulations.

yewear, and hearing protection.

and solvents that are compatible with equipment wetted parts. See Technical Data

ipment manuals. Read ﬂuid and solvent manufacturer’s warnings. For complete

ion about your material, request MSDS from distributor or retailer.

uipment daily. Repair or replace worn or damaged parts immediately with genuine

turer’s replacement parts only.

ipment only for its intended purpose. Call your distributor for information.

hildren and animals away from work area.

332458B

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 and understand 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.

Eventually a ﬁlm will form on the surface and the ISO will begin to gel, increasing in viscosity.

NOTICE

Partially c the life of a

• Always use a sealed container with a desiccant 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.

ured ISO will reduce performance and

ll wetted parts.

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.

Chang

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

•When

•Alw

•Che

•Wh

ing Materials

NOTIC

changing materials, ﬂush the equipment

tiple times to ensure it is thoroughly clean.

mul

ays clean the ﬂuid inlet strainers after hing.

ﬂus

ck with your material manufacturer for

mical compatibility.

che

en changing between epoxies and urethanes

polyureas, disassemble and clean all ﬂuid

mponents and change hoses. Epoxies often

ve amines on the B (hardener) side. Polyureas

ten have amines on the A (resin) side.

8 332458B

System Control D

rawing 16P577

System Contro

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)

l Drawing 16P577

Alternate

Cable Part No. Length ft (m)

16V423

16V424

16V425

M12 CAN Cables, for Hazardous Locations

2.0 (0.6)

3.0 (1.0

6.0 (2.0)

)

16V426

16V427

16V428

16V4

16V430

2. The non-intrinsically safe terminals (power rail) must not be connected to any device which uses or generates more than Um = 250 Vrms or dc unless it has been determined that the voltage has been adequately isolated.

The electrical enclosure ground screw must be connected to a true earth ground using the supplied

3. ound strap (223547) or by an equivalent 10 AWG or larger isolated conductor. Resistance from the

lectrical 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).

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.

10.0 (3.0)

5.0)

15.0 (

25.0 (8.0)

50.0 (16.0)

.0 (32.0)

100

9. For IECEx install per IEC 60079–14 and applicable local and national codes.

332458B 9

System Control D

rawing 16P577

NON-HAZARDOUS LOCATION ONLY HAZARDOUS (CLASSIFIED) LOCATION

Class 1, Div 1, Group D, T3 (USA and Canada)

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

Class 1, Zone 1

, Group IIA, T3 (ATEX and IECEx)

Ta = 2°C to 50°C

HAZARDOUS (CLASSIFED) LOCATION

CLASS 1, DIV 1, GROUP D, T3 (USA AND CANADA) CLASS 1, ZONE 1, GROUP IIA, T3 (ATEX AND IECEx) Ta = 2ºC TO 50ºC

COLOR CHANGE MODULE (24R219, 24R220, 24R221, 24R222)

CABLE (16V429)

CABLE

(24V406, 24V407, 24V408) (24V409, 24V410, 24V411) FM13ATEX0026 IECEx FMG 13.0011 INTRINSIC SAFE APPARATUS

COLOR CHANGE MODULE

(16V426)

(24R219, 24R220, 24R221, 24R222) (24V406, 24V407, 24V408) (24V409, 24V410, 24V411) FM13ATEX0026 IECEx FMG 13.0011 INTRINSIC SAFE APPARATUS

(16V426)

BOOTH CONTROL (24M731) FM13ATEX0026 IECEx FMG 13.0011 INTRINSIC SAFE APPARATUS

Figure 7 System Control Drawing 16P577

10 332458B

Conﬁgure Your Sy

stem

Conﬁgure Your

1. Select a Bas

Choose a PD2K base model that meets your application’s requirements. See Models, page 3 .

Base models i in the Typic

Component

Fluid Pump

Solvent Flow Switch (C) Conﬁrms solvent ﬂow to gun during purge.

Electrical Control Box (D) The electrical control box includes a barrier board, intrinsically safe

Advanc

nclude components A through F shown

al Installation drawing on the next page.

s (A, B)

ed Display Module (E)

e Model

System

Base unit components are described in the following table.

Descriptio

Thebasemo catalyst.

isolation board, 24 Vdc and 48 Vdc power supplies, Enhanced Fluid Control Module, and Pump Control Modules. The Gateway communication module, shipped separately, is installed in the electrical control box. 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.

The Adv and con

dels include two ﬂuid pumps, one for resin and one for

Install in the non-hazardous area.

anced Display Module (ADM) enables the user to setup, monitor,

trol the system. Install the ADM in the non-hazardous area.

CAN cable (F) The CAN cable connects the Gateway communication module to theIS

remote mix control module.

332458B

Conﬁgure Your Sy

HAZARDOUS (CLASSIFIED) LOCATION NON-HAZARDOUS LOCATION ONLY

stem

Figure 8 Typical Installation

Component

★ Components A through F are included with the base unit.

A★

B★

C★ Solvent Flow Switch

D★

E★ Advanced Display Module

F★

Components G through K are included in optional color change kits.

G Color Change Valves (accessory, non-hazardous area)

omponents L through S are accessories and must be ordered separately.

Description

Materia

Material B (Catalyst) Pump

Elect

CAN C

Catalyst Change Valves (accessory, non-hazardous area)

Catalyst Change Module (accessory, non-hazardous area)

Fluid/Air Hose Bundle (accessory)

Remote Color Change Manifold (accessory, hazardous area)

l A (Color) Pump

rical Control Box

ommunication Cable

lor Change Module (accessory, non-hazardous area)

S Gun Fluid Hose (accessory)

Remote Mix Manifold (accessory, hazardous area)

Automatic Spray Gun (accessory)

IS Remote Mix Control Module (accessory, hazardous area)

Supply Line Drain Valves (accessory, required, not shown)

332458B

+ 26 hidden pages

Graco 332458B User Manual

Contents

Related Manuals

Models

Warnings

Isocyanate Conditions

Keep Components A and B Separate

Moisture Sensitivity of Isocyanates