Graco 333282B User Manual

Instructions/Parts

Color Change an

d Remote Mix

333282B

Manifold Kits

To add optional color change function and at-the-gun mixing of two component materials when used with a ProMix™ PD2K Proportioner for Automatic Spray Applications. For professional use only.

Important Safety Instructions Read all warnings and instructions in this manual and in your system installation, operation, and repair/parts manuals. Save these instructions.

See page 3 approvals information.

for model part numbers and

PROVEN QUALITY. LEADING TECHNOLOGY.

Related Manuals ................................................ 3

Models............................................................... 4

Non-Intrinsically Safe Modules...................... 4

Warnings ........................................................... 9

Important Isocyanate (ISO) Information................ 12

Setup the Modules.............................................. 13

Setup Non-IS Control Modules...................... 13

Setup IS Control Modules............................. 16

Installat

Troubleshooting.................................................. 32

ion.......................................................... 18

Mounting t Air Supply Grounding Non-Hazar Hazardous Connect t Connect t Install a

he Control Modules ...................... 18

.................................................... 18

................................................... 18

dous Location.............................. 19

Location ..................................... 22

he Valve Air Lines.......................... 24

he Fluid Lines................................ 26

n Expansion Kit ................................ 30

Color Change Solenoid Valves ..................... 32

Color Change Board .................................... 34

Electrical Schematics.......................................... 36

Optional Cables and Modules ....................... 42

Repair................................................................ 43

Replace a Col Replace a So Replace the Replace the

Parts.................................................................. 46

Non-IS Color Change Kits ............................ 46

IS Color Change Kits.................................... 50

Valve Manifold Kits ...................................... 53

Color Change Control Module Kits ................ 64

Expansion Kits............................................. 69

Dimensions ........................................................ 71

Technica

Graco Standard Warranty....................................76

l Data ................................................... 75

or Valve.................................. 43

lenoid...................................... 44

Color Change BoardFuse........... 44

Color Change Board.................. 45

333282B

Related Manuals

Current manua

Manual No. Description

332458 PD2K Proportioner, Installation

332564

332565 PD2K Proportioner Repair-Parts

ls are available at www.graco.com.

Manual, Systems for Automatic Spray Applications

PD2K Propor Manual, Sys Spray Appli

Manual, Systems for Automatic Spray Applications

tioner Operation

tems for Automatic

cations

Manual No. Description

332709 Pump Repair-Parts Manual

332454

332456 3rd and 4th Pump Kits

Color Change Manual

Instructions-Parts Manual

Valve Repair-Parts

333282B 3

Models

Non-Intrinsically Safe Modules

These kits ar part number. and certiﬁca

Non-Intri

Kit No.

24R915 A 2 color or 2 catalyst

24R916 A 4 color or 4 catalyst

e installed in the non-hazardous location, near the pumps. See the Kit label for the product

See the module identiﬁcation label for maximum air working pressure, approval information

tion.

nsically Safe Color Change Control Module Label

Series

Kit Description Maximum Air Working Pressure

Low Pressure Non-Circulating Color Change Kits

Kit Identi

(Control Module)

100 psi (0.7 MPa, 7.0 bar) 300 psi (2.068 MPa, 20.68 bar)

ﬁcation Label

Maximum Fluid Working Pressure (Valves)

24R917 A 6 color

24R918 A 8 color

24R919 A 2 color

24R920 A 4 color

24R921 A 6 color

24R922 A 8 color

100 psi (0.7 MPa, 7.0 bar) 300 psi (2.068 MPa, 20.68 bar)

Low Pressure Circulating Color Change Kits

100 psi (0.7 MPa, 7.0 bar) 300 psi (2.068 MPa, 20.68 bar)

333282B

Models

Kit No.

24R959 A 2 color or 2 cat

24R960 A 4 color or 4 catalyst

24R961 A 6 color

24R962 A 8 color

24T579 A

24T580 A

24R963 A 2 color

24R96

24R965 A 6 color

24R966 A 8 color

Series

Kit Descriptio

High Press

2 catalyst (acid compatible)

4 catalyst (acid compatible)

A4colo

High Pressure Non-Circulating Color Change Kits

alyst

ure Acid Compatible Non-Circulating Catalyst Change Kits

High Pr

Maximum Air Wor (Control Modul

100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar)

100 psi (0.7 M

100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar)

essure Circulating Color Change Kits

100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar)

100 ps

100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar)

i(0.7MPa,7.0bar)

king Pressure

Pa, 7.0 bar)

Maximum Fluid W Pressure (Valv

1500 psi (10.

1500 p

si (10.34 MPa, 103.4 bar)

orking

es)

34 MPa, 103.4 bar)

NOTE: Systems can use 1 to 30 colors and up to 4 catalysts. To add colors/catalysts:

urrent control module is full: If all solenoid ports

• If c in use in your control module(s), an additional

are

trol module is needed. Order another complete

con

lor change change kit, shown above.

current control module is not full: If empty

• If

lenoid ports remain in your control module, see

pansion Kits, page 69.

333282B 5

Models

Intrinsicall

These kits utilize intrinsically safe control modules that are installed in the hazardous area, near the dispense valve. See the kit identiﬁcation label for the product part number. See the module identiﬁcation label for maximum air working pressure, approval information and certiﬁcation.

Intrinsically Safe Color Change Module Identiﬁcation Label Kit Identiﬁcation Label

Table 1 . Low Pressure, Non-Circulating Remote Mix Manifold Kits Maximum Fluid Working Pressure: 300 psi (2.07 MPa, 20.7 bar)

Number of Color + Solvent Valves

1 24V157

2 24V158 24V331

4 24V159 24V332 24V343

6 24V160 24V333 24V344

8 24V161 24V334 24V345

12 24V162 24V335 24V346

Control Module Expansion Kits: Use to add a second control module (includes all needed solenoids, manifolds, valves and a CAN cable).

13–1

13–24 24V164

13–30 24V165

y Safe Modules

0359

II 2 G

Number of Catalyst + Solvent Valves

24V1

6 333282B

Table 2 . Low Pressure, Circulating Remote Mix Manifold Kits Maximum Fluid Working Pressure: 300 psi (2.07 MPa, 20.7 bar)

Models

Number of Color + Solvent Valves

1 24V166

2 24V167 24V336

4 24V308 24V337 24V347

6 24V309 24V338 24V348

8 24V326 24V339 24V349

12 24V327 24V340 24V350

Control Module Expansion Kits: Use to add a second control module (includes all needed solenoids, manifolds, valves and a CAN cable).

13–18 24V328

13–24 24V329

13–30 24V330

Table 3 . High-Pressure, Non-Circulating Remote Mix Manifold Kits Maximum Fluid Working Pressure: 1500 psi (10.34 MPa, 103.4 bar)

Number of Color + Solvent Valves

1 24V35

2 24V360 24V381

4 24V361 24V382 24V396

6 24V3

8 24V363 24V384 24V398

12 24V364 24V385 24V399

Control Module Expansion Kits: Use to add a second control module (includes all needed solenoids, manifolds, valves and a CAN cable).

13–

13–24 24V366

13–30 24V367

Number of Catalyst + Solvent Valves

24V

365

24V3

dels continue on next page.

333282B

Models

Table 4 . High-Pressure, Circulating Remote Mix Manifold Kits Maximum Fluid Working Pressure: 1500 psi (10.34 MPa, 103.4 bar)

Number of Color + Solvent Valves

1 24V369

2 24V370 24V389

4 24V371 24V390 24V402

6 24V372 24V391 24V403

8 24V373 24V392 24V404

12 24V374 24V393 24V405

Control Module Expansion Kits: Use to add a second control module (includes all needed solenoids, manifolds, valves and a CAN cable).

13–18 24V375

13–24 24V376

13–30 24V377

NOTE: Systems can use 1 to 30 colors and up to 4 catalysts. To add colors/catalysts:

• If current control module is full: If all solenoid ports are in use in your IS control module, an additional IS control module is needed. Order a Control Module Expansion Kit, shown above.

• If current control module is not full: If empty solenoid ports remain in your control module, see

Expansion Kits, page 69.

Number of Catalyst + Solvent Valves

8 333282B

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

333282B 9

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.

10 333282B

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.

333282B

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.

333282B

Setup the Module

Setup the Modu

Setup Non-IS C

NOTE: The PD2K System can use up to four pumps and six color change modules in the non-hazardous area. Use the following table to understand how many color change modules are needed for the number of pumps in your system, and which module should be associated to which pump.

Table 5 . Relationship of Non-IS Color Change Control Modules to Pumps

System Pum

Color

Pump(s)

1 0 1 Not Appli

112

213

p Conﬁguration

Catalyst

Pump(s)

ontrol Modules

Total

Pumps

les

Module 1

(Colors

1–8)

Color Chan

Module 2

(Colors

9–16)

All Non-IS modules ship from the factory as Module 1 (Colors 1–8). Labels for Modules 2 through 6 are provided with the module kit. Afﬁx the labels according to your system conﬁguration.

ge Control Modules, Colors, and Catalysts

Module

3(Colors

17–24)

Pump # 1 Pump # 1

Module 4

(Colors

25–30)

Catalyst

1–2

Module # 5

Pump # 2

Module # 5

Pump # 2

Catalyst

3–4

cable

2 0 2 Not Applicable

Pump#1

224

314

303

404

Pump#1

Pump #

Pump#2

Pump # 3

Pump # 4

Modul

Pump #

Module # 5

Pump # 2

Not A

Not Applicable

Modul

Pump #

pplicable

333282B 13

Setup the Module

Conﬁgure each module according to its designated number, as follows:

NOTICE

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

To avoid elec system power

1. Remove elec

2. Open the col S4, S5, and S switches a

3. For each module, set the switches to ON or OFF, as shown in the following table.

trical component damage, remove all

before plugging any connectors.

trical power from the system.

or change module. Locate switches

6onthecontrolmoduleboard. The

re shipped in the OFF position.

Non-IS Control Module Switch Settings

Control

S6 S5 S4

Module

Module 1

Module 2

Module 3

Module 4

Module 5

Module 6

OFF

4. Use the following ﬁgure and tables to determine the solenoid valve assigned to each valve in the valve manifold.

NOTE: There can be only one solvent valve and one dump valve per pump.

Inlet Manifold Outlet Manifold

Figure 1 Non-IS Control Module

333282B

Setup the Module

Non-IS Control Module 1

Inlet Manifol

Solenoid

Inlet Manifold Outlet Manifold

Solenoid

Valve

Solvent

Color 1

Color 2

Color 3

Color 4

Color 5

Color 6

Color 7

Color 8

Non-IS Control Module 2

Valve

(Solvent)*

Color 9

Color 10

Color 11

Color 12

Color 13

Color 14

Color 15

Outlet Manifo

Solenoid

1Dump

Solenoid

Valve

Color 1

Color 2

Color 3

Color 4

Color 5

Color 6

Color 7

Color 8

Valve

(Dump)*

Color 9

Color 10

Color 11

Color 12

Color 13

Color 14

Color 15

Non-IS Control Module 4

Inlet Manifol

Solenoid

8 Not Used 8 Not Used

9NotUse

Inlet Manifold Outlet Manifold

Solenoid

6 Not Used 6 Not Used

8 Not Used 8 Not Used

Valve

(Solvent)*

Color 25

Color 26

Color 27

Color 28

Color 29

Color 30

Non-IS Control Module 5

Valve

(Solvent)*

Catalyst 1

Catalyst 2

Catalyst 3

Catalyst 4

Not Used

Outlet Manifo

Solenoid

9NotUse

Solenoid

Valve

(Dump)*

Color 25

Color 26

Color 27

Color 28

Color 29

Color 30

Valve

(Dump)*

Catalyst 1

Catalyst 2

Catalyst 3

Catalyst 4

Not Used

Inlet Manifold Outlet Manifold

Solenoid

* There should be only one solvent valve and one dump valve per pump.

Color 16

Non-IS Control Module 3

Valve

(Solvent)*

Color 17

Color 18

Color 19

Color 20

Color 21

Color 22

Color 23

Color 24

Solenoid

Color 16

Valve

(Dump)*

Color 17

Color 18

Color 19

Color 20

Color 21

Color 22

Color 23

Color 24

9 Not Used 9 Not Used

Non-IS Control Module 6

Inlet Manifold Outlet Manifold

Solenoid

4 Not Used 4 Not Used

6 Not Used 6 Not Used

8 Not Used 8 Not Used

9 Not Used 9 Not Used

Valve

(Solvent)*

Catalyst 3

Catalyst 4

Not Used

Solenoid

Valve

(Dump)*

Catalyst 3

Catalyst 4

Not Used

333282B 15

Setup the Module

Setup IS Contr

ol Modules

NOTE: Two IS color change control modules may be installed in the hazardous area. The module for colors 1–12 is labeled board 7. The module for colors 13–30 is labeled board 8. An alternate label for Module 8 (Colors 13–30) is provided with the module kit. Afﬁx the label according to your system conﬁguration.

Conﬁgure ea number, as f

ch module according to its designated

ollows:

NOTICE

To avoid da No. 112190 ground app

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

1. Remove electrical power from the system.

2. Open the color change module. Locate switches S4, S5, and S6 on the control module board. The switches may be shipped in the OFF position.

maging the circuit boards, wear Part

grounding strap on your wrist and

ropriately.

3. For each module, set the switches to ON or OFF, as shown in the following table.

IS Control Mod

Control

ule Switch Settings

S6 S5 S4

Module

Module 7

Module 8

OFF

4. Use the following ﬁgure and tables to determine the solenoid valve assigned to each valve in the valve manifold.

Figure 2 IS Control Module

16 333282B

Setup the Module

Solenoid

IS Control Module 7

Valve

Color Solvent

Color 1

Color 2

Color 3

Color 4

Color 5

Color 6

Color 7

Color 8

Solenoid

Valve

Catalyst Solvent

Catalyst 1

Catalyst 2

Catalyst 3

Catalyst 4

Color 9

Color 10

Color 11

Color 1

Solenoid

IS Control Module 8

Valve

Color 13

Color 14

Color 15

Color 16

Color 17

Color 18

Color 19

Color 20

Color 2

Solenoid

Valve

Color 22

Color 23

Color 24

Color 25

Color 26

Color 27

Color 28

Color 29

Color 3

333282B

Installation

• To avoid electric shock, turn off power at the main circuit breaker before opening the enclosure.

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

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

• 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.

3. Using the equipment as a template, mark the mounting holes on the wall at a convenient height for the operator and so the equipment is easily accessible for maintenance.

NOTE: The smaller color change control modules must be mounted in the Non-IS area. The larger remote color change module may be mounted in the IS area.

4. Drill mounting holes in the wall. Install anchors as needed.

5. Bolt the equipment securely.

Air Supply

Connect a clean and dry air supply to the air inlet ﬁtting (317) of each color change control module in the non-hazardous area and each remote module in the hazardous area. The ﬁtting is for 1/4 in. (6 mm) ODtubing. Usea5micronﬁlter. Regulatetheair pressure to 85–100 psi (0.6–0.7 MPa, 6.0–7.0 bar).

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized ﬂuid, such as skin injection, splashing ﬂuid and moving parts, follow the Pressure Relief Procedure in the PD2K Operation Manual before installing the kit.

Mounting the Control Modules

1. See Dimensions, page 71.

2. Ensure that the wall and mounting hardware are strong enough to support the weight of the equipment, ﬂuid, hoses, and stress cause during operation.

Grounding

This equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current.

Connect a ground wire from each color change module in the non-hazardous area to a true earth ground.

Intrinsically safe remote color change modules located in the hazardous area must be connected to a true earth ground in the hazardous area.

18 333282B

Non-Hazardous Location

Connect the Color Change Control Modules

NOTE: Non-IS color change control modules provide control for the pump’s inlet and outlet color/catalyst change valves. Depending on the number of valves in the system, as many as six control modules may be installed in the non-hazardous location.

1. Mount the ﬁrst non-IS color

control module as described in

Mounting the Control Modules, page 18.

2. Connect the 5–pin CAN cable (109) to J7 on the

color control module (108).

Installation

7. To install additional color control modules (six maximum), mount the module(s) as described in

Mounting the Control Modules, page 18. Connect

a 5–pin CAN cable from J11 of the previous color control module to J7 of the next control module.

8. Replace the cover of the PD2K electrical control box before turning on power to the system.

Figure 3 Cable Connector J7 at Non-IS Color Control Module

NOTICE

To avoid damaging the circuit boards, 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.

3. Remove electrical power from the system.

4. Remove the cover from the PD2K electrical control box.

5. Install the supplied 2–cable grommet (110) on the cable (109) and secure the grommet to the side of the electrical control box.

6. Connect the cable (109) to J2 on the non-IS side of the isolation board inside the electrical control box. See Electrical Schematics, page 36 for a list of M12 CAN cables for use in a non-hazardous area.

Figure 4 Cable Connection at PD2K Electrical Control Box

Figure 5 Detail of Isolation Board Cable Connections

333282B 19

Installation

Install the Valve Manifolds

NOTE: Always label the color connections to prevent cross-connections. Label the inlet manifold, outlet manifold, and each color valve with its assigned color. The solvent and dump valves should be furthest from the manifold stack primary inlet or outlet.

1. Install a mou with four scr For stabilit (103) to the

nting bracket (101) on the PD2K

ews (103). High pressure systems:

y, be sure to fasten the bottom screws

pump bracket.

with 16 valve positions (14 colors). On high pressure systems, the supplied bracket (101) will accommodate a manifold with 14 valve positions (12 colors). A larger valve stack will require a customer supplied/sourced bracket.

3. Repeat for the opposite side of the PD2K.

4. Connect the air lines from the solenoids to the valves. See Connect the Valve Air Lines, page 24.

NOTE: On high pressure systems, see

Install the Back Pressure Regulator (High Pressure Systems Only), page 21.

5. Connect the ﬂuid supply lines to the valves. See

Connect the Fluid Lines, page 26.

2. Install the inlet and outlet valve manifolds (102) on the mounting bracket (101) with four screws (104), washers (105), and nuts (106).

NOTE: On low pressure systems, the supplied bracket (101) will accommodate a manifold

Figure 6 Install the Valve Manifolds

20 333282B

Install the Back Pressure Regulator (High Pressure Systems Only)

Installation

NOTE: The back pressure regulator is required on high pressure systems to prevent the system’s feed pumps from overdriving the dosing pumps during color change pump ﬂush and color ﬁll operations. Adjust the back pressure during the dump process to be approximately 75% of the supply pressure from the feed pumps, but never more than 300 psi (2.1 MPa, 21 bar) less than the supply pressure.

Install the attaching h manifold st

1. Install the gauge (123) in the open port of the

2. Screw the tee (122) onto the dump valve ﬁtting of

3. Assemble the two nipples (121) to the back

4. Connect a 1/4 npt(f) dump line to the downward

back pressure regulator (120) and

ardware at the dump valve of the outlet ack.

tee (122).

the outlet manifold stack.

pressure regulator (120). Screw the regulator assembly into the tee (122) as shown.

facing nipple (121).

5. Connect the ﬂuid supply lines to the valves. See

Connect the Fluid Lines, page 26.

Figure 7 I Valve of O

nstall Back Pressure Regulator at Dump

utlet Stack

333282B

Installation

Hazardous Location

Connect Remot

e Color Change Control

Module

NOTE: IS color change control modules provide control for remote color/catalyst change valves located in the hazardous location for use with automatic spray systems. A maximum of two IS control modules may be installed in the hazardous location. See

IS Color Change Control Modules, page 66 for a list

of modules approved for installation in a hazardous location.

NOTICE

To avoid damaging the circuit boards, 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 8 Intrinsically Safe Cable Connections

3. Connect the hazardous location cable (C1) to J7 on the remote color control module (108).

Only approved cables may be used in the hazardous location. Hazardous location cables are marked with a light blue ﬂag next to each connector. See Optional Cables and Modules, page 42 for a list of M12 CAN cables for use in a hazardous area.

1. Remove electrical power from the system.

2. Mount the ﬁrst remote color change control module as described in

Mounting the Control Modules, page 18.

Figur Color

4. Remo rol box. Install the grommet (G) on the

cont supp to th J4 on

ctrical control box. Connect the cable (C1) to

ele

See Electrical Schematics, page 36.

J4.

e 9 Cable Connectors J7 and J11 at IS

Control Module

ve the cover from the PD2K electrical

lied cable (C1) and secure the grommet

e side of the electrical control box. Locate

theISsideoftheisolationboardinthe

333282B

Installation

J11ontheﬁrst color control module to J7 on the second module.

6. Replace the cover of the PD2K electrical control box before turning on power to the system.

Install the Remote Valve Manifolds

1. Using the equipment as a template, mark the mounting holes on the wall at a convenient height for the operator and so the equipment is easily accessible for maintenance. Mount the remote valve manifolds near the remote color module and the automatic dispensing device.

2. Install the mounting brackets for the color valve manifolds and the catalyst valve manifolds. See

Dimensions, page 71. Use bolts to attach the

equipment securely.

Figure 10 Detail of Isolation Board Cable Connections

5. If your system includes a second remote color control module mount it as described in

Mounting the Control Modules, page 18. Connect

the supplied hazardous location cable (C2) from

3. Install the color and catalyst valve manifolds to the brackets with four screws, washers, and nuts.

4. Connect the air lines from the solenoids to the valves. See Connect the Valve Air Lines, page 24.

5. Connect the ﬂuid supply lines to the valves. See

Connect the Fluid Lines, page 26.

333282B 23

+ 53 hidden pages

Graco 333282B User Manual

Contents

Related Manuals

Models

Non-Intrinsically Safe Modules

Table 1 . Low Pressure, Non-Circulating Remote Mix Manifold Kits Maximum Fluid Working Pressure: 300 psi (2.07 MPa, 20.7 bar)

Table 2 . Low Pressure, Circulating Remote Mix Manifold Kits Maximum Fluid Working Pressure: 300 psi (2.07 MPa, 20.7 bar)

Table 3 . High-Pressure, Non-Circulating Remote Mix Manifold Kits Maximum Fluid Working Pressure: 1500 psi (10.34 MPa, 103.4 bar)

Table 4 . High-Pressure, Circulating Remote Mix Manifold Kits Maximum Fluid Working Pressure: 1500 psi (10.34 MPa, 103.4 bar)

Warnings

Isocyanate Conditions

Keep Components A and B Separate

Moisture Sensitivity of Isocyanates

Table 5 . Relationship of Non-IS Color Change Control Modules to Pumps

Installation

Air Supply

Mounting the Control Modules

Grounding

Non-Hazardous Location

Connect the Color Change Control Modules

Install the Valve Manifolds

Install the Back Pressure Regulator (High Pressure Systems Only)

Hazardous Location

Install the Remote Valve Manifolds