Installation ProMix® PD2K Electronic Proportioner 332457C EN Electronic positive displacement proportioner for fast-setting two-component materials. Manual system with Advanced Display Module. For professional use only. Important Safety Instructions Read all warnings and instructions in this manual. Save these instructions. See page 3 for model part numbers and approvals information. PROVEN QUALITY. LEADING TECHNOLOGY.
Contents Warnings ........................................................... 5 Fluid Supply ....................................................... 22 Fluid Requirements ...................................... 22 Single Color Connections ............................. 23 Color Change Connections........................... 23 Important Isocyanate (ISO) Information ................ 8 TSL Cup Kit........................................................ 24 System Control Drawing 16P577 ......................
Models Models See Figs. 1–7 for component identification labels, including approval information and certification. Part No. Series Maximum Air Working Pressure Maximum Fluid Working Pressure MC1000 A 100 psi (0.7 MPa, 7.0 bar) 300 psi (2.068 MPa, 20.68 bar) MC2000 A 100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.
Models Figure 3 Model MC2000 (High Pressure) Identification Label Figure 4 Non-Intrinsically Safe Color Change Control (Accessory) Identification Label Figure 5 Intrinsically Safe Color Change Control (Accessory) Identification Label Figure 6 Booth Control Identification Label Figure 7 Pump Expansion Kit (Accessory) Identification Label 4 332457C
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 INTRINSIC SAFETY WARNING 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.
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: • Protective eyewear, and hearing protection. • Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer. EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury.
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.
System Control Drawing 16P577 System Control Drawing 16P577 Do not substitute or modify system components as this may impair intrinsic safety. For installation, maintenance, or operation instructions, read instruction manuals. 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.
System Control Drawing 16P577 NON-HAZARDOUS LOCATION ONLY HAZARDOUS (CLASSIFIED) LOCATION Class 1, Div 1, Group D, T3 (USA and Canada) Class 1, Zone 1, Group IIA, T3 (ATEX and IECEx) Ta = 2°C to 50°C NON-HAZARDOUS LOCATION ONLY POWER IN 250 VAC MAXIMUM SUPPLY VOLTAGE HAZARDOUS (CLASSIFED) LOCATION CLASS 1, DIV 1, GROUP D, T3 (USA AND CANADA) CLASS 1, ZONE 1, GROUP IIA, T3 (ATEX AND IECEx) Ta = 2 C TO 50 C PROMIX PD2K ELECTRICAL ENCLOSURE (24M672) POWER BARRIER (248192) CABLE (16V426) FM13ATEX0026 IECE
Configuring Your System Configuring Your System 1. Select a Base Model Choose a PD2K base model that meets your application’s requirements. See Models, page 3 . Base models include components A through F shown in the Typical Installation Drawing. Base unit components are described in the following table. Component Description Fluid Pumps (A, B) The base models include two fluid pumps, one for resin and one for catalyst. Install in the non-hazardous area.
Configuring Your System HAZARDOUS (CLASSIFIED) LOCATION NON-HAZARDOUS LOCATION ONLY Figure 9 Typical Installation Component Description ★ Components A through F are included with the base unit. A★ Material A (Color) Pump B★ Material B (Catalyst) Pump C★ Solvent Valve D★ Booth Control E★ Electrical Control Box F★ Advanced Display Module Components G through K are included in optional color change kits.
Configuring Your System 2. Select Hoses Hose Selection Tool Use this chart to determine the proper size hose bundle for your mix ratio and viscosity, then select a hose bundle for your application from the tables on the following page. NOTE: Always use Graco hoses. NOTE: Shaded areas may use hose sizes from either of the two adjacent areas. LOW PRESSURE SYSTEM, 0–300 psi (0–2.
Configuring Your System 1/4 in. (6 mm) ID Hose Bundles Select a hose bundle from the following table. Always use Graco hoses. Application Hose Bundle Part No. Length Material Low Pressure Conventional Air Spray 24T140 25 ft (7.6 m) 24T141 50 ft (15.2 m) Nylon (A side and Solvent), Moisture Guard (B side), Air Hose 24T138 25 ft (7.6 m) 24T139 50 ft (15.2 m) 24T247 25 ft (7.6 m) 24T248 50 ft (15.2 m) 24T245 25 ft (7.6 m) 24T246 50 ft (15.
Configuring Your System 3. Select Mix Manifold The following mix manifold kits are available. The mix manifolds attach to the painter’s belt, allowing mixing to occur at the point of spray. See manual 3A2801 for further information. Mix Manifold Description Maximum Fluid Working Pressure 24R99 1 Low pressure mix manifold 300 psi (2.1 MPa, 21 bar) 24R99 2 High pressure mix manifold 1500 psi (10.5 MPa, 105 bar) 24T273 High pressure mix manifold, for acid-compatible materials 1500 psi (10.
Configuring Your System 5. Select Color and Catalyst Change Kits Using the following table, choose color/catalyst change kits that meet your application’s requirements. The kits include a manifold with valves and a control module. See color change kit manual 332455 for further information. Table 1 . Low Pressure Color/Catalyst Change Kits (300 psi [2.068 MPa, 20.68 bar]) Kit Part No. Kit Description Table 2 . High Pressure Color/Catalyst Change Kits (1500 psi [10.34 MPa, 103.4 bar]) Kit Part No.
General Information General Information Location • Reference numbers and letters in parentheses in the text refer to numbers and letters in the illustrations. • Be sure all accessories are adequately sized and pressure-rated to meet system requirements. • To protect the screens from paints and solvents, clear-plastic protective shields (10 per pack) are available. Order Part No. 197902 for the Advanced Display Module and Part No. 15M483 for the Booth Control.
Install the Display Module Install the Display Module 1. Use the screws (11) to mount the bracket (10) for the Advanced Display Module (12) on the front of the Control Box or on the wall, as you prefer. 2. Snap the Advanced Display Module into the bracket. Figure 11 Advanced Display Module Connection Ports Figure 10 Install Display Module 3. Connect one end of the 5 ft (1.5 m) CAN cable (provided) to the Advanced Display Module (M).
Install the Booth Control Install the Booth Control 1. Use screws (S) to mount the bracket (10) for the Booth Control (13) on the wall. Connect a ground wire (G) to one of the screws. Connect the other end of the ground wire to a true earth ground. 2. Snap the Booth Control into the bracket. 3. Connect the Booth Control to the Isolation Board in the Electrical Control Box, using the 50 ft (15.2 m) intrinsically safe CAN cable (163).
Air Supply Air Supply Air Requirements switch detects air flow to the gun and signals the controller when the gun is being triggered. • Compressed air supply pressure: 85-100 psi (0.6–0.7 MPa, 6.0-7.0 bar). NOTE: If there is more than one gun (for example, a separate gun for each color), the atomizing air outlet (159c) must be branched to each gun. For ease of maintenance, install a ball valve at all air line tees. • Air hoses: use grounded hoses that are correctly sized for your system.
Fluid Supply Fluid Supply Fluid Requirements • Materials can be transferred from their original containers or from a central paint recirculating line. • Install a 100 mesh (minimum) fluid filter in the fluid supply line, with a drain valve. • To reduce the risk of equipment overpressurization and rupture which can cause injury, including skin injection, do not exceed the pressure rating of the lowest rated system component. See the identification label for the maximum working pressure of the equipment.
Fluid Supply Single Color Connections Color Change Connections NOTE: Check valves (J, L) are provided on the inlet and outlet manifolds of each pump. If you are installing the color change accessory kit, make the fluid connections as described in manual 332455. 1. Connect the color supply line to the pump fluid inlet fitting (S). 2. Connect the color outlet line to the pump fluid outlet fitting (R). 3. Make the same connections on the catalyst side.
TSL Cup Kit TSL Cup Kit Throat Seal Liquid (TSL) lubricates the pump throat packings and dosing valves. The PD2K Proportioner includes two TSL Cup Kits, one for each pump. The kits supply TSL to the upper and lower throat cartridges of each 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.
Solvent Meter Accessory Solvent Meter Accessory To install Solvent Meter Kit 280555, see manual 308778. NOTE: Install the solvent meter downstream of the solvent cutoff switch near the base unit. Electrostatic Air Hose Quick Disconnect Kit 24S004 Light Tower Accessory NOTE: To use a quick disconnect on an existing electrostatic air hose, order Part No. 24S004 Kit. You will also need to order Part No. 24U059 Electrostatic Air Whip Hose (6 ft) [1.8 m].
Electrical Supply Electrical Supply Electrical Connections See Electrical Schematics, page 31. Improper wiring may cause electric shock or other serious injury if work is not performed properly. All electrical wiring must be completed by a qualified electrician and comply with all local codes and regulations. Electrical Requirements Enclose all cables routed in the spray booth and high traffic areas in conduit to prevent damage from paint, solvent, and traffic.
Grounding Grounding Booth Control 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. Electrical Control Box The electrical control box has two ground points. Both connections must be made. • Connect the ground wire (Y) to the ground screw on the electrical control box.
Grounding HAZARDOUS LOCATION NON-HAZARDOUS LOCATION Figure 21 System Grounding Key 1 Electrical Control Box ground screw 2 Electrical Control Box ground wire 3 Color Change Module (CC) ground wires 4 Intrinsically Safe (IS) cable 28 5 True Earth Ground; check local code for requirements 6 Non-Intrinsically Safe cable 7 Booth Control (BC) mounting bracket ground wire 332457C
Grounding Object Being Sprayed Check Resistance Follow local code. All Solvent Pails Used When Purging Follow local code. Use only conductive metal pails/containers placed on a grounded surface. Do not place the pail/container on a nonconductive surface, such as paper or cardboard, which interrupts the grounding continuity. 332457C To ensure proper grounding, resistance between components and true earth ground must be less than 1 ohm.
Notes Notes 30 332457C
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, page 37 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
Electrical Schematics Optional Cables and Modules NOTE: The total length of all cable used in the system must not exceed 150 ft (45 m). See the Electrical Schematics, page 31. M12 CAN Cables, for Hazardous Locations CAN Cables, for Non-Hazardous Locations Only NOTE: The total length of cable used in the hazardous location must not exceed 120 ft (36 m). Cable Part No. Length ft (m) Cable Part No. Length ft (m) 125306 1.0 (0.3) 16V423 2.0 (0.6) 123422 1.3 (0.4) 16V424 3.0 (1.0) 121000 1.6 (0.
Dimensions Dimensions Figure 28 Figure 29 Figure 30 B A 58.20 in. (1478 mm) 38 with ADM without ADM 14.5 in. (368 mm) 11.12 in. (282 mm) C D E F G H 22.0 in. (559 mm) 19.26 in. (489 mm) 2.0 in. (51 mm) 18.0 in. (457 mm) 17.26 in. (438 mm) 0.52 in.
Technical Data Technical Data Positive Displacement Proportioner U.S. Metric MC1000 Air Spray Systems 300 psi 2.1 MPa, 21 bar MC2000 Air-Assisted Spray Systems 1500 psi 10.5 MPa, 105 bar 100 psi 0.7 MPa, 7.0 bar 85–100 psi 0.6–0.7 MPa, 6.0–7.
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.
