Graco 332709B User Manual

Repair-Parts

ProMix® PD2K Pr

Automatic Spr

Electronic positive displacement proportioner for fast-setting two-component materials. System for automatic dispense, with Advanced Display Modules. For professional use only.

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

See page 3 approvals information.

for model part numbers and

ay Applications

oportioner for

332709B

EN

PROVEN QUALITY. LEADING TECHNOLOGY.

• 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 prev

•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.

332709B

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

IC FLUID OR FUMES

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.

gu

equipment.

7

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.

•Checkeq 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.

8 332709B

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 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.

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

or

mponents and change hoses. Epoxies often

co

ve amines on the B (hardener) side. Polyureas

ha

tenhaveaminesontheA(resin)side.

of

E

332709B 9

Troubleshootin

g

Troubleshooting

NOTE: Check all possible remedies before disassembling the system.

System Troubleshooting

Problem

Unit will not operate.

Pump output low on both strokes.

Pump output low on only one stroke.

No output. Improperly installed dosing valves.

Cause Solution

Inadequate power supply.

Power switch is off.

Main power is shut off.

Exhausted ﬂuid supply. Reﬁll and reprime pump.

Clogged ﬂuid outlet line, valves, etc.

Fluid dried on piston rod. Disassemble and clean pump.

Inadequate power supply.

Exhausted ﬂuid supply. Reﬁll and reprime pump.

Clogged ﬂuid outlet line, valves, etc.

Worn piston packings.

Held open or worn dosing valves.

Worn piston packing.

See Technical Data, page 61.

Turn switch on.

Turn main power switch on.

Clear.

See pump manual. In future, stop pump at bottom of stroke.

See Technical Data, page 61.

Clear.

Replace. See pump manual.

Check and repair. See pump manual.

Replace. See pump manual.

Check solenoid connections to valves. See pump manual.

Pump operates erratically.

Exhausted ﬂuid supply. Reﬁll and reprime pump.

Held open or worn dosing valves.

Worn piston packing.

Check and repair. See pump manual.

Replace. See pump manual.

10 332709B

Troubleshootin

g

Error Code Tro

System errors alert you of a problem and help prevent off-ratio spraying. There are three types: Advisory, Deviation, and Alarm.

An Advisory r clear itself

A Deviation records an error in the system but does not shut down the equipment. The deviation must be acknowledged by the user.

If an Alarm occurs, operation stops.

If any of th

• Alarm buzzer sounds (unless in silent mode).

• Alarm popup screen shows the active alarm code.

• Status bar on the Advanced Display Module shows the active alarm code.

• Alarm is saved in the date/time stamped log.

Code

B9A0 Advi-

ecords an event in the system, and will

after 60 seconds.

e three types occur:

Type Description Problem

sory

ubleshooting

Volume Rollove Current

Batch counter for

rA

material A rolled over.

NOTE: When an error occurs be sure to determine the code before resetting it. If you forget which code occurred, the Errors screen displays the 200 most recent errors, with date, time, and description.

NOTE: In some is shown as th applicable display wil last digit i

Cause Solution

The tota reached capable starte

error codes listed below, a # symbol

e last digit. This symbol represents the

pump number, which can vary. The unit’s

l show the applicable pump number as the

n the code.

lizer has

maximum

value and

doveratzero.

n/a

B9AX Advi-

sory

B9B0 Advi-

sory

B9BX Advi

sory

B9D#

Advisory

-

Volume Rollover A Lifetime

Volume Rollover B Current

me

Volu

over B

Roll

time

Life

Volume Rollover Pump #

Grand total counter for material A rolled over.

counter for

Batch

ial B rolled over.

mater

Grand total counter for material B rolled over.

Grand total counter for pump # rolled over.

The totalizer has reached maximum capable value and started over at zero.

otalizer has

The t

hed maximum

reac

ble value and

capa

ted over at zero.

star

The totalizer has reached maximum capable value and started over at zero.

n/a

332709B

11

Troubleshootin

g

Code

B9S0

B9SX

CAC#

CA0X

CADX

Type Description Problem

Advisory

Alarm

Volume Rollover Solvent Current

Volume Rollover Solvent Lifetime

Comm. Error Color Change #

Comm. Error ADM

Comm. Error Fluid Module

Batch counter solvent rolle

Grand total counter for solvent rolled over.

System does not detect the Color Change Module #.

System does not detect the Advanced Display Module.

System does not detect the Enhanced Fluid Control Module (EFCM).

for

dover.

Cause Solution

The totalizer has reached maximum capable value and started over at zero.

The totalize reached maxi capable valu started over

This communication error indicates that the network has lost communication with the Color Change Module #.

This comm error ind the Netwo communic the Adva Module.

This communication error indicates that the Network has lost communication with the EFCM.

r has

mum

eand

at zero.

unication

icates that

rk has lost ation with

nced Display

n/a

Check CAN cable connections to the Color Change Module # and any interconnected modules.

Check CAN cable connecting ADM to the EFCM.

Check CAN cables connecting ADM to the EFCM. Replace Cable or EFCM as necessary.

CDC#

Alarm Duplic

Color Chang

ate

e#

System detects two or more identical Color Change Modules.

More than one Color Change Module with the same address is connected in the system .

Check the system and remove the extra color change module. Re-address one of the color change boards.

2

1

332709B

Troubleshootin

g

Code

CDDX

DA0#

DE0#

Type Description Problem

Alarm Duplicate

Fluid Module

Alarm Exceeded

Max Flow Pump #

Alarm Leak

Detecte Pump #

System sees tw or more identi Enhanced Flui Control Modul EFCM).

Pump was driven to its maximum allowed speed.

This is a

d

test fai pump can pressur

Test Pressure.”

“Stall

ult after 30

Will fa second

o

cal

d

es

manual stall

lure when the

not build

etothetarget

s.

Cause Solution

tating,

thout

FCM

nthe

Check the syst and remove the EFCM.

Inspect system for leaks.

Verify that the pump is being supplied with material.

Reduce nozzle size to create more restriction. Reduce paint pressure to lower the ﬂow rate.

Make sur and down line are

al.

materi

Determine if leak is external or internal by visually inspecting the system for ﬂuid leakage. Fix all loose or worn hoses, ﬁttings, and seals. Inspect all valve seats and needles for wear, and replace worn piston or throat seals.

More than one E is connected i system.

System has a leak or open valve that is allowing unrestricted ﬂow.

Pump is cavi cycling wi restricti

Viscosit too thin f

No mater pump or l

Leak in the system.

on.

y of material is

or nozzle size.

ial in the ine.

em

extra

e the pump

stream color

loaded with

DF0#

Alar

m

No Stall Up Pump #

Pump failed the stall test; did not stall on the upstroke.

Valve failure, seal failure, worn rod or cylinder.

ace inlet and

Repl

let valve and

out

l for up stroke.

sea

lace piston and

Rep

oat seals. Replace

thr

and cylinder as

rod

cessary.

ne

332709B 13

Troubleshootin

g

Code

DG0#

DH0#

DK0#

EAUX Advi-

Type Description Problem

Alarm

Alarm Position

sory

No Stall Down Pump #

No Stall Pump #

Pump #

USB Busy USB driv

Pump failed th test;didnots downstroke.

Pump failed the stall test; did not stall on either the upstroke or the downstroke.

The pump was detected to be out of position.

d, download is

inserte in progr

estall

tall on the

e has been

ess.

Cause Solution

Valve failure failure, worn cylinder.

Valve failure, seal failure, worn rod or cylinder.

Indicat is uploa downloa

,seal

rod or

es USB port

ding or

ding data.

Replace inlet and outlet valve and seal for down stroke. Replace piston and throat seals. Replace rod and cylinder as necessary.

Replace inle outlet valv for up and do strokes. Re piston and t seals. Rep rod and cyl necessary

Re-enable pump power to reset pump. Make sure inlet supply pressure is not too high.

Wait for

t and

e and seal

wn

place

hroat

lace

inder as

.

USB Idle.

EB00 Record

EBH#

EBUX Record

EC00

Recor

ord

Rec

d

Stop Button Pressed

Home

ete

Compl Pump #

USB drive was removed.

Setup Value(s) Changed

Recordofastopbutton press.

Record of pump homing is complete.

USB drive was removed while downloading or uploading.

Record of changing setup variables.

Indicates system stop key on ADM was pressed.

ication on the

An ind

ay that the pump

displ

eted the home

compl

ion

funct

Downloading/uploading data on USB was interrupted by the USB device being removed.

icates date and time

Ind

n setup values

whe

e changed.

wer

n/a

ion required.

No act

Replace the USB device and begin process again.

n/a

4

1

332709B

Troubleshootin

g

Code

EF0#

EF1#

Type Description Problem

Alarm Timeout

Startup Pump #

Alarm Timeout

Shutdown Pump #

Pump tried but was not able to move to the home position within a speciﬁed amount of time.

Pump tried but was not able to move to the park position within a speciﬁed amount of time.

Cause Solution

Pump dose valves did not actuate.

Motor could not drive pumps and linear actuator.

Pump stroke length is shortened by mechanical system tolerance.

Pump dose valves did not actuate.

Pump is ﬁ thick pa not driv end of s or driv damage

lled with

int and could

epistonto

troke. Motor

eiswornor

d.

Verify air pre to solenoid va Verify the val actuating.

Verify motor is driving the pump.

Verify corr assembly of actuator an piston rod manual.

Visually inspect valves to ensure they are operating properly; verify they have air pressure above 85 psi (0.6 MPa, 6.0 bar).

Observe drive as verify t genera

ssure

lves.

ves are

ect

linear

d pump

s. See pump

motor and

sembly to

hat the motor is

ting force.

EL00 Record

EM00 Record

EMIX Advi

0

EQU

EQU1

-

sory

Advisory

Record

System Power On

em

Syst

rOff

Powe

Pump Off

Idle

USB

USB Sys. Settings Downloaded

Record of power cycle (ON).

rd of power cycle

Reco

).

(OFF

umps are not

The p

red and are

powe

le to move.

unab

download

USB

ocess completed,

pr

ive may be removed.

dr

Settings were downloaded to USB drive.

Indicates date and time when system was started.

Indicates date and time when system was turned off.

power was

Pump

ed off or an error

turn

rred.

occu

atransferis

Dat

mpletedtotheUSB

co

vice.

de

User installed USB device in ADM USB port.

n/a

Start pumps by pressing pump start key on Advanced Display module.

ove USB device

Rem

om ADM.

fr

n/a

332709B 15

Troubleshootin

g

Code

EQU2

EQU3

EQU4

EQU5

ES00

EVUX Advi-

F1F#

Type Description Problem

Record

Advisory

sory

Alarm Flow Low

USB Sys. Settings Uploaded

USB Custom Lang. Downloaded

USB Custom Lang. Uploaded

USB Logs Downloaded

Factory Defaults

USB Disabled

Fill Pump #

Settings were uploaded from drive.

Custom Language was downloaded to USB drive.

Custom Language was uploaded from USB drive.

Data logs were downloaded to USB drive.

Record of defaults being loaded.

USB drive has been inserted, downloading is disabled.

There has been no/low ﬂow during a ﬁll pump operation.

USB

Cause Solution

User installe device in ADM U port.

User installed USB device in ADM USB port.

User inst device in port.

Conﬁguration of system is blocking data transfer.

There is a restriction on the outlet side of the pump or color stack.

dUSB

SB

alled USB

ADM USB

n/a

Change conﬁguration to enable USB download function.

Make sure there are no restrictions in the color stack and that thedumpvalveis actuating.

F1S#

F#

F6

Alarm Flow Low

Purge Pump #

Alarm Press.

Sens. Removed Inlet #

There has been no ﬂow or low ﬂow during a pump purge operation.

No inlet pressure transducer is detected when the system is expecting one.

k viscosity

Thic

t requires more

pain

sure to pump.

pres

Restriction in the outlet side of the pump or color stack resulting in the solvent ﬂow being too low.

Disconnected transducer.

ease non-mix

Incr

sure if necessary

pres

eate ﬂow during

to cr

ll function.

the ﬁ

Make sure there are no restrictions in the system. Increase non-mix pressure if necessary to create ﬂow during the purge function.

rify transducer

Ve

connected

is

roperly. Replace if

p

econnecting does not

r

liminate the alarm.

e

16 332709B

Troubleshootin

g

Code

F7D#

F7S1

F7S2

F8D1 Alarm Flow Not

Type Description Problem

Alarm Flow

Detected Pump #

Alarm Flow

Detected Solvent Gun

Alarm Flow

Detected Solvent Mix

Detected

Thepumpﬂow exceeded 20 cc ﬂow coming int mode.

One of the solvent ﬂow switches is indicating unexpected solvent ﬂow.

The system detects both solvent ﬂow switches open at the same time.

No Flow while mixing.

/min

oIdle

Cause Solution

There is a leak in the system or the gun was open when the system went into Idle mode.

Solvent ﬂow switch is stuck in ﬂow position.

There is a le the solven valve.

The EFCM is damaged.

One or bo solvent are stuc positio

Restriction in the outlet side of the pump or color stack.

ak through

t cutoff

th of the

ﬂow switches

kintheﬂow

n.

Verify there a leaks in the sy Make sure the a switch is actu properly. Do trigger the g atomizing ai

Clean or replace switch.

Check for leaks and repair valve.

Unplug both connectors on the EFCM.Ifalarmclears, replace the EFCM.

Clean or switch.

Make sure there are no restrictions in the system.

re no

stem.

ir ﬂow

ating

not un without r.

replace

F9D#

MMUX Advi

F#

P1

P2F#

P3D#

Alarm Flow

sory

Alarm Pressure

De

on

ti

Deviation

-

via-

Unstable Pump #

Maint. USB Logs Full

Low Inlet Pump #

essure

Pr

wInlet

Lo

ump #

P

Pressure High Outlet Pump #

Thepumpﬂowrate did not stabilize while entering Idle mode.

USBmemoryismore than 90% full.

The inlet pressure on pump # is less than the user-entered alarm limit.

e inlet pressure on

Th

mp # is less than the

pu

ser-entered deviation

u

imit.

l

The outlet pressure on pump # is greater than the user entered deviation limit.

tﬂowrateisset

Targe

o.

to zer

Potential leak in the system.

Conﬁguration parameter on system is enabled to generate this advisory.

arget ﬂow rate.

Set a t

Check the system for leaks and run manual stall test.

Complete download to ensure no data is lost.

Increase inlet pressure.

crease inlet

In

essure.

pr

Relieve system pressure.

332709B

17

Troubleshootin

g

Code

P3F#

P4D#

P4F#

P6D#

P9D#

Type Description Problem

Deviation

Alarm Pressure

Alarm Press.

Pressure High Inlet Pump #

High Outlet Pump #

High Inlet Pump #

Sens. Removed Outlet #

Sens. Failed Outlet #

The inlet pressure on pump # is greater than the user-entered deviation limit.

The outlet pr pump # is grea the user ente limit.

The inlet pressure on pump # is greater than the user-entered alarm limit.

No outlet pressure transducer is detected when the system is expecting one

Outlet pressure transducer has failed.

essure on

ter than

red alarm

Cause Solution

Decrease inlet pressure.

Relieve syst pressure.

Decrease inlet pressure.

Disconnected transducer.

Outlet pressure transducer has failed orthepressureis above the readable range.

Verify tra is connect properly reconnec eliminat

Relieve system pressure. Verify connections, or replace if reconnecting does not eliminate the alarm.

em

nsducer

ed

. Replace if

ting does not

e the alarm.

P9F#

QADX

QBDX

Alarm Press.

Sens. Failed Inlet #

Alarm

Differential Pressure A Over B

Differential Pressure B Over A

Inlet pressure transducer has failed.

Low differential pressure. This alarm is active only during Mix mode.

High differential pressure. This alarm is active only during Mix mode.

Inlet pressure transducer has failed orthepressureis above the readable range.

isaleakonthe

There

.

Bside

The B side pump is cavitating.

There is a leak on the Aside.

he A side pump is

T

avitating.

c

Relieve system pressure. Verify connections, or replace if reconnecting does not eliminate the alarm.

Check the system for internal and external leaks on all catalyst manifolds and plumbing.

ck paint supply on

Che

B side, increase

the

nt supply pressure.

pai

Check the system for internal and external leaks on all color manifolds and plumbing.

Check paint supply on the A side, increase paint supply pressure.

18 332709B

Troubleshootin

g

Code

QPD1

SND1

SPD1

Type Description Problem

Deviation

Alarm Mix Fill

Alarm

Potlife Expired

Incomplete

Gun Pur Incomp

ge

lete

Potlife time h expired befor system has mov the required a of material ( volume) thro mixed materi

The system timed out before the mix ﬁll cycle loaded the gun with mixed material.

The system timed out without reaching the user-speciﬁed volume of solvent for a purge.

as

ethe

ed

mount

potlife

ugh the

al line.

Cause Solution

Purge process was not completed.

Solvent supply shut off or empty.

Mix manifold not set to spray position.

Spray gun was not triggered.

Restrictions in mixer, manifold, or spray gun.

Target ﬂow rate is set to zero.

Solven workin

Solvent ﬂow is too low to actuate the solvent switch.

t ﬂow switch not

g.

Make sure purge process is completed.

Verify solvent supply is available and on, supply valves are open.

Set manifold to spray.

Allow ﬂow through gun during ﬁll process until the ﬁll complete LED stops ﬂashing.

Fix restrictions.

Set a target ﬂow rate.

Replace switch.

Increase solvent pressure to drive a high purge ﬂow rate

i-

WSUX

WX00 Alarm

XUD

W

WXUU Advi-

Adv sor

dvi-

A

ory

s

sory

y

USB Conﬁg. Err.

ftware

So

rrors

E

USB Download Err.

USB Upload Err.

USB conﬁguration ﬁle does not match expected, checked on startup.

An unexpected software error has occurred.

n error occurred

A

hile downloading to

w

he USB drive.

t

An error occurred while uploading from the USB drive.

Gun is not triggered. Operator must

continue ﬂushing for conﬁgured time, until the booth control indicates purge is completed.

Valve stuck or broken. Replace valve.

A software update was not completed successfully.

ser installed

U

ncompatible USB

i

evice in ADM USB

d

ort.

p

User installed incompatible USB device in ADM USB port.

Reinstall software.

ll Graco Technical

Ca

upport.

S

epeat process with

R

ompatible USB

c

evice.

d

Repeat process with compatible USB device.

332709B 19

Troubleshootin

Maintenance Error Codes

g

Perform the re

Code

END#

ENS0

ENT#

MAD#

MAT#

MEB#

MED#

MEF#

MEG#

MES#

MFF#

MFS0

quired maintenance if the following codes occur.

Type Name Description

Record

Advisory

ry

Adviso

Advisory

sory

Advi

Calibration P

Calibration Solvent Meter

Calibration Stall Test Pump #

Maint. Out

Maint. Stall Test Pump #

Maint. Valve Catalyst (B) #

Maint. V

Maint. Valve Inlet #

Maint. Valve Gun #

.ValveSolvent

Maint #

Maint. Meter Flow # Maintenance is due on ﬂow meter.

Maint. Meter Solvent

ump #

let Pump #

alve Outlet #

A calibration test was run on the pump.

A calibration test was run on the solvent meter.

A stall test was completed successfully on pump #.

Maintenance is due on pump.

Maintenance stall test is due on pump.

Maintena

Maintenance is due on outlet valve.

Maintenance is due on inlet valve.

Mainte

Maintenance is due on solvent valve.

tenance stall test is due on solvent meter.

Main

nce is due on catalyst valve.

nance is due on gun valve.

MGH

MGP0

0

Advisory Maint. Filter Fluid

Advisory Maint. Filter Air

ntenance is due on ﬂuid ﬁlter.

Mai

Maintenance is due on air ﬁlter.

20 332709B

Power Barrier Board Diagnostics

Troubleshootin

g

Figure 7 Power Barrier Board

Table 1 . Power Barrier Board Diagnostics

ID

D4

D5

F3 Fuse, 400 mA, 250 V

F4 Fuse, 400 mA, 250 V

J4

J5

Component or Indicator

LED (green) IS Power

LED (green)

Connector

Connector +12 Vdc intrinsically safe power output

332709B

Function

Power

If either F3 or F4 is blown, there is no power to the IS location. D4 is out.

24 Vdc power input

21

Troubleshootin

g

Isolation Board Diagnostics

Figure 8 Isolation Board

Table 2 . Isolation Board Diagnostics

ID

D6

D7

D8

D14

J1

J2

J3

4

J

S1 Pushbutton Switch For Non IS connectors. If switch S1 is off, yellow LED (D14) is

S2 Pushbutton Switch For Intrinsically Safe connectors. If switch S2 is off, yellow LED

Compo

LED (yellow) IS Communication

LED (green) IS Power

LED

LED (yellow) Non-IS Communication

Connector Non-IS, Gateway

Co

Connector Intrinsically Safe, Barrier Board

Connector Intrinsically Safe, Optional Color Change Module

nent or Indicator

(green)

nnector

Function

-IS Power

Non

n-IS, Optional Color Change Module

No

steady on. Push switch to turn switch on.

(D6) is steady on. Push switch to turn switch on.

2

332709B

Troubleshootin

g

Enhanced Flui

Figure 9 Enhanced Fluid Control Module

Table 3 . Enhanced Fluid Control Module Diagnostics

d Control Module (EFCM) Diagnostics

ID

1 25 pin connector Pump 1 Module

2 25 pin connector Pump 2 Module

3 25 pin connector

4 25 pin connector

5

6 12 pin connector

7

8 5 pin connector

9 5 pin connector Advanced Display Module

10 5 pin connector 24 Vdc Input

CPLD (D37) LED (orange)

POW (D19) LED (green)

CAN (D69) LED (yellow) Communication.

ERR (D38) LED (red) Blinks an error code. If the LED is on steady,

Component or Indicator

12 pin connector

Function

Pump 3 Module (accessory)

Pump 4 Module (accessory)

Multiple purpose I/O

24 Vdc Power/CAN (Communication Barrier)

Heartbeat

Power

the system is down. Cycle power.

332709B 23

Troubleshootin

g

Pump Module Diagnostics

Figure 10 Pump Module

Table 4 . Pump Module Diagnostics

ID

1 25 pin connector

2 5 pin connector Pump connection

3 5 pin connector Motor encoder connection

4 5 pin connector Pump Inlet Transducer

5

6 4 pin connector Not used

7 8 pin connector

8 4 pin connector

9

10

11

24V

48V

Component or Indicator

5 pin connector

LED (red) Pump Up Valve Output

LED (red) Pump Down Valve Output

LED (red)

LED (green)

Function

Input from EFCM

Pump Outlet Transducer

Dose Valve Solenoids

48 Vdc Input Power and fan connection

Not used

24 Vdc power supplied

48 Vdc power supplied

4

2

332709B

Advanced Display Module Diagnostics

Troubleshootin

g

Figure 11 Advanced Display Module

Table 5 . Advanced Display Module Diagnostics

ID

D1

D6

J1 8 pin connector Token port

J2 8 pin

J3 5 pin connector

J7 5 pin connector

Compone

LED (yellow/green) Green: USB inserted

LED (red/yellow/green) Green: Power

nt or Indicator

connector

Function

Yellow

Yello

Red: Error

USB port

Lig

CAN power/communication port

: USB communication

w: Communication

ht tower (accessory)

332709B 25

Notes

26 332709B

Electrical Sche

matics

Electrical Sc

hematics

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 33 for a list of cable options.

RELAY

(16U820)

16W159

BREAKOUT MODULE PUMP 2

BREAKOUT MODULE PUMP 4

POWER MODULE

(24R257)

16W159

(24N527)

SPLITTER

(16P243)

4

CABLE (16T659) CABLE (16T659) CABLE (16T659) CABLE (16T659)

(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

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 12 Electrical Schematic, Sheet 1

INTEGRATION

GATEWAY

3

AWI

GATEWAY

(24R910)

CABLE (15V206)

2

CABLE

3

16T072

CAN

IS BOARD

(24M485)

CABLE

(16T280)

BARRIER

BOARD

(248192)

065161, 065159

5

CABLE

(121227)

5

(121227)

CABLE 3

(121001)

6

(24N935)

MODULE 1

COLOR CHANGE

CABLE

2

(15V206)

GCA

MODULE

EFCM

(24N913)

FLOW RATE ANALOG IN

1

CABLE (16V429)

2

CABLE

(15V206)

6

(24N935)

MODULE 2

COLOR CHANGE

FLOW RATE ANALOG IN

2

CABLE

(15V206)

6

(24N935)

MODULE 3

COLOR CHANGE

CABLE

2

(15V206)

GUN TRIGGER INPUTS

119159 119159 119159 119159

SOLENOID (121324)

PRESSURE SW (121323)

SOLVENT CUTOFF (121324)

SWITCH (120278)

SOLVENT METER (258718)

SAFETY INTERLOCK SWITCH

3

ADVANCED

CABLE

DISPLAY MODULE

(121003)

CABLE

1

(24N935)

MODULE 4

MODULE 5

CATALYST CHANGE

CABLE

2

(15V206)

(24E451)

COLOR CHANGE MODULE 7

(24R219)

COLOR CHANGE MODULE 8

(24R219)

(16V426)

BOOTH CONTROL (24M731)

HAZARDOUS LOCATION

NON-HAZARDOUS LOCATION

INTERFACES

SOLVENT

6

MODULE 6

CATALYST CHANGE

GFB

FLOW

INPUTS

LIGHT

TOWER

(15X472)

7

(24N935)

CABLE

1

(16V426)

332709B

27

Electrical Sche

matics

SPLITTER

(16P243)

UNUSED

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

345

24V

2

1

UNUSED

GRND (GRN/YEL)

N (BLUE)

CABLE (16V429)

1

CONTINUED ON PAGE 3

2

3

CABLE

(15V206)

1 2 3 4 5

CAN IS BOARD

2

(NON IS)

(IS)

4

(24M485)

1 2 3 4 5

UNUSED

1 2 3 4 5

CABLE

(16T280)

1 2 3 1 2 3

BARRIER

BOARD

(248192)

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)

CABLE (121227)

16T072

1 2 3 4 5

1

3

UNUSED

RED WIRE (065161)

BLACK WIRE (065159)

1 2 3 4 5 1 2 3 4

(24R257)

POWER MODULE

3

DRAIN/FOIL

CABLE

1 2 3 4 5

P3

GATEWAY

(24R910)

1 2 3

P4

4 5

AWI

(121227)

3

1 2 3

P3

4 5

INTEGRATION

5

GFB INTERFACE

(121324)

SOLVENT CUTOFF (121324)

SOLVENT

METER

(258718)

PWR (RED) SIG (WHITE) COM (BLACK) SHIELD/GRN

GROUND BAR

BREAKOUT MODULE PUMP 1 (24N527)

2

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 1

SEE DETAIL A OR B

3

1 2 3 4 5 1 2 3 4 5 1 2

TWISTED PAIR CABLE (16W159)

5

4

PUMP 1

(16P289 OR 16P290)

INLET TRANSDUCER

(16P289 OR 16P290)

OUTLET TRANSDUCER

DETAIL B, HIGH PRESSURE PUMPS (24M707, 24M715)

BREAKOUT MODULE

2

1 2 3 4 5 1 2 3 4

GATEWAY

5

6

1 2 3 4

(24N527)

WIRE HARNESS

(24P685)

1 2 3

P4

4 5

+12VDC COM UNUSED UNUSED +12VDC COM +12VDC COM

UNUSED

PUMP 1

+24VDC

V/P FOR FLUID REG.

PUMP 1

MANIFOLD

UNUSED UNUSED

UNUSED

CABLE

(121001)

3

1

7

3 4

5 6 7 8

COM

+24VDC

UP

DOWN

PUMP 1

G3000 METER PUMP 1

(EITHER, 239716,

258718,16M510,

OR 16M519)

(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

+48V

COM

PWR (RED)

SIG (WHITE)

COM (BLACK)

SHIELD/GRN

GRND SCREW

DRAIN/FOIL

CONTINUED ON PAGE 3

GCA MODULE

EFCM

(24N913)

12

4

252423222120191817161413121110 15987654321

BREAKOUT MODULE PUMP 2 (24N527)

2

1 2 3 4 5 1 2 3 4

+48V

COM

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 2

SEE DETAIL A OR B

(24P658)

FAN PUMP 1

252423222120191817161413121110 15987654321 252423222120191817161413121110 15987654321

3

1 2 3 4 5 1 2 3 4 5 1 2

4

PUMP 2

(16P289 OR 16P290)

INLET TRANSDUCER

5

PUMP 2

OUTLET TRANSDUCER

TWISTED PAIR CABLE (16W159)

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

+24VDC

UP

DOWN

PUMP 2

MANIFOLD

(16P812 QTY 2)

MAC SERIES 46

7

5 6 7 8

METER

PUMP 2

(EITHER, 239716,

258718,16M510,

PWR (RED)

SIG (WHITE)

COM (BLACK)

G3000

OR 16M519)

SHIELD/GRN

GRND

SCREW

1 2 3 4

+48V

88

COM

+48V

FAN PUMP 2

252423222120191817161413121110 15987654321

COM

(24P658)

DRAIN/FOIL

UNUSED UNUSED

UNUSED

UNUSED UNUSED

UNUSED

UNUSED UNUSED

POWER IN

UNUSED

DRAIN/FOIL

1 2 3 4 5 6 7 8 9

PUMP ENCODER AND MOTOR

MOTOR MOUNTING SCREW

UNUSED

UNUSED UNUSED

UNUSED

12

11

10

(16P037)

UNUSED

1 2 3 4 5 6 7 8 9

UNUSED

UNUSED UNUSED UNUSED

UNUSED

12

11

1 2

MOTOR MOUNTING SCREW

1 2 3 4 5 6 7 8 9

PUMP ENCODER AND MOTOR

10

(16P036)

1 2 3 4 5 6 7 8 9

UNUSED

10

Figure 13 Electrical Schematic, Sheet 2, Part 1

CONTINUED ON THE NEXT PAGE

28 332709B

GUN TRIGGER INPUTS

SIG

1

COM

2

SIG

3

COM

4

SIG

5

COM

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 SIG COM SIG COM

CABLE

(121003)

3

GCA MODULE

EFCM

(24N913)

34

252423222120191817161413121110 15987654321 252423222120191817161413121110 15987654321

119159

GFB PRESSURE SWITCH (121323) SOLVENT FLOW SWITCH 1 (120278)

SOLVENT FLOW SWITCH 2 (120278) SAFETY INTERLOCK SWITCH

1

ADVANCED

2

DISPLAY MODULE

3 4

(24E451)

5

Electrical Sche

1 2 3 4 5

LIGHT

TOWER

(15X472)

matics

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

UP

PUMP 3

MANIFOLD

(16P812 QTY 2)

MAC SERIES 46

7

COM

DOWN

5 6 7 8

PWR (RED)

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 14 Electrical Schematic, Sheet 2, Part 2

CONTI

NUED ON THE NEXT PAGE

SIG (WHITE)

COM (BLACK)

SHIELD/GRN

GRND

SCREW

25 PIN D-SUB CABLE

(16T659)

8

1 2 3 4

+48V

COM

(24P658)

FAN PUMP 3

4

2

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

V/P FOR FLUID REG.

PUMP 4

3 4

COM

+24VDC

UP

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

8

COM

FAN PUMP 4

+48V

COM

(24P658)

332709B 29

Electrical Sche

matics

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

+12VDC +12VDC +12VDC

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC +12VDC +12VDC

COM COM COM

1 2 3 4 5 6

2

1 2 3 4 5 6

FROM CAN IS BOARD (24M485) ON PAGE 2

2

345

1

COLOR

CHANGE

MODULE 1

(COLORS

6

1 THRU 8)

J8

J15

J14

1

2

6

J16

J10

345

COM

5

+12VDC

4

COM

J9

3

+12VDC

2

COM

1

+12VDC

6

COM

5

+12VDC

4

COM

3

+12VDC

2

COM

1

+12VDC

6

COM

5

+12VDC

4

COM

3

+12VDC

2

COM

1

+12VDC

CABLE

J8

J15

J14

2

345

1

COLOR

CHANGE

MODULE 2

(COLORS

9 THRU 16)

6

2

345

1

J16

J10

J9

(15V206)

6 5 4 3 2 1

COM +12VDC COM +12VDC COM +12VDC

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

COM +12VDC COM +12VDC COM +12VDC

COM +12VDC COM +12VDC UNUSED UNUSED

UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED

MANIFOLD

DUMP CATALYST 1 CATALYST 2

CATALYST 3 CATALYST 4

6 5 4

J9

3 2 1

6 5 4 3 2 1

2

*FLUSH COLOR 17 COLOR 18

COLOR 19 COLOR 20 COLOR 21

COLOR 22 COLOR 23 COLOR 24

MANIFOLD

+12VDC

COM

+12VDC

COM

+12VDC

COM +12VDC +12VDC +12VDC

+12VDC

COM +12VDC

COM

COM COM COM

CABLE

1

17 THRU 24)

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 3

(COLORS

6

4

5

3

2

J9

J16

J10

1

(15V206)

6 5 4 3 2 1

COM +12VDC COM +12VDC COM +12VDC

Figure 15 Electrical Schematic, Sheet 3

* 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

CABLE

2

1

COLOR

CHANGE

MODULE 4

(COLORS

25 THRU 32)

J8

J15

J14

2

1

345

6

345

J16

J10

J9

(15V206)

6 5 4 3 2 1

COM +12VDC COM +12VDC COM +12VDC

COM +12VDC UNUSED UNUSED UNUSED UNUSED

MANIFOLD

DUMP* COLOR 25 COLOR 26

COLOR 27 COLOR 28 COLOR 29

COLOR 30

30 332709B

FLUSH CATALYST 3 CATALYST 4

FLUSH

CATALYST 1 CATALYST 2

MANIFOLD

+12VDC

COM

+12VDC

COM

+12VDC

COM

UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED

+12VDC

COM

+12VDC

COM

+12VDC

COM

UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED

1 2 3 4 5 6

22

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

6 5 4 3 2 1

(15V206)

6 5 4 3 2 1

COM +12VDC COM +12VDC COM +12VDC

UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED

COM +12VDC COM +12VDC COM +12VDC

UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED

MANIFOLD

Electrical Sche

DUMP CATALYST 3 CATALYST 4

DUMP CATALYST 1 CATALYST 2

matics

Figure 16 Electrical Schematic, Sheet 3, Alternate Conﬁguration for Catalyst Change Control

INUED ON THE NEXT PAGE

CONT

2

CABLE

2

345

1

COLOR

CHANGE

MODULE 4

(COLORS

25 THRU 32)

(15V206)

332709B 31

Electrical Sche

matics

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

+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 +12VDC +12VDC

+12VDC

COM +12VDC

COM

COM COM COM

1 2 3 4 5 6

1 2 3

J15

4 5 6

1 2 3 4

J14

5 6

1

1 2 3 4 5 6

2

345

1

COLOR

CHANGE

MODULE 7

(COLORS

33 THRU 40)

J8

7

2

345

1

CABLE

2

345

1

COLOR

CHANGE

MODULE 8

(COLORS

41 THRU 48)

J8

7

J15

J14

5

3

4

J16

J10

J16

J10

2

J9

1

6 5 4 3 2 1

(16V426)

6 5 4 3 2 1

NON-HAZARDOUS LOCATION

HAZARDOUS LOCATION

MANIFOLD

COM +12VDC COM +12VDC COM +12VDC

MANIFOLD

COM +12VDC COM +12VDC COM +12VDC

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 17 Electrical Schematic, Sheet 3, Hazardous Location

32 332709B

Electrical Sche

matics

Optional Cabl

NOTE: The total length of all cable used in the system must not exceed 150 ft (45 m). See the

Electrical Schematics, page 27.

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 N

16V423

16V424

16V425

16V426

16V427

16V428

16V429

16V430

M12 CAN Ca

15U531

15U532

15V205

15V206

15V207

15V208

15U533

15V213

CAN Cables, for Non-Hazardous

Part No.

Cable

125306

123422

121000

121227

121001

121002

121003

120952

121201

121004

121228

es and Modules

o.

Location

Locations Only

Length ft (m

2.0 (0.6)

3.0 (1.0)

6.0 (2.0)

10.0 (3.0)

15.0 (5.0)

25.0 (8.0)

50.0 (16.

100.0 (32

bles, for Non-Hazardous

sOnly

2.0 (0.6)

3.0 (1.0)

6.0 (2.0)

10.0 (3.0)

15.0 (5.0)

25.0 (8.0)

50.0 (16.0)

100.0 (32.0)

Lengt

1.0 (0

1.3 (0

1.6 (

2.0 (

3.0 (

5.0 (

10.0

13.

20.

25.

50.

0)

hft(m)

.3)

.4)

0.5)

0.6)

1.0)

1.5)

(3.0)

0 (4.0)

0 (6.0)

0 (8.0)

0 (15.0)

.0)

25 Pin D-SUB Cables, for Non-Hazardous

Locations Only

16T659

)

16V659

Alternates f

for Non-Haza

Module Part

CGMDN0*, DeviceNet CGMPB0*, Proﬁbus

CGMEP0*, Ethernet IP CGMPN0*, Proﬁnet

* You must purchase Map Token Kit 17C087 for usewiththesekits.

by Part Num

Module Par

24T557 2 color/2

24T558 4 color/4

24T559 6 color/6

24T560 8 color/

by Part Number (Factory Conﬁguration), for

24T571 2 color/2 catalyst

24T572 4 color/2 catalyst

24T573 6 color/2 catalyst

24T574 8 color/2 catalyst, 13–24

24T774 12 color/2 catalyst

24T775 4 color/4 catalyst

24T776 6 color/4 catalyst

24T777 8 color/4 catalyst

24T778 12 color/4 catalyst, 13–30

24T779 13–18 color

or Communication Module 24R910,

No.

Alternate

Non-Hazar

Alternates for Color Change Modules

s for Color Change Modules

ber (Factory Conﬁguration), for

tNo.

Hazardous Locations Only

2.5 (0.8)

6.0 (1.8)

rdous Locations Only

Module Part

dous Locations Only

Descripti

color

on

catalyst

8 catalyst

No.

332709B 33

Repair

Before Servi

• Servicing the electrical control box exposes you to high voltage. To avoid electric shock, turn off power at the main circuit breaker before opening the enclosure.

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

cing

1. Flush the system as explained in your PD2K Operation Manual if service time may exceed pot life time. Follow the

Pressure Relief Procedure, page 35 before

servicing ﬂuid components.

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

3. Shut off the power switch (P) at the electrical control box.

4. If servicing the electrical control box, shut off power at the main circuit breaker before opening the enclosure.

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

NOTICE

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

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

Figure 18 Control Box Power Switch

34 332709B

Repair

Pressure Reli

Follow the Pressure Relief Procedure whenever you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized ﬂuid, such as skin injection, splashing ﬂuid and moving parts, follow the Pressure Relief Procedure whenyoustopspraying and before cleaning, checking, or servicing the equipment.

ef Procedure

Without Color Change

NOTE: The following procedure relieves all ﬂuid and air pressure in the system. Use your control interface to issue the necessary commands to your system.

1. Turn off the supply pumps. Open the drain valve on the supply line ﬂuid ﬁlter to relieve pressure in the supply line.

NOTE: If your system does not include a drain valve on the supply line, command the system to Mix. Cycle the A and B dosing pumps a couple of times to drain the pumps through the spray device.

2. Command the system to Standby. Trigger the spray device to relieve pressure.

3. Flush the remote mix manifold and spray device.

4. Shut off the solvent supply pump. To relieve pressure, command the system to Purge and trigger the spray device. When the pressure is relieved, command the system to Standby to avoid getting a Purge Incomplete alarm.

5. If pressure remains in the solvent line between the solvent supply pump and the solvent valve:

• VERY SLOWLY loosen a ﬁtting to relieve

pressure gradually.

• Loosen the ﬁtting completely.

With Color Change

NOTE: The following procedure relieves all ﬂuid and air pressure in the system.

1. Turn off the s on the supply the supply li

If using an electrostatic gun, shut off the electrostatics before ﬂushing the gun.

2. Trigger the gun to relieve pressure. From Maintenance Screen 4 on the ADM, check the box in the ﬁeld labeled Gun for each color in the system.

3. Command the system to Purge. Hold the gun trigger open after the solvent valve shuts off to relieve all pressure.

4. Set the system to Recipe 0 to ﬂush the pumps and to purge to the spray device. When ﬂushing is complete the system will go to Standby.

5. Shut off the solvent supply pump. Set the system to Recipe 0 to ﬂush solvent from the pumps and to purge to the spray device. Command the system to Standby after just a couple of second, to avoid getting a Purge Incomplete alarm.

6. If pressure remains in the solvent line between the solvent supply pump and the solvent valve:

• VERY SLOWLY loosen a ﬁtting to relieve

pressure gradually.

• Loosen the ﬁtting completely.

7. Verify on the ADM Home Screen that neither pump is showing any pressure.

NOTE: If pressure remains in the solvent line between the solvent supply pump and the solvent valve, VERY SLOWLY loosen a ﬁtting to relieve pressure gradually.

upply pumps. Open the drain valve

line ﬂuid ﬁlter to relieve pressure in

nes. Do this for each color.

332709B 35

Repair

Repairing the

Replace the AD

To replace the Advanced Display Module, disconnect the cable from the module and remove the module from the bracket. Install the new module on the bracket and attach the cable.

Advanced Display Module (ADM)

M

3. Remove blue ke

4. Insert and pr into slot.

NOTE: There i token.

Figure 21 Insert Token

5. Turn the power switch back on. The red indicator light (L) will ﬂash until the new ﬁrmware is completely loaded.

6. Remove the token (T).

7. Replace the blue key token.

y token.

ess black upgrade token (T) ﬁrmly

s no preferred orientation of the

Figure 19 Replace the Advanced Display Module

Install Key Token or Upgrade Token

1. Shut off the PD2K power switch.

2. Remove the token access panel.

gure 20 Remove Token Access Panel

Fi

NOTE: The blue key token is required for proper operation.

8. Replace the token access panel.

36 332709B

Replace the Battery

A lithium battery maintains the ADM clock when the power is not connected.

Sparking can occur when changing the battery. Replace the battery only in a non-hazardous location, away from ﬂammable ﬂuid or fumes.

1. Turn off the PD2K power switch.

2. Remove the rear access panel.

Repair

Figure 22 Remove Battery Panel

3. Removetheoldbatteryandreplacewithanew

CR2032 battery.

4. Replace the rear access panel.

5. Turn the power switch on.

6. Dispose of the old battery according to your

federal, state, and local waste regulations.

332709B 37

Repair

Servicing the

Control Box

Replacing the Isolation Board

NOTICE

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

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

1. Follow the steps in Before Servicing, page 34.

2. Loosen the screws (124) and remove the enclosure cover (117).

3. Note the position of the isolation board cables. See the following table,

Electrical Schematics, page 27, and Figure 24.

Disconnect the cables from the isolation board (111). Remove the brackets (110).

4. Remove the screws (128) holding the isolation board (111) to the barrier cover (107). Remove the isolation board.

5. Install the new isolation board, using the screws (128).

6. Install the brackets (110). Reconnect the cables to the positions as noted above.

7. Turn on power at the main circuit breaker.

8. Turn on the control box power switch. Check that the two green LEDs (D7, D8) and two yellow LEDs (D6, D14) are on. See Figure 24.

9. Reinstall the cover (117) and tighten the screws (124).

Isolation Board Connector

J1 (non-intrinsically safe)

J2 (non-intrinsically safe)

J3 (intrinsically safe)

J4 (intrinsically safe) Optional IS Color

To reduce the risk of ﬁre or explosion, be certain that the barrier board is connected to J3, on the IS side of the isolation board. If connected incorrectly, the intrinsic safety of your system is compromised.

Cable Destination

Gateway Module

Optional Non-IS Color Change Module

Barrier Board

Change Module

Figure 23 Replacing the Isolation Board

38 332709B

Repair

Figure 2 Connect

4 Detail of Isolation Board Cable

ions

332709B 39

Repair

Replacing the Barrier Board

NOTICE

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

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

1. Follow the steps in Before Servicing, page 34.

2. Loosen the screws (124) and remove the enclosure cover (117).

3. Loosen the screws (125) and remove the barrier cover (107), leaving the isolation board (111) attached to the cover.

4. Note the position of the barrier board input and output cables. See

Electrical Schematics, page 27. Disconnect the

cables from the barrier board (106).

11. Reinstal (124).

l the cover (117) and tighten the screws

5. Remove the two screws (108), and the three screws (109), spacers (105), and lockwashers (104). Remove the barrier board (106).

6. Install the new barrier board, using the screws, spacers, and lockwashers.

7. Reconnect the cables to the barrier board, as noted above.

8. Install the barrier cover (1 (111).

9. Turn on power at the main circuit breaker.

10. Turn on the control box power switch. Check that the system is operating.

NOTE: The two green LEDs (D4, D5) on the barrier board will light if the board has power.

07) and isolation board

Figure 25 Replacing the Barrier Board

40 332709B

Repair

Replacing the Barrier Board Fuses

NOTICE

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

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

1. Follow steps 1–4 under

Replacing the Barrier Board, page 40.

2. Remove the fuse (F3 or F4) from its fuseholder.

3. Snap the new fuse (Graco PN 15D979) into the fuseholder.

4. Follow steps 7–11 under

Replacing the Barrier Board, page 40.

Replacing the Enhanced Fluid Control Module (EFCM)

9. Turn on the control box power switch. Check that the green is on, the orange and yellow LEDs are blinking, and the red LED is off.

NOTICE

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

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

1. Follow the steps in Before Servicing, page 34.

2. Loosen the screws (124) and remove the enclosure cover (117, not shown).

3. Note the position of the EFCM input and output cables. See Electrical Schematics, page 27. Disconnect the cables from the EFCM (139).

4. Loosen the screws (142) holding the EFCM to the enclosure. Remove the module.

5. Install the new EFCM, using the screws (142).

6. Reconnect the cables to the positions as noted above.

7. Turn on power at the main circuit breaker.

8. Load the software to the ADM. See

Install Key Token or Upgrade Token, page 36.

10. Reinstall the cover (117) and tighten the screws (124).

Figure 26 Replacing the EFCM Control Module

332709B

41

Repair

Replacing the 24 Vdc Power Supply

NOTICE

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

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

1. Follow the steps in Before Servicing, page 34.

2. Loosen the screws (124) and remove the enclosure cover (117, not shown).

3. Note the position of the power supply input and output wires. See Electrical Schematics, page 27. Disconnect the wires from the power supply (120).

4. Remove the screws (129) holding the power supply to the side of the enclosure. Remove the power supply.

7. Reinstall the (124).

8. Turn on power a

9. Turn on the con

NOTE: The gre the green pow and the 24V gr control mod

cover (117) and tighten the screws

er LED on the EFCM module (139),

ules (132) will light when operating.

t the main circuit breaker.

trol box power switch.

en LED on the barrier board (106),

een LED on each of the pump

5. Install the new power supply, using the screws (129).

6. Reconnect the wires to the positions as noted above.

NOTICE

Failure to follow the electrical schematic could result in damage to the electrical components.

Figure 27 Replacing the 24 Vdc Power Supply

2

4

332709B

Replacing the 48 Vdc Pump Power Supply

Repair

NOTICE

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

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

1. Follow the steps in Before Servicing, page 34.

2. Loosen the screws (124) and remove the

enclosure cover (117).

3. Note the position of the power supply input and

output wires. See Electrical Schematics, page 27. Disconnect the wires from the power supply (103).

4. Remove the screws (128) and washers (176)

holding the power supply din rail to the enclosure. Removetheentireassembly,mountedtothe din rail.

7. Reinstall the (124).

8. Turn on power a

9. Turn on the con

NOTE: The 48V green LED on each of the pump control modules (132) will light when operating.

cover (117) and tighten the screws

t the main circuit breaker.

trol box power switch. Press

to turn pump power on.

5. Install the new power supply assembly, using the screws (128) and washers (176).

6. Reconnect the wires to the positions as noted above.

NOTICE

Failure to follow the electrical schematic could result in damage to the electrical components.

Figure

28 Replacing the 48 Vdc Power Supply

332709B 43

Repair

Replacing a Pump Control Module

NOTICE

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

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

1. Follow the steps in Before Servicing, page 34.

2. Loosen the screws (124) and remove the enclosure cover (117).

3. Note the position of the pump control module cables. See Electrical Schematics, page 27. Disconnect the cables from the pump control module (132).

4. Remove the screws (143) and washers (177) holding the pump control module to the enclosure. Remove the pump control module.

5. Instal

6. Reconnect the cables to the positions as noted

l the new pump control module, using the

screws

above.

(143) and washers (177).

7. Turn on power a

8. Turn on the con the 48V green L each of the pum

NOTE: If the pumps do not work, recheck the wiring.

9. Reinstall the cover (117) and tighten the screws (124).

Figure 29 Replacing a Pump Control Module

t the main circuit breaker.

trol box power switch. Check that

ED and the 24V green LED on p control modules (132) are on.

4

332709B

Replacing a Communication Gateway Module

Repair

NOTICE

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

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

1. Follow the steps in Before Servicing, page 34.

2. Loosen the screws (124) and remove the enclosure cover (117).

3. Remove the screws (182b) holding the communication gateway module (CGM) to the module base. Remove the CGM. You do not have to disconnect the cables.

4. Install the new CGM (182a), using the screws (182b).

5. Turn on

power at the main circuit breaker.

6. Turn on the con the three stat

7. Reinstall the (124).

Figure 3 Module

0 Replacing a Communication Gateway

us indicator lights are green.

cover (117) and tighten the screws

trol box power switch. Check that

332709B 45

Repair

Replacing the Line Filter

NOTICE

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

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

1. Follow the steps in Before Servicing, page 34.

2. Loosen the screws (124) and remove the enclosure cover (117).

3. Note the position of the line ﬁlter input and output wires. See Electrical Schematics, page 27. Disconnect the wires from the line ﬁlter (115).

Figure 31 R

eplacing the Line Filter

4. Remove the screws (142) holding the line ﬁlter to the enclosure. Remove the line ﬁlter.

5. Install the new line ﬁlter, using the screws (142).

6. Reconnect the wires to the positions as noted above.

NOTICE

Failure to follow the electrical schematic could result in damage to the electrical components.

7. Reinstall the cover (117) and tighten the screws (124).

8. Turn on power at the main circuit breaker.

46 332709B

Replacing the Power Switch

Repair

NOTICE

Failure to follow the electrical schematic could result in damage to the electrical components.

NOTICE

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

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

1. Follow the steps in Before Servicing, page 34.

2. Loosen the screws (124) and remove the

enclosure cover (117).

3. Note the position of the power switch input and

output wires. See Electrical Schematics, page 27. Disconnect the wires from the power switch (112).

4. Remove the switch terminal blocks (T), unscrew

the retaining nut (N), and remove the switch.

5. Install the new switch.

6. Reconnect the wires to the positions as noted

above.

7. Reinstall th (124).

8. Turn on powe

Figure 32 Replacing the Power Switch

e cover (117) and tighten the screws

r at the main circuit breaker.

332709B

47

Repair

Servicing the

Fluid Section

RemovingaPump

1. Follow the steps in Before Servicing, page 34.

2. Remove the screws (56) holding the cover (8) to the front of the unit.

3. Disconnect the cable from the pump driver (101).

4. Disconnect the air lines from the dosing valves (V).

5. Disconnect the ﬂuid inlet and outlet lines from the pump manifolds (IN, OUT).

6. Remove the screws (15) and pump bracket (7).

7. Loosen the jam nuts holding the pump to the mounting bracket (4). Remove the pump.

8. See manual 332339 to repair the pump.

Installing a Pump

1. Slide the pump into the mounting bracket (4). Tighten the jam nuts to secure.

2. Install the pump bracket (7) and screws (15).

3. Connect the ﬂuid inlet and outlet lines to the pump manifolds (IN, OUT).

4. Connect the air lines to the dosing valves (V).

5. Connect the cable to the pump driver (101).

6. Install the cover (8) to the front of the unit with the screws (56).

7. Open the main air shutoff valve on the air supply line.

8. Restore power to the unit. Turn on the power switch at the electrical control box.

Figure 33 Installing a Pump

48 332709B

Replacing a Solenoid

NOTICE

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

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

1. Follow the steps in Before Servicing, page 34.

2. Remove the screws (56) holding the cover (8) to the front of the unit.

3. Loosen the screws (124) and remove the enclosure cover (117).

Repair

4. Disconnect the 2 solenoid wires from J1 on the pump control module. See

Electrical Schematics, page 27.

5. Remove 2 screws (303) and the solenoid (305).

6. Install the new solenoid (305) with the screws (303).

7. Connect the 2 solenoid wires to J1 on the pump control module. See

Electrical Schematics, page 27.

8. Replace the covers (8, 117).

Figure 34

Solenoid Replacement

332709B 49

Repair

Replacing a Fan

NOTICE

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

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

1. Follow the steps in Before Servicing, page 34.

2. Remove the screws (56) holding the cover (8) to the front of the unit.

3. Loosen the screws (124) and remove the enclosure cover (117).

4. Disconnect the 2 fan wires from the pump control module. See Electrical Schematics, page 27.

5. Remove the 4 screws, nuts, and washers to remove the fan (9).

6. Install the new fan (9) and attaching hardware.

7. Connect the 2 fan wires to the pump control module. Use terminal 8, pins 3 and 4. See

Electrical Schematics, page 27.

8. Replace the covers (8, 117).

50 332709B

Repair

Figure 35 Replacing a Fan

332709B 51

Repair

Replacing a Solvent Flow Switch

1. Follow the steps in Before Servicing, page 34.

2. Remove the screws (56) holding the cover (8) to the front of the unit.

3. Disconnect the solvent ﬂow switch wires from J6 pins 11–12 (Switch 1) or J7 pins 9–10 (Switch 2) on the EFCM. See

Electrical Schematics, page 27.

4. Disconnect the solvent lines.

5. Unscrew the adapter (45) from the solvent ﬂow switch (19).

6. Unscrew the solvent ﬂow switch from the elbow (18).

7. Remove the solvent ﬂow switch (159).

8. Screw the new solvent ﬂow switch onto the elbow (18).

9. Screw the adapter (45) into the solvent ﬂow switch (19).

10. Connect the wires to J6 pins 11–12 (Switch 1) or J7 pins 9–10 (Switch 2). Reconnect the solvent lines.

11. Install the cover (8) to the front of the unit with the screws (56).

12. Open the main air shutoff valve on the air supply line.

13. Restore power to the unit. Turn on the power switch (P) at the electrical control box.

52 332709B

Notes

332709B 53

Parts

Proportioner Parts

Part No. AC10 Part No. AC20

00 Low Pressure Proportioner 00 High Pressure Proportioner

54 332709B

Part No. AC1000 Low Pressure Proportioner

Parts

Part No. AC200

Part Description

Ref

———

1

———

2

———

3

———

4

5

24T790 PUMP, 70 cc, A side,

24T791 PUMP, 70 cc

6 24T788 PUMP, 35 cc, B side,

24T789 PUMP, 35 cc, B side,

———

7

8 24T771

9 24T770

10 277853

0 High Pressure Proportioner

FRAME 1

CONTROL BOX, electrical; see

Control Box Parts, page 57

PANEL, ﬂuid

BRACKET, mo

low pressure; for Model MC1000; see manual 332339

high press Model MC2 manual 33

low pressure; for Model MC1000; see manual 332339

high pressure; for Model MC2000; see manual 332339 BRACKET, mounting, pump COVER of ite KIT, fan

BRACKET, mounting

; includes (2)

m56

unting

,Aside,

ure; for

000; see

2339

Qty

1

2

1

2

1

2

Part Description

Ref

———

11

12 24U602

12a 16X039

14 24T772

15

C19798 SCREW, c

16 16U655

17 10464

18 11176

19 24T787

27

28

29

1

3

———

—

——

SCREW, machine, pan head; M5 x 0.8; 10 mm MODULE, disp advanced; in item 12a TOKEN; latest version of software for the Advanced Display Module; not shown MANIFOLD, solenoid; see

Solenoid Manifold Parts, page 60

head; 1/ (10 mm) BRACKET, mounting, valve FITTING, bulkhead

ELBOW; 1/4 npt (mbe) SWIT ﬂow; GUSSET

LEG, ﬂoor stand

PLUG, tube, square

4–20 x 3/8 in.

CH, solvent

1/4 npt(f) ports

lay,

cludes

ap, socket

Qty

2

1

2

8

1

2

4

2

6

332709B 55

Parts

Part Description

Ref

———

30

———

31

———

32

———

33

———

34

———

43

———

45 15F741

50 11528

51

53

54

7

———

—

——

Qty

WASHER; 3/8

SCREW, cap, hex head; 3/8–16 x 2.75 in. (70 mm) SCREW, cap, h head; 3/8–16 (22 mm) NUT, lock; 3/8–16 10

SCREW, cap, hex head; 3/8–16 x 3 in. (76 mm) WIRE HARNESS; for Model MC1000 (not shown) WIRE HAR Model MC shown) FITTING, adapter; 1/4 npt(m) x 1/4 npt(f) FITTING, Y-tube; for 1/4 in. (6 mm) OD tubing TUBE, polyethylene; 1/4 in. (6 mm) OD x 3ft

E, nylon, green;

TUB

control air to turn

for

ves on; 5/32 in. (4

val

OD x 20 ft (cut

mm)

ength required)

to l TUBE, nylon, red; for control air to turn valves off; 5/32 in. (4 mm) OD x 20 ft (cut to length required)

ex

x7/8in.

NESS; for

2000 (not

40

4

10

8

2

1

A/R

Part Description

Ref 55

223547 ———

56

———

69

70 16V429

73 24T302

———

73a

73b 24U617

———

73c

———

73d

———

73e

74 166421 NIPPLE, pipe; 1/4

ms marked — — — are not available separately.

Ite

GROUND WIRE

SCREW, cap, socket head; 1/4–20 x 3/4 in. (19 mm) GROMMET, cab

CABLE, CAN, intrinsica pin; for boo fbe; 50 ft (1 KIT, cup, TSL; includes items 73a-73e BRACKET

KIT, barbed ﬁttings; includes o-rings; package of 12 TUBE, polyurethane; 1/4 in. (6 mm) OD; 10 ft (3.05 m); cut to ﬁt PLUG, screw; 10–32; to replace unused item 73b at TSL cup; not shown GASKE 73d; n

npt

lly safe, 5

T; for item

ot shown

le

th control;

5m)

Qty

1

2

1

2

1

4

1

56 332709B

Parts

Control Box Pa

Electrical Control Box

rts

332709B 57

Parts

Electrical Control Box (continued)

Ref

101

102

103 24T769

104

105

106 255786

106a15D979

107

10

109

Part Description ———

———

8

——

—

ENCLOS

PANEL, back 1

POWER Vdc; 1

WASH

SPAC

BOAR incl

FUS act

COVER, barrier

SCREW, machine, pan head; 6–32 x 1.5 in. (38 mm)

SCREW, machine, pan head; 6–32 x 0.375 in. (10 mm)

URE

SUPPLY; 48

0A;480W

ER, lock; no. 6

ER, standoff

D, barrier;

udes item 106a

E; 400 mA, quick

ing

Qty

1

3

1

2

1

2

3

Ref

110

111 24M485

112 16U725

113

114

115 16V446 FILTER , line; 10A 1

116

117

118

119

120 16T660

Part Description ———

———

BRACKE

BOARD

SWITC posit

DUCT

COVE

BLO

COV

GRO

LIG

PO Vd

T, board

,isolation,IS

H, selector, 2

ion

,wire

R, duct

CK, terminal

ER, enclosure

MMET

HT

WER SUPPLY; 24

c,4A,96W

Qty

2

1

2

1

2

4

1

58 332709B

Parts

Ref

121

122

123

124

125

126

127

128

129

130 121

131

13

1

139 24T773

140

141

142

143

Part Description ———

———

003

———

2

33

34

37

38

N527

24

6P243

1 ———

———

CONNECTOR, bar ground

SCREW, ground; M5 x

0.8 NUT, hex, ﬂange head;

1/4–20 SCREW, ﬂanged, hex

head; 1/4–20 x 0.75 in. (19 mm)

SCREW, machine, pan head; 10–24 x 0.375 in. (10 mm)

SCREW, ma head; 10 (19 mm)

FITTING, connector; 1/8 npt(m) x 1/4 in. (6 mm) OD tube

SCREW, machine, pan head; 8–32 x 0.25 in. (6 mm)

SCRE bind

0.25 CABLE, CAN; fbe; 3.0

m MANIFOLD, air

MODULE, control, pump

CABLE, splitter

UFFLER

M

PLUG, pipe; 1/8 npt(f)

STRAIN RELIEF, cord

MODULE, control, enhanced ﬂuid

SCREW, machine, pan head; 1/4–20 x 0.5 in. (13 mm)

SCREW, cap, socket head; 8–32 x 0.625 in. (16 mm)

SCREW, machine, pan head; 10–32 x 0.25 in. (6 mm)

SCREW, machine, pan head; 10–32 x 1.5 in. (38 mm)

–32 x 0.75 in.

W, machine,

ing head; 6–32 x

in. (6 mm)

,

chine, pan

Qty

1

3

4

2

3

1

8

4

1

2

1

4

1

2

10

8

Ref

144▲172953 LABEL, ground symbol 1

145

147▲15W598 LABEL, warning 1

148

150 16T072

151 121227

152

153

154 16T659

155

163 16V429

168 16U600 LABEL,

169

170

173▲15W776 LABEL, warning,

176

177

178 289

17

18

1

185 121901

186 121001

Items marked — — — are not available separately.

Part Description

———

-——

697

-——

9

-——

0

-——

1

82

83

84

4W777

2

77674

2

———

CLAMP; for 3/8 in. (10 mm) OD cable

HARNESS, CAN isolation, power (not shown)

ADAPTER, C IS to non-I

CABLE, CAN m

HARNESS,

CABLE, D

2.5 ft SCREW, s

CABLE, 50 ft. 1

NUT, hex, self-locking; 1/4–20

SCREW, machine, pan head; 8–32 x 0.312 in. (8 mm)

electrical shock WASHER, ﬂat

WASHER, #10, sst

MODULE, base

SCREW, machine, pan, 6–32 x 1–1/2

SCREW, pan, #6–32

SCREW, pan, #8–32

MODULE, modbus tcp

ENCLOSURE, cube, door

BRACKET, mount, modbus

SUPPRESSOR, box snap, ferrite

CABLE, CAN, fbe, 1m

AN cable,

S

;fbe;0.6

3–wire

2–wire

-SUB, 25 pin,

elf sealing

CAN, I.S.; fbe;

5.25 m) isolation board

Qty

4

1

2

1

4

1

2

1

4

1

3

1

▲ Replacement Danger and Warning labels, tags, and cards are available at nocost.

332709B 59

Parts

Solenoid Mani

Part No. 24T772 Solenoid Manifold

fold Parts

Part Description

Ref

———

301

———

302

———

303

304 115671

305 16P812 VALVE, solenoid 2

307 114151

308 114263

309

C06061

Items marked — — — are not available separately.

PLATE 1

MANIFOLD

SCREW, cap, socket head; 1/4–20 x 0.375 in. (10 mm) CONNECTOR; 1/8 npt(m) x 1/4 in. (6 mm) OD tube

FITTING, swivel; 1 5/32 in. ( tube FITTING, straight; 1/8 npt(m) x 5/32 in. (4 mm) OD tube MUFFLE

elbow,

/8 npt(m) x

4 mm) OD

R

Qty

1

4

1

4

2

60 332709B

Technical Data

Positive Displacement Proportioner

Maximum ﬂuid working pressure:

AC1000 Air Spray

Systems

AC2000 Air-Assisted

Spray Systems

Maximum wo pressure:

Air supply: 85–100 psi

Air ﬁlter

ation for air logic

Air ﬁltr (user-s

ration for atomizing

Air ﬁlt

er-supplied):

air (us

Mixing ratio range:

Fluids handled:

rking air

inlet size:

upplied):

one or

• solvent and waterborne paints

• polyurethanes

two component:

U.S.

300 psi 2.1 MPa, 21 ba

1500 psi 10.5 MPa, 10

100 psi 0.7 MPa, 7.

5micron

30 micr

(minimum) ﬁltration required; clean and dry air

on (minimum) ﬁltration required; clean and dry air

3/8 npt(f

0.1:1

0.6–0.7 M

)

— 50:1, ±1%

Metric

r

5bar

0bar

Pa, 6.0–7.0 bar)

• epoxies

• acid catalyzed varnishes

• moisture sensitive isocyanates

5000 centipoise

Viscosity range of ﬂuid:

Fluid ﬁltration (user-supplied):

Maximum ﬂuid ﬂow: 800 cc/minute (depending on material viscosity)

luid outlet size:

F

xternal power supply

E requirements:

Operating temperature range:

Storage temperature range:

Weight of base model (approximate):

Sound data: Less than 75 dB(A)

Wetted parts:

17–4PH, 303, 304 SST, Tungsten carbide (with nickel binder),

0 - 250 Vac, 50/60 Hz, 7 amps maximum draw

9

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

20–

0meshminimum

10

1/4 npt(m)

perﬂuoroelastomer; PTFE, PPS, UHMWPE

332709B 61

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 Grac

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage o 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 SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not 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 furnishing, performance, or use of any products or other goods sold 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.

o’s written recommendations.

r wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper

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 332709

Graco Headquarters: Minneapolis

International Ofﬁces: Belgium, China, Japan, Korea

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

www.graco.com

Revision B, September 2014

Graco 332709B User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Models

Related Manuals

Warnings

Isocyanate Conditions

Keep Components A and B Separate

Moisture Sensitivity of Isocyanates

Troubleshooting

System Troubleshooting

Power Barrier Board Diagnostics

Table 1 . Power Barrier Board Diagnostics

Isolation Board Diagnostics

Table 2 . Isolation Board Diagnostics

Table 3 . Enhanced Fluid Control Module Diagnostics

Pump Module Diagnostics

Table 4 . Pump Module Diagnostics

Advanced Display Module Diagnostics

Table 5 . Advanced Display Module Diagnostics

Notes

Repair

Without Color Change

With Color Change

Install Key Token or Upgrade Token

Replace the Battery

Replacing the Isolation Board

Replacing the Barrier Board

Replacing the Barrier Board Fuses

Replacing the Enhanced Fluid Control Module (EFCM)

Replacing the 24 Vdc Power Supply

Replacing the 48 Vdc Pump Power Supply

Replacing a Pump Control Module

Replacing a Communication Gateway Module

Replacing the Line Filter

Replacing the Power Switch

RemovingaPump

Installing a Pump

Replacing a Solenoid

Replacing a Fan

Replacing a Solvent Flow Switch

Notes

Parts

Proportioner Parts

Technical Data

Graco Standard Warranty

Graco Information