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
EN
PROVEN QUALITY. LEADING TECHNOLOGY.
Contents
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
2
333282B
Related Manuals
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
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)
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)
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)
100 psi (0.7 MPa, 7.0 bar) 300 psi (2.068 MPa, 20.68 bar)
100 psi (0.7 MPa, 7.0 bar) 300 psi (2.068 MPa, 20.68 bar)
100 psi (0.7 MPa, 7.0 bar) 300 psi (2.068 MPa, 20.68 bar)
4
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
4
Kit Descriptio
High Press
2 catalyst (acid
compatible)
4 catalyst (acid
compatible)
A4colo
r
n
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)
100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar)
100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar)
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 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
e)
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.
co
current control module is not full: If empty
• If
lenoid ports remain in your control module, see
so
pansion Kits, page 69.
Ex
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).
8
13–1
13–24 24V164
13–30 24V165
y Safe Modules
0359
II 2 G
Number of Catalyst + Solvent Valves
12
63
24V1
4
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).
18
13–
13–24 24V366
13–30 24V367
Number of Catalyst + Solvent Valves
12
Number of Catalyst + Solvent Valves
12
9
24V
62
365
24V3
83
Mo
97
24V3
dels continue on next page.
4
4
333282B
7
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
12
4
8 333282B
Warnings
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.
gu
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
11
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
or
mponents and change hoses. Epoxies often
co
ve amines on the B (hardener) side. Polyureas
ha
ten have amines on the A (resin) side.
of
E
2
1
333282B
Setup the Module
s
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
3
Pump # 3
Pump # 4
e
Modul
#5
Pump #
2
Module # 5
Pump # 2
Not A
Not Applicable
Modul
#6
Pump #
pplicable
e
4
333282B 13
Setup the Module
s
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
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
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
4
1
333282B
Setup the Module
s
Non-IS Control Module 1
Inlet Manifol
Solenoid
1
2
3
4
5
6
7
8
9
Inlet Manifold Outlet Manifold
Solenoid
1
2
3
4
5
6
7
8
d
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
2
3
4
5
6
7
8
9
Solenoid
1
2
3
4
5
6
7
8
ld
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
1
2
3
4
5
6
7
8 Not Used 8 Not Used
9NotUse
Inlet Manifold Outlet Manifold
Solenoid
1
2
3
4
5
6 Not Used 6 Not Used
7
8 Not Used 8 Not Used
d
Valve
(Solvent)*
Color 25
Color 26
Color 27
Color 28
Color 29
Color 30
d
Non-IS Control Module 5
Valve
(Solvent)*
Catalyst 1
Catalyst 2
Catalyst 3
Catalyst 4
Not Used
Outlet Manifo
Solenoid
1
2
3
4
5
6
7
9NotUse
Solenoid
1
2
3
4
5
7
ld
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
d
9
Inlet Manifold Outlet Manifold
Solenoid
1
2
3
4
5
6
7
8
9
* 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
9
Solenoid
1
2
3
4
5
6
7
8
9
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
1
2
3
4 Not Used 4 Not Used
5
6 Not Used 6 Not Used
7
8 Not Used 8 Not Used
9 Not Used 9 Not Used
Valve
(Solvent)*
Catalyst 3
Catalyst 4
Not Used
Not Used
Solenoid
1
2
3
5
7
Valve
(Dump)*
Catalyst 3
Catalyst 4
Not Used
Not Used
333282B 15
Setup the Module
s
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
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
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
s
Solenoid
1
2
3
4
5
6
7
8
9
IS Control Module 7
Valve
Color
Solvent
Color 1
Color 2
Color 3
Color 4
Color 5
Color 6
Color 7
Color 8
Solenoid
1
2
3
4
5
6
7
8
9
Valve
Catalyst
Solvent
Catalyst 1
Catalyst 2
Catalyst 3
Catalyst 4
Color 9
Color 10
Color 11
Color 1
2
Solenoid
1
2
3
4
5
6
7
8
9
IS Control Module 8
Valve
Color 13
Color 14
Color 15
Color 16
Color 17
Color 18
Color 19
Color 20
Color 2
1
Solenoid
1
2
3
4
5
6
7
8
9
Valve
Color 22
Color 23
Color 24
Color 25
Color 26
Color 27
Color 28
Color 29
Color 3
0
333282B
17
Installation
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
21
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
2
2
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
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