Positive displacement proportioning of 2-component materials helps reduce waste. Manual system with
Advanced Display Module. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
PD2K Proportioner Operation
Manual, Manual Systems
Manual
-Parts Manual
Manual No.Description
332454
332455
3324563rd and 4th P
Color Change V
Manual
Color Change Kits
Instructions-Parts Manual
Instructio
ns-Parts Manual
alve Repair-Parts
ump Kits
3A2800B5
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 EXPLOSION HAZARD
Flammable
prevent fir
• Use equipment only in well ventilated area.
• Eliminat
plastic d
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable
fumes are present.
•Grounda
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless
they are antistatic or conductive.
• Stop op
equipm
• Keep a working fire extinguisher in the work area.
fumes, such as solvent and paint fumes, in work area can ignite or explode. To help
e and explosion:
e all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and
rop cloths (potential static arc).
ll equipment in the work area. See Grounding instructions.
eration immediately if static sparking occurs or you feel a shock, Do not use
ent until you identify and correct the problem.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can
cause electric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before
servicing or installing equipment.
• Connect only to grounded power source.
lectrical wiring must be done by a qualified electrician and comply with all local codes
•Alle
egulations.
and r
63A2800B
Warnings
WARNING
INTRINSIC SAFETY
Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe
equipment will create a hazardous condition and can cause fire, explosion, or electric shock.
Follow local regulations and the following safety requirements.
•Besureyouri
electrical a
and 2 (Europ
NFPA 33, NEC
• To help prevent fire and explosion:
• Do not install equipment approved only for a non-hazardous location in a hazardous
location. See model ID label for the intrinsic safety rating of your model.
• Do not subs
• Equipment that comes in contact with the intrinsically safe terminals must be rated for Intrinsic
Safety. This includes DC voltage meters, ohmmeters, cables, and connections. Remove the
unit from the hazardous area when troubleshooting.
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may
look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
• Do not sp
• Engage trigger lock when not spraying.
• Do not point gun 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 spraying/dispensing and before
cleaning, checking, or servicing equipment.
•Tight
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
en all fluid connections before operating the equipment.
nstallation complies with national, state, and local codes for the installation of
pparatus in a Class I, Group D, Division 1 (North America) or Class I, Zones 1
e) Hazardous Location, including all of the local safety fire codes (for example,
500 and 516, OSHA 1910.107, etc.).
titute system components as this may impair intrinsic safety.
ray without tip guard and trigger guard installed.
ut your hand over the spray tip.
3A2800B
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.
ssurized equipment can start without warning. Before checking, moving, or servicing
•Pre
ipment, follow the Pressure Relief Procedure and disconnect all power sources.
equ
7
Warnings
WARNING
TOXIC FLUID OR FUMES
Toxic fluids or fumes can cause serious injury or death if splashed in the eyesoronskin,
inhaled, or swallowed.
• Read MSDSs to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.
• Always wear
equipment.
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:
chemically impermeable gloves when spraying, dispensing, or cleaning
•Protectiv
• 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.
•Useflui
in all e
inform
• 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
manuf
• 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.
•Usee
• 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.
•Kee
• Comply with all applicable safety regulations.
e eyewear, and hearing protection.
ds and solvents that are compatible with equipment wetted parts. See Technical Data
quipment manuals. Read fluid and solvent manufacturer’s warnings. For complete
ation about your material, request MSDS from distributor or retailer.
equipment daily. Repair or replace worn or damaged parts immediately with genuine
acturer’s replacement parts only.
quipment only for its intended purpose. Call your distributor for information.
p children and animals away from work area.
83A2800B
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 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.
Keep Components A and B Separate
Cross-contamination can result in cured
material in fluid lines which could cause serious
injury or damage equipment. To prevent
cross-contamination:
• Never interchange component A and component
B wetted parts.
• Never use solvent on one side if it has been
contaminated from the other side.
Moisture Sensitivity of Isocyanates
Exposure to moisture (such as humidity) will cause
ISO to partially cure; forming small, hard, abrasive
crystals, which become suspended in the fluid.
Eventually a film will form on the surface and the ISO
will begin to gel, increasing in viscosity.
NOTICE
Partially cured ISO will reduce performance and
the life of all wetted parts.
• Always use a sealed container with a desiccant
Material Self-ignition
Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings
and material MSDS.
3A2800B9
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.
Important Isocy
anate (ISO) Information
Changing Mate
rials
NOTICE
Changing the material types used in your
equipment requires special attention to avoid
equipment damage and downtime.
• When changi
multiple ti
• Always clea
flushing.
•Checkwith
chemical c
• When chang
or polyur
componen
have amin
often hav
ng materials, flush the equipment
mes to ensure it is thoroughly clean.
n the fluid inlet strainers after
your material manufacturer for
ompatibility.
ing between epoxies and urethanes
eas, disassemble and clean all fluid
ts and change hoses. Epoxies often
es on the B (hardener) side. Polyureas
eaminesontheA(resin)side.
103A2800B
Troubleshooting
NOTE: Check all possible remedies before disassembling the system.
System Troubleshooting
Troubleshootin
g
Problem
Unit will not operate.
Pump output low on both strokes.
p output low on only one
Pum
roke.
st
No output.Improperly installed dosing valves.
CauseSolution
Inadequate power supply.
Power switch is off.
Main power is shut off.
Exhaust
Clogged fluid outlet line, valves,
etc.
Fluid d
Inadequate power supply.
Exhausted fluid supply.Refill and reprime pump.
Clog
etc.
Worn piston packings.
Hel
Worn piston packing.
ed fluid supply.
ried on piston rod.
ged fluid outlet line, valves,
d open or worn dosing valves.
See Techni
Turn switch on.
Turn main
Refill an
Clear.
Disass
See pum
pump at
See Technical Data, page 59.
r.
Clea
Replace. See pump manual.
Check and repair. See valve
manual.
place. See pump manual.
Re
Check solenoid connections to
valves. See pump manual.
cal Data, page 59.
power switch on.
d reprime pump.
emble and clean pump.
p manual. In future, stop
bottom of stroke.
ump operates erratically.
P
3A2800B
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.
11
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
theactivealarmcode.
• Alarm is saved in the date/time stamped log.
Code
B9A0AdvisoryVolume
ecords an event in the system, and will
after 60 seconds.
e three types occur:
TypeDescriptionProblem
ubleshooting
Batch counter for
Rollove
Current
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
CauseSolution
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
d over at zero.
n/a
B9AXAdvisory Volume
Rollover A
Lifetime
B9B0Advisory Volume
Rollover B
Current
B9BXAdvi
B9D#
Advisory Volume
sory
me
Volu
over B
Roll
time
Life
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#rolledover.
The totalizer has
reached maximum
capable value and
started over at zero.
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
n/a
n/a
n/a
2
1
3A2800B
Troubleshootin
g
Code
B9S0
B9SX
CAC#
CA0X
CADX
TypeDescriptionProblem
Advisory Volume
Rollover
Solvent
Current
Advisory Volume
Rollover
Solvent
Lifetime
Alarm
Alarm
Alarm
Comm.
Error Color
Change #
Comm.
Error ADM
Comm.
Error Fluid
Module
Batch counter
material S rol
Grand total counter for
material S rolled over.
System does not see
the Color Change
Module #.
System does not see
the Advanced Display
Module.
System does not
see the Enhanced
Fluid Control Module
(EFCM).
for
led over.
CauseSolution
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
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.
CANX
CDC
Adviso
AlarmDuplicate
#
ry
Comm.
Error Booth
Control
Color
Change #
System does not see
the Booth Control (and
manual system).
tem sees two or
Sys
e identical Color
mor
nge Modules.
Cha
ommunication
This c
indicates that
error
twork has lost
the Ne
commu
the Bo
modu
Mor
Cha
con
sys
ad
nication with
oth Control
le.
e than one Color
nge Module is
nected in the
tem with the same
dress.
Check CAN cables
connecting booth
control to the Isolation
board. Check Isolation
board power. Replace
cable, booth control,
Isolation board or
Barrier board as
necessary.
ck the system and
Che
ove the extra color
rem
nge module.
cha
3A2800B13
Troubleshootin
g
Code
CDDX
CDNX
DA0#
DE0#
TypeDescriptionProblem
AlarmDuplicate
Fluid
Module
AlarmDuplicate
Booth
Control
AlarmExceeded
Max Flow
Pump #
AlarmLeak Pump#This is a manual stall
System sees tw
more identica
Control Modul
System sees two or
more identical Booth
Control Modules.
Pump was driven to
its maximum allowed
speed.
test failure when the
pump cannot build
pressure to the target
“Stall Test Pressure.”
Will fault after 30
seconds.
oor
l Fluid
es.
CauseSolution
More than one Fluid
Control Module is
connected in the
system.
More than one
Control Modu
connected in
system.
System has a leak
or open valve that is
allowing unrestricted
flow.
Pump is cav
cycling wi
ion.
restrict
Viscosity of material is
too thin for nozzle size.
No material in the
pump or line.
Leak in
the system.
Booth
le is
the
itating,
thout
Check the syst
remove the ext
control modul
Check the system
and remove the extra
booth control module.
Inspect system for
leaks.
Verify pump is being
supplied material.
Reduce nozzle size
to create more
restriction. Reduce
paint pressure to lower
the flow rate.
Make sure the pump
and down stream color
line are loaded with
material.
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.
em and
ra fluid
e.
DF0
4
1
Alarm
#
No S
Pum
tall Up
p#
p stall test failed;
Pum
p did not stall on
pum
up stroke.
the
ve failure, seal
Val
lure, worn rod or
fai
inder.
cyl
Replace inlet and
outlet valve and
seal for up stroke.
Replace piston and
throat seals. Replace
rod and cylinder as
necessary.
3A2800B
Troubleshootin
g
Code
DG0#
DH0#
DK0#
EAUXAdvisory
TypeDescriptionProblem
Alarm
Alarm
AlarmPosition
No Stall
Down
Pump #
No Stall
Pump #
Pump #
USB BusyUSB driv
Pump stall tes
pump did not st
the down strok
Pump stall test failed;
pump did not stall on
either the up or down
stroke.
Thepumpwas
detected to be out
of position.
d, download is
inserte
in progr
t failed;
all on
e.
e has been
ess.
CauseSolution
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.
Wait for
t and
e and seal
wn
place
hroat
lace
inder as
.
USB Idle.
EB00Record
EBH#
EBUXRecord
EC00
0#
EF
RecordHome
rd
Reco
AlarmTimeout
Stop
Button
Pressed
Comple
Pump #
USB
drive was
removed.
Setup
Value(s)
Changed
Startup
Pump #
te
Recordofastopbutton
press.
Record of pump
homing complete.
USB drive was
removed while
downloading or
uploading.
Record of changing
setup variables.
Pump tried but was not
able to move to the
home position within
a specified amount of
time.
Indicates system stop
key on ADM was
pressed.
An indi
displa
compl
funct
Downloading/uploading
data on USB was
interrupted by the USB
device being removed.
Indi
whe
wer
Pump dose valves did
not actuate.
Motor could not drive
pumps and linear
actuator.
Pump stroke length
is shortened by
mechanical system
tolerance.
cation on the
y that the pump
eted the home
ion
cates date and time
n setup values
e changed.
n/a
No acti
Replace the USB
device and begin
process again.
n/a
Ve
to
Ve
ac
Verify motor is driving
the pump.
V
assembly of linear
actuator and pump
piston rods. See pump
manual.
on required.
rify air pressure
solenoid valves.
rify the valves are
tuating.
erify correct
3A2800B15
Troubleshootin
g
Code
EF1#
EL00Record
EM00Record
EMIXAdvisory
TypeDescriptionProblem
AlarmTimeout
Shutdown
Pump #
System
Power On
System
Power Off
Pump Off
Pump tried but was not
able to move to the
park position within a
specified amount of
time.
Record of p
(ON).
Record of power cycle
(OFF).
The pumps are not
powered and are
unable to move.
ower cycle
CauseSolution
Pump dose valves did
not actuate.
Pump is filled with
thick paint and could
not drive piston to
end of stroke. Motor
or drive is worn or
damaged.
Indicates date and
time when system was
started.
Indicate
time when
turned of
Pump power was
turned off or an error
occurred.
s date and
system was
f.
Visually inspect valves
to ensure they are
operating properly;
verify they have air
pressure above 85 psi
(0.6 MPa, 6.0 bar).
Observe motor and
drive assembly to
verify that the motor is
generating force.
n/a
n/a
Start pumps by
pressing pump start
key on Advanced
Display module,
or hold down the
Standby key on the
booth control for 1-2
seconds..
EQU0
EQU1
EQU2
Advis
Record
Record
ory
USB IdleUSB download
process completed,
drive may be removed.
USB S
Sett
Down
USB Sys.
Settings
Uploaded
ys.
ings
loaded
Sett
down
driv
Settings were
uploaded from USB
drive.
ings were
loaded to USB
e.
Data transfer is
completedtotheUSB
device.
installed USB
User
ce in ADM USB
devi
.
port
User installed USB
device in ADM USB
port.
Remove USB device
from ADM.
n/a
n/a
163A2800B
Troubleshootin
g
Code
EQU3
EQU4
EQU5
ES00
EVUXAdvisory
F1F#
TypeDescriptionProblem
Record
Record
Record
Advisory Factory
AlarmFlow Low
USB
Custom
Lang.
Downloaded
USB
Custom
Lang.
Uploaded
USB Logs
Downloaded
Defaults
USB
Disabled
mp #
Fill Pu
Custom Langua
downloaded to
drive.
Custom Language was
uploaded from USB
drive.
Data logs we
downloaded
drive.
Record of
being loa
USB drive has been
inserted, downloading
is disabled.
There ha
flow dur
operat
s been no/low
ing a fill pump
ion.
ge was
USB
re
to USB
defaults
ded.
CauseSolution
User installe
device in ADM U
port.
User installed USB
device in ADM USB
port.
User installed USB
device in ADM USB
port.
Configuration of
system is blocking
data transfer.
There is
on the o
pump or
dUSB
SB
a restriction
utlet side of the
color stack.
n/a
n/a
n/a
n/a
Change configuration
to enable USB
download function.
Make sur
no rest
color s
the dum
ing.
actuat
ethereare
rictions in the
tack and that
pvalveis
F1S#
F6F#
7D#
F
AlarmFlow Low
Purge
Pump #
rm
Ala
AlarmFlow
ss.
Pre
s.
Sen
oved
Rem
let #
In
Detected
Pump #
There has been no/low
flow during a purge
pump operation.
et pressure
Inl
nsducer has been
tra
connected when the
dis
stem is expecting
sy
e.
on
he pump flow
T
xceeded 20 cc/min
e
ow coming into Idle
fl
ode.
m
Thick viscosity
paint requires more
pressure to pump.
Restriction in the outlet
side of the pump or
color stack resulting in
the solvent flow being
too low.
connected
Dis
nsducer.
tra
There is a leak in the
system or the gun was
open when the system
went into Idle mode.
Increase non-mix
pressure if necessary
to create flow during
the fill function.
Make sure there are
no restrictions in the
system. Increase
non-mix pressure if
necessary to create
flow during the purge
function.
Verify transducer
is connected
properly. Replace if
reconnecting does not
eliminate the alarm.
erify there are no
V
eaks in the system.
l
ake sure the air flow
M
witch is actuating
s
roperly. Do not
p
rigger the gun without
t
atomizing air.
3A2800B
17
Troubleshootin
g
Code
F7P1AlarmFlow
F7S1
F8D1AlarmFlow Not
F9D#
MMUXAdvisory
TypeDescriptionProblem
Detected
Air Gun
AlarmFlow
Detected
Solvent
Gun
Detected
AlarmFlow
Unstable
Pump #
Maint. USB
Logs Full
CauseSolution
The air flow swi
indicating un
atomizing air
The solvent flow
switch is indicating
unexpected solvent
flow.
No Flow while mixing.Restriction in the outlet
The pump
did not s
enterin
USB memory is >90%
full.
tabilize while
g Idle mode.
tch is
expected
flow.
flow rate
Air flow switch
in flow positio
Leak downstream in
air line or fitting.
Air supply pr
fluctuation
Solvent flow switch is
stuck in flow position.
There is a l
the solven
valve.
side of the pump or
color stack.
Potential leak in the
system.
Configuration
parameter on system
is enabled to generate
this advisory.
is stuck
n.
essure
.
eak through
t cutoff
Clean or repla
switch.
Check for leaks and
tighten fittings.
Eliminate pr
fluctuation
Clean or replace
switch.
Check for leaks and
repair valve.
Make sure there are
no restrictions in the
system.
Check th
leaks an
st.
stall te
Complete download to
ensure no data is lost.
ce
essure
s.
esystemfor
d run manual
P1F#
P2F#
P3D
P3F#
P4D#
P4F#
AlarmPress
Deviation Pressure
Deviation Pressure
#
viationPressure
De
AlarmPressure
AlarmPressure
ure
Low In
Pump #
Low Inlet
Pump #
High Outlet
Pump #
Hi
Pu
High Outlet
Pump #
High Inlet
Pump #
let
gh Inlet
mp #
let pressure on
The in
pump #
the us
limit
The inlet pressure on
pump # is less than the
user-entered deviation
limit.
The outlet pressure
on pump # is greater
than the user entered
deviation limit.
Th
on
th
de
The outlet pressure on
pump # is greater than
the user entered alarm
limit.
The inlet pressure on
pump # is greater than
the user-entered alarm
limit.
is less than
er-entered alarm
.
e inlet pressure
pump # is greater
an the user-entered
viation limit.
ase inlet
Incre
ure.
press
Increase inlet
pressure.
Relieve system
pressure.
crease inlet
De
essure.
pr
Relieve system
pressure.
Decrease inlet
pressure.
183A2800B
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