Installation-Parts Pump Expansion Kits 332456B To add a third or fourth pump to a ProMix® PD2K Proportioner. Each kit includes one pump and associated parts. PD2K is shown with two kits added. For professional use only. Important Safety Instructions Read all warnings and instructions in this manual and in your PD2K manual. Save these instructions. See page 3 for model part numbers and approvals information. PROVEN QUALITY. LEADING TECHNOLOGY.
Contents Related Manuals ................................................ 2 Models............................................................... 3 Warnings ........................................................... 4 Important Isocyanate (ISO) Information ................ Isocyanate Conditions .................................. Material Self-ignition..................................... Keep Components A and B Separate ............ Moisture Sensitivity of Isocyanates................ Changing Materials ...
Models Models Kit Part No. Series Description Maximum Fluid Working Pressure 24R968 A 70 cc Low Pressure Color Pump Kit 300 psi (2.068 MPa, 20.68 bar) 24R969 A 70 cc High Pressure Color Pump Kit 1500 psi (10.34 MPa, 103.4 bar) 24R970 A 35 cc Low Pressure Color or Catalyst Pump Kit 300 psi (2.068 MPa, 20.68 bar) 24R971 A 35 cc High Pressure Color or Catalyst Pump Kit 1500 psi (10.34 MPa, 103.4 bar) Figure 1 .
Warnings Warnings The following warnings are for the setup, use, grounding, maintenance and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.
Warnings WARNING 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. • Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources. TOXIC FLUID OR FUMES Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.
Important Isocyanate (ISO) Information Important Isocyanate (ISO) Information Isocyanates (ISO) are catalysts used in two component materials. Keep Components A and B Separate Isocyanate Conditions Cross-contamination can result in cured material in fluid lines which could cause serious injury or damage equipment. To prevent cross-contamination: Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates.
Important Isocyanate (ISO) Information Changing Materials NOTICE Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime. • When changing materials, flush the equipment multiple times to ensure it is thoroughly clean. • Always clean the fluid inlet strainers after flushing. • Check with your material manufacturer for chemical compatibility.
Installation Installation Before Installing the Kit Install the Frame 1. Follow the steps in Before Installing the Kit, page 8 . • 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. • Do not substitute or modify system components as this may impair intrinsic safety.
Installation Figure 2 Install the Frame and Pump 332456B 9
Installation TSL Cup Kit Throat Seal Liquid (TSL) lubricates the pump throat packings and dosing valves. The TSL Cup Kit supplies TSL to the upper and lower throat cartridges of the pump, and to the four pump dosing valves. NOTE: TSL must be ordered separately. Order Part No. 206995, 1 quart (0.95 liter). 1. Slide the kit mounting bracket onto any side of the pump’s hex nut. NOTE: If you are not lubricating the dosing valves, remove the unused barbed fittings (73b) from the bottom of the TSL cup (73).
Installation Air Connections NOTE: A 6 ft (1.83 m) length of 1/4 in. (6 mm) OD polyethylene tubing (35) is supplied with the kit to supply air to the expansion pump’s solenoid manifold (3). 1. See the PD2K Repair-Parts Manual. Remove the PD2K fluid panel cover to expose the air supply tubing to the two existing solenoid manifolds. 2. Cut the air supply tubing upstream of the Y-fitting. 4. Connect the supplied 1/4 in.
Installation Fluid Connections 1. Connect a 1/4 npt(f) fluid hose from the fluid source to the pump’s fluid inlet fitting (S). 2. Connect a 1/4 npt(f) fluid outlet hose from the pump’s fluid outlet fitting (R) to the gun’s fluid supply.
Installation Electrical Connections NOTICE To avoid electrical component damage, remove all system power before plugging any connectors. NOTE: See the Electrical Schematics, page 21. 1. Verify that electrical power is removed from the system. 2. Remove the cover from the PD2K electrical control box. 3. Remove the knockout (K) from the side of the electrical control box. Figure 6 Install Grommet in Electrical Control Box 4.
Installation 5. The PD2K fluid panel cover was previously removed in Air Connections, page 11. Thread the 2–wire cable (22) through the grommet (42) on the bottom of the fluid panel and up into the electrical box through an existing grommet and the wireway. Connect the cable (22) to the appropriate terminals on the top of the 48 Vdc power supply (P3 for pump 3, P4 for pump 4); red wire to + terminal, black wire to - terminal. 6.
Installation 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. Verify that the added pump is grounded by taking a resistance reading from the ground screw (7) on the added pump kit’s back panel (2) to the system’s true earth ground. Resistance must be less than 1 ohm. 1.
Installation Complete the Installation 1. Install the cover (12) on the expansion kit, using the screw (37) and nut (18). 3. Turn on the control box power switch. and navigate to System Screen 1 4. Press on the Advanced Display Module. Change the number of Color Pumps and Catalyst Pumps as needed, based on the kit installation. Figure 10 Install Expansion Kit Cover Figure 11 System Screen 1 2. Restore electrical power to the PD2K.
Installation 5. Go to the Pump Screens. The menu bar at the top of the screen will now show separate tabs for the added pump(s) 3 and 4. Each pump has three screens. Enter the required information, as explained in the PD2K Operation Manual. NOTE: At a minimum, you must enter the Pump Size on Pump Screen 1 and transducer calibration data “Outlet Offset Factor” and “Outlet Sensitivity Factor” on Pump Screen 2 (see your PD2K Operation Manual).
Repair Repair Dose Valve Tubing Connections NOTE: Red and green 5/32 in. (4 mm) tubing connects the solenoid manifold to the pump’s dosing valves. See the Pump Tubing Schematic on the next page. Tubing lengths must be 18 in. ± 1/2 in. (457 mm ± 13 mm) for all connections. Always use equal lengths of tubing, to balance the timing of the valves. Lengths longer than 18 in. (457 mm) will increase valve response time. 1.
Repair c. Connect green tubing (G) from the DOWN OPEN fitting to the 90° tube fitting on the side of the OUTLET DOWN dosing valve. d. Connect red tubing (R) from the DOWN CLOSED fitting to the 90° tube fitting on the end of the OUTLET DOWN dosing valve. 3. Repeat these steps for each pump in your system.
Repair Replace Pump Control Module If the pump control module needs replacement, install a new module as follows. NOTICE To avoid electrical component damage, remove all system power before plugging any connectors. NOTE: See the Electrical Schematics, page 21. 1. Connect the motor cable connectors (25) to connection ports 2 and 3 on the pump control module (5) and to the pump motor (N). NOTE: The wire harness has two cables, one for the motor control and the other for encoder feedback.
Electrical Schematics Electrical Schematics 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 for a list of cable options. FAN (24P658) ENCODER AND MOTOR (16P036, 16P037) WIRE HARNESS (24P684, 24P685) PUMP OUTLET TRANSDUCER (16P289, 16P290) MAC SERIES 46 SOLENOID (16P812) PUMP V/P FOR FLUID REG.
Electrical Schematics CONTINUED ON PAGE 3 CONTINUED ON PAGE 3 (NON IS) (IS) 3 (24M485) UNUSED UNUSED SOLVENT CUTOFF BARRIER BOARD (248192) UNUSED 8 3 1 2 3 4 5 6 7 8 9 10 11 12 5 (121227) GCA MODULE EFCM (24N913) PWR (RED) SIG (WHITE) COM (BLACK) SHIELD/GRN SOLVENT METER (258718) RED WIRE (065161) +12VDC COM UNUSED UNUSED +12VDC COM +12VDC COM UNUSED GROUND BAR BLACK WIRE (065159) 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 4 25 PIN D-SUB CABLE (16T659) 24
Electrical Schematics GUN TRIGGER INPUTS SIG COM SIG COM SIG COM SIG COM SIG COM SIG COM 7 1 2 3 4 5 6 7 8 9 10 11 12 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 UNUSED UNUSED UNUSED UNUSED 9 1 2 3 4 5 6 GCA MODULE EFCM (24N913) 3 4 LIGHT TOWER (15X472) 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1 BREAKOUT MODULE PUMP 3 (24N
Electrical Schematics FROM CAN IS BOARD (24M485) ON PAGE 2 FROM CAN IS BOARD (24M485) ON PAGE 2 2 CABLE (15V206) MANIFOLD FLUSH COLOR 1 COLOR 2 COLOR 3 COLOR 4 COLOR 5 COLOR 6 COLOR 7 COLOR 8 12 34 5 COLOR CHANGE MODULE 1 (COLORS 1 THRU 8) +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 J15 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 J14 J8 J9 1 2 3 4 5 6 +12VDC COM +12VDC COM +12VDC COM J16 1 2 3 4 5 6 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4
Electrical Schematics MANIFOLD FLUSH CATALYST 3 CATALYST 4 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED 1 2 3 4 5 6 UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED 1 2 3 4 5 6 CATALYST CHANGE MODULE 6 (CATALYST 3 THRU 4) J8 J9 1 2 3 4 5 6 +12VDC COM +12VDC COM +12VDC COM J16 1 2 3 4 5 6 UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED J10 1 2 3 4 5 6 UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED 6 J15 J14 MANIFOLD DUMP CATALYST 3 CATALYST 4 2 CABLE (15V206)
Electrical Schematics FROM CAN IS BOARD (24M485) ON PAGE 2 NON-HAZARDOUS LOCATION HAZARDOUS LOCATION MANIFOLD COLOR FLUSH COLOR 1 COLOR 2 COLOR 3 COLOR 4 COLOR 5 COLOR 6 COLOR 7 COLOR 8 12 34 5 COLOR CHANGE MODULE 7 (COLORS 33 THRU 40) +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 J8 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 J15 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 J9 1 2 3 4 5 6 +12VDC COM +12VDC COM +12VDC COM J16 1 2 3 4 5 6 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 +12VD
Pump Expansion Kit Parts Pump Expansion Kit Parts 332456B 27
Pump Expansion Kit Parts Part No. 24R968, 70 cc Low Pressure Color Pump Kit Part No. 24R969, 70 cc High Pressure Color Pump Kit Part No. 24R970, 35 cc Low Pressure Catalyst Pump Kit Part No. 24R971, 35 cc High Pressure Catalyst Pump Kit Ref 1 Part ——— 2 ——— BRACKET, mounting, pump PANEL, back 3 24T772 MANIFOLD, solenoid 1 4 5 24T770 KIT, fan 1 24N527 1 6 ——— 7 ——— 8 16V659 9 24T790 MODULE, control, pump SCREW, cap, socket head; 10–32 x 1.5 in. (38 mm) SCREW, ground; M5 x 0.
Pump Expansion Kit Parts Ref 73 Part Description 24T302 73a ——— KIT, cup, TSL; includes items 73a-73e BRACKET 73b 24U617 73c ——— 332456B 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 Qty 1 1 1 1 Ref 73d Part ——— 73e ——— Description PLUG, screw; 10–32; to replace unused item 73b at TSL cup; not shown GASKET; for item 73d; not shown Qty 4 4 Items marked — — — are not available separately.
Notes Notes 30 332456B
Technical Data Technical Data Pump Expansion Kit U.S. Metric Kits 24R968 and 24R970 300 psi 2.1 MPa, 21 bar Kits 24R969 and 24R971 1500 psi 10.5 MPa, 105 bar Maximum working air pressure: 100 psi 0.7 MPa, 7.0 bar Maximum fluid working pressure: Wetted parts: 332456B See Pump manual 332339.
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.
