Graco 332455F User Manual

Instructions-PartsColor Change Kits332455FENTo add optional color change function to ProMix® PD2K Electronic Proportioners. Kits include low orhigh pr

Important Isocyanate (ISO) InformationImportant Isocyanate (ISO) InformationIsocyanates (ISO) are catalysts used in twocomponent materials.Isocyanate

Important Isocyanate (ISO) InformationChanging MaterialsNOTICEChanging the material types used in yourequipment requires special attention to avoidequ

Setup the ModulesSetup the ModulesSetup Non-IS Control ModulesNOTE: The PD2K System can use up to four pumpsand six color change modules in the non-ha

Setup the ModulesConfigure each module according to its designatednumber, as follows:NOTICETo avoid damaging the circuit boards, wear PartNo. 112190 gr

Setup the ModulesNon-IS Control Module 1Inlet ManifoldOutlet ManifoldSolenoidValveSolenoidValve1Solvent1Dump2Color 12Color 13Color 23Color 24Color 34C

Setup the ModulesSetup IS Control ModulesNOTE: Two color change control modules may beinstalled in the hazardous area. The modules arelabeled 7 or 8.

Setup the ModulesIS Control Module 7SolenoidValveSolenoidValve1ColorSolvent1CatalystSolvent2Color 12Catalyst 13Color 23Catalyst 24Color 34Catalyst 35C

InstallationInstallation• To avoid electric shock, turn off power atthe main circuit breaker before opening theenclosure.• All electrical wiring must

InstallationNon-Hazardous LocationNOTE: Non-IS color change control modules providecontrol for the pump’s inlet and outlet color/catalystchange valves

InstallationNotes332455F 19

ContentsRelated Manuals ... 3Models... 4Non-I

InstallationHazardous LocationNOTE: IS colorchange control modules providecontrol for color/catalyst change valves located in thehazardous location. A

Installation5. Mount a second color control module asdescribed in Mounting the Color ChangeControl Module, page 17. Connect the suppliedhazardous loca

InstallationNotes22332455F

InstallationInstall the Back Pressure Regulator(High Pressure Systems Only)NOTE: The back pressure regulator is required onhigh pressure systems to pr

InstallationConnect the Fluid LinesConnect Non-Circulating Fluid LinesNOTE: There can be only one solvent valve (S) andone dump valve (D) per pump.NOT

Installation6. Connect a dedicated gun supply line for eachcolor to the corresponding color valve fitting (C1,C2, etc.) on the outlet color valve stack

InstallationConnect Circulating Fluid LinesCirculation valves enable constant circulation of acolor when that color is not being sprayed:•Whenacolorva

InstallationFluid Flow Schematic Diagram in Circulating Mode (Pump Not Shown for Clarity)KEYAColor supplyB Inlet color stackC Outlet color stackDY fitt

InstallationInstall an Expansion KitExpansion Kits are available to addvalves or manifolds to your system. SeeExpansion Kits, page 64 for available ki

InstallationInstall an Expansion Kit (Low PressureValve Manifold Shown)Non-CirculatingCirculating332455F 29

Related ManualsRelated ManualsManual No. Description3A2800 PD2K Proportioner Repair-PartsManual, ManualSystems332457 PD2K Proportioner InstallationMan

TroubleshootingTroubleshootingNOTE: Check all possible remedies before disassembling the system.Color Change Solenoid ValvesNOTE: Refer to Electrical

TroubleshootingCause Solution4. Control board or cablefailure.Ifthereisnovoltage across the pins on the board or it is less than 9 Vdc, checkLEDs D8,

TroubleshootingColor Change BoardNOTICETo avoid damaging the circuit boards, wear PartNo. 112190 grounding strap on your wrist andground appropriately

TroubleshootingColor Change Board DiagnosticsComponent orIndicatorDescription DiagnosisD8LED (green) Blinks (heartbeat) during normal operation.D9LED

Electrical SchematicsElectrical SchematicsNOTE: The electrical schematic illustrates all possiblewiring expansions in a ProMix PD2K system. Somecompon

Electrical Schematics+24VDCCOM+24VDCCOMPWR (RED)SIG (WHITE)COM (BLACK)SHIELD/GRNMANIFOLDGROUND BARINLET TRANSDUCERPUMP 1(16P289 OR 16P290)OUTLET TRANS

Electrical SchematicsGUN TRIGGER INPUTSGFB PRESSURE SWITCH (121323)SOLVENT FLOW SWITCH (120278)1234512345LIGHTTOWER(15X472)ADVANCEDDISPLAY MODULE(24E4

Electrical SchematicsCOLOR CHANGEMODULE 1(COLORS1 THRU 8)123456MANIFOLD123456123456J8J15J14J9J10J161234512345COLORCHANGEMODULE 2(COLORS9 THRU 16)J8J15

Electrical SchematicsCATALYSTCHANGEMODULE 5(CATALYST1 THRU 2)123456MANIFOLD123456123456J8J15J14J9J10J161234512345CATALYSTCHANGEMODULE 6(CATALYST3 THRU

Electrical SchematicsFROM CAN IS BOARD (24M485) ON PAGE 2BOOTH CONTROL(24M731)COLORCHANGEMODULE 7(COLORS33 THRU 40)J8J15J14J9J10J161234512345COLORCHAN

ModelsModelsNon-Intrinsically Safe KitsSee the module identification label for product part number, maximum air working pressure, and approvalinformati

Electrical SchematicsOptional Cables and ModulesNOTE: Thetotallengthofallcableusedinthesystemmustnotexceed150ft(45m). See theElectrical Schematics, pa

RepairRepair• To avoid electric shock, turn off power at themain circuit breaker before opening the controlmodule.• All electrical wiring must be done

RepairReplace a Solenoid1. Remove electrical power from the system.2. Remove air supply pressure from the system.3. Remove the color change module cov

RepairReplace the Color Change BoardNOTICETo avoid damaging the circuit boards, wear PartNo. 112190 grounding strap on your wrist andground appropriat

PartsPartsNon-IS SystemShownDetail of Back Pressure Regulator (High Pressure Outlet Stack only)44332455F

PartsNon-IS Color Change KitsRef.No.PartNo.DescriptionQty101 24U237BRACKET, mounting1102◆KIT, manifold, valve2103 100157SCREW, cap, hex head;1/4–20 x

PartsHigh Pressure Non-IS KitsKit No. Kit DescriptionStandard ValveManifold Kits(102) [seeHigh PressureValve ManifoldKits, page 55 forall availablekit

PartsIS Color ChangeKitsRef.No.PartNo.DescriptionQty101 24U237BRACKET, mounting1102◆KIT, manifold, valve; mustbe ordered separately. SeeValve Manifold

PartsHigh Pressure IS KitsKit No. Kit DescriptionStandard ValveManifold Kits(102) [seeHigh PressureValve ManifoldKits, page 55 forall availablekits]Co

PartsValve ManifoldsLow Pressure Valve Manifold KitsNon-Circulating Valve Manifold KitsKit No.SeriesKit Description24T457 A 2 valves24T458 A 3 valves2

ModelsKit No.SeriesKit DescriptionMaximum Air Working Pressure(Control Module)Maximum Fluid WorkingPressure (Valves)High Pressure Non-Circulating Colo

PartsValve Manifold Kit PartsNon-CirculatingKitsCirculating Kits50 332455F

PartsRef.No.PartNo.DescriptionQty116P259MANIFOLD2111450O-RING; chemically resistant24T441VALVE, for non-circulatingkits; includes item 2324T442VALVE,

PartsReference NumbersKit No.12345678 1012 131415161718 1924T4751020 20 0 20 11 1 1 3 21 21 20 15 0 1 20 024T4761122 21 1 22 12 1 1 3 22 22 21 15 3 1

PartsLow Pressure Circulating Valve Manifold Kit Part QuantitiesReference NumbersKit No.12345678 1012131415 161718 192224T487121022 11355203100124T488

PartsNotes54 332455F

PartsHigh Pressure Valve Manifold KitsNon-Circulating Valve Manifold KitsKit No.SeriesKit Description24T647 A 2 valves24T648 A 3 valves24T649 A 4 valv

PartsValve Manifold Kit PartsNon-CirculatingKitsCirculating Kits56 332455F

PartsRef.No.Part No. DescriptionQty116N271MANIFOLD, for circulating kits2111450O-RING; chemically resistant24T581VALVE, for non-circulatingkits; inclu

PartsReference NumbersKit No.12345678 1012 131415 1618 1924T6661122 21 1 22 12 1 1 3 22 22 21511224T6671122 22 0 22 12 1 1 3 23 23 22510024T6681224 23

PartsHigh Pressure Circulating Valve Manifold Kit Part QuantitiesReference NumbersKit No.12345678 1012 1314151618 192224T677121 022 1135520100124T6782

ModelsIntrinsicallySafeKitsSee the module identification label for product part number, maximum air working pressure, and approvalinformation and certi

PartsColor Change Control Module KitsNon-IS Color Change Control Modules60 332455F

PartsRef.No.PartNo.DescriptionQty301 16P855 PANEL 1302 24T566BOARD, circuit1302a 123690FUSE; 125 mA1303 112324SCREW, machine, pan head;4–40 x 0.25 in.

PartsIS Color Change Control Modules62 332455F

PartsRef.No.PartNo.DescriptionQty301 16U742 PANEL 1302 24T566BOARD, circuit1302a 123690FUSE; 125 mA1303 112324SCREW, machine, pan head;4–40 x 0.25 in.

PartsExpansion KitsNon-IS Expansion KitsThe followingkits are available to add color valves in a non-IS area. See Install an Expansion Kit, page 28 fo

PartsIS Expansion KitsThefollowingkitsareavailabletoaddcolorvalvesinanISarea. SeeInstall an Expansion Kit, page 28 forinstructions.Low Pressure Expans

DimensionsDimensionsFigure 25 Non-IS Control ModuleABCDEF11.30 in. (1478mm)7.67 in. (195mm)9.8 in. (249 mm) 5.70 in. (145mm)0.31 in. (8 mm) 5.80 in. (

DimensionsNOTE: Total height of valve stack = H + K + (J xnumber of manifold blocks in your stack).Figure 27 ManifoldGHJKLMNPRSLow Pressure Valve Mani

DimensionsFigure 28 Manifold Mounting BracketTUV3.84 in. (98mm)11.44 in. (291mm)0.312 in. (8mm) diameter68 332455F

WeightsWeightsLow Pressure Non-Circulating Valve Manifold KitsKit No. lbgrams24T457 1.90 86324T458 2.82 127724T459 2.80 126924T460 3.71 168424T461 3.6

WarningsWarningsThe followingwarnings are for the setup, use, grounding, maintenance and repair of this equipment. Theexclamation point symbol alerts

WeightsHigh Pressure Non-Circulating Valve Manifold KitsKit No. lbgrams24T6477.7350324T648 11.5 521024T649 11.7 532924T650 15.5 703624T651 15.8 715424

WeightsNon-IS Color Change Control ModulesKit No. lbgrams24T557 9.7 438624T558 10.1 457624T559 10.5 476624T560 10.9 4956Non-IS Color Change Control Mo

NotesNotes72332455F

Technical DataTechnical DataColor Change Kits U.S.MetricMaximum fluid workingpressure:Low pressure kits 300 psi 2.1 MPa, 21 barHigh pressure kits1500 p

Graco Standard WarrantyGraco warrants all equipment referenced in this document which is manufactured by Graco and bearing itsname to be free from def

WarningsWARNINGINTRINSIC SAFETYIntrinsically safe equipment that is installed improperly or connected to non-intrinsically safeequipment will create a

WarningsWARNINGPERSONAL PROTECTIVE EQUIPMENTWear appropriate protective equipment when in the work area to help prevent serious injury,including eye i