Graco 24W159 User manual

Installation-Parts
Isolated Isolated
IsolatedPump Pump PumpExpansion Expansion ExpansionKits Kits Kits334512C
EN
For For
Foruse use usewith with witha a aProMix® ProMix® ProMix®MC0500 MC0500 MC0500Proportioner Proportioner Proportionerto to topump pump pumpcolor, color, color,catalyst, catalyst, catalyst,and and andsolvent. solvent. solvent.For For Forprofessional professional professionaluse use use
only. only.
only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
ReadallwarningsandinstructionsinthismanualandinyourPD2K
Installation,Operation,andRepairmanuals.
Save Save
Savethese these theseinstructions. instructions. instructions.
Seepage3formodelpartnumbersand
approvalsinformation.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
RelatedManuals................................................2
Models...............................................................3
Warnings...........................................................4
ImportantIsocyanate(ISO)Information................7
IsocyanateConditions..................................7
MaterialSelf-ignition.....................................7
KeepComponentsAandBSeparate............7
MoistureSensitivityofIsocyanates................8
ChangingMaterials......................................8
Installation..........................................................9
BeforeInstallingtheKit.................................9
InstallthePump..........................................9
TSLCupKit.................................................11
FluidConnections........................................13
ElectricalConnections..................................14
Grounding...................................................16
CompletetheInstallation..............................17
Repair................................................................19
DoseValveTubingConnections...................19
ReplacePumpControlModule.....................21
ElectricalSchematics..........................................22
PumpExpansionKitParts...................................28
Notes................................................................31
Dimensions........................................................32
TechnicalData...................................................33
GracoStandardWarranty....................................34
Related Related
RelatedManuals Manuals Manuals
Manual Manual
ManualNo. No. No.Description Description Description
3A2800PD2KProportionerRepair-Parts
Manual,ManualSystems
332457PD2KProportionerInstallation
Manual
332562PD2KProportionerOperation
Manual,ManualSystems
3A2801MixManifoldInstructions-Parts
Manual
Manual Manual
ManualNo. No. No.Description Description Description
332339PumpRepair-PartsManual
332454ColorChangeValveRepair-Parts
Manual
332455ColorChangeKitsInstructions-
PartsManual
332456PumpExpansionKits
Installation-PartsManual
2334512C

Models
Models Models
Models
Kit Kit
KitPart Part PartNo. No. No.Pump Pump PumpUsed Used UsedDescription Description DescriptionMaximum Maximum MaximumFluid Fluid Fluid
Working Working
WorkingPressure Pressure Pressure
24W15924W273♦35ccLowPressureColororCatalyst
PumpKit(Isolated)
300psi(2.068
MPa,20.68bar)
24W16024W274♦70ccLowPressureColorPump
Kit(Isolated)
300psi(2.068
MPa,20.68bar)
24W27724W303♦35ccHighPressureColororCatalyst
PumpKit(Isolated)
1500psi(10.34
MPa,103.4bar)
24W27824W304♦70ccHighPressureColorPump
Kit(Isolated)
1500psi(10.34
MPa,103.4bar)
♦The󰘱uidsectionofthesepumpsisapprovedforplacementinthehazardousarea.Themountingplateis
anapprovedpartitionbetweenthehazardousandnon-hazardousareas.
Figure1.PumpExpansionKitIdenti󰘰cationLabel
334512C3

Warnings
Warnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.The
exclamationpointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰c
risks.Whenthesesymbolsappearinthebodyofthismanualoronwarninglabels,referbacktothese
Warnings.Product-speci󰘰chazardsymbolsandwarningsnotcoveredinthissectionmayappearthroughout
thebodyofthismanualwhereapplicable.
WARNING WARNING
WARNING
FIRE FIRE
FIREAND AND ANDEXPLOSION EXPLOSION EXPLOSIONHAZARD HAZARD HAZARD
Flammablefumes,suchassolventandpaintfumes,inwork work
workarea area areacanigniteorexplode.Tohelp
prevent󰘰reandexplosion:
•Useequipmentonlyinwellventilatedarea.
•Eliminateallignitionsources;suchaspilotlights,cigarettes,portableelectriclamps,and
plasticdropcloths(potentialstaticarc).
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Useonlygroundedhoses.
•Holdgun󰘰rmlytosideofgroundedpailwhentriggeringintopail.Donotusepaillinersunless
theyareantistaticorconductive.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock,Donotuse
equipmentuntilyouidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
ELECTRIC ELECTRIC
ELECTRICSHOCK SHOCK SHOCKHAZARD HAZARD HAZARD
Thisequipmentmustbegrounded.Impropergrounding,setup,orusageofthesystemcan
causeelectricshock.
•Turnoffanddisconnectpoweratmainswitchbeforedisconnectinganycablesandbefore
servicingorinstallingequipment.
•Connectonlytogroundedpowersource.
•Allelectricalwiringmustbedonebyaquali󰘰edelectricianandcomplywithalllocalcodes
andregulations.
4334512C

Warnings
WARNING WARNING
WARNING
SKIN SKIN
SKININJECTION INJECTION INJECTIONHAZARD HAZARD HAZARD
High-pressure󰘱uidfromgun,hoseleaks,orrupturedcomponentswillpierceskin.Thismay
looklikejustacut,butitisaseriousinjurythatcanresultinamputation.Get Get
Getimmediate immediate immediatesurgical surgical surgical
treatment. treatment.
treatment.
•Donotspraywithouttipguardandtriggerguardinstalled.
•Engagetriggerlockwhennotspraying.
•Donotpointgunatanyoneoratanypartofthebody.
•Donotputyourhandoverthespraytip.
•Donotstoporde󰘱ectleakswithyourhand,body,glove,orrag.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopspraying/dispensingandbefore
cleaning,checking,orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.
MOVING MOVING
MOVINGPARTS PARTS PARTSHAZARD HAZARD HAZARD
Movingpartscanpinch,cutoramputate󰘰ngersandotherbodyparts.
•Keepclearofmovingparts.
•Donotoperateequipmentwithprotectiveguardsorcoversremoved.
•Pressurizedequipmentcanstartwithoutwarning.Beforechecking,moving,orservicing
equipment,followthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedureanddisconnectallpowersources.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMES
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,
inhaled,orswallowed.
•ReadMSDSstoknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicable
guidelines.
•Alwayswearchemicallyimpermeablegloveswhenspraying,dispensing,orcleaning
equipment.
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,
includingeyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotective
equipmentincludesbutisnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolvent
manufacturer.
334512C5

Warnings
WARNING WARNING
WARNING
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestrated
systemcomponent.SeeTechnical Technical
TechnicalData Data Datainallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
TechnicalData Data Data
inallequipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcomplete
informationaboutyourmaterial,requestMSDSfromdistributororretailer.
•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovals
andcreatesafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
6334512C

ImportantIsocyanate(ISO)Information
Important Important
ImportantIsocyanate Isocyanate Isocyanate(ISO) (ISO) (ISO)Information Information Information
Isocyanates(ISO)arecatalystsusedintwo
componentmaterials.
Isocyanate Isocyanate
IsocyanateConditions Conditions Conditions
Sprayingordispensing󰘱uidsthatcontain
isocyanatescreatespotentiallyharmfulmists,
vapors,andatomizedparticulates
•Readandunderstandthe󰘱uidmanufacturer’s
warningsandSafetyDataSheet(SDS)toknow
speci󰘰chazardsandprecautionsrelatedto
isocyanates.
•Useofisocyanatesinvolvespotentially
hazardousprocedures.Donotspraywiththe
equipmentunlessyouaretrained,quali󰘰ed,
andhavereadandunderstoodtheinformation
inthismanualsandinthe󰘱uidmanufacturer’s
applicationinstructionsandSDS.
•Useofincorrectlymaintainedormis-adjusted
equipmentmayresultinimproperlycured
material.Equipmentmustbecarefully
maintainedandadjustedaccordingto
instructionsinthemanual.
•Topreventinhalationofisocynatemists,vapors,
andatomizedparticulates,everyoneinthe
workareamustwearappropriaterespiratory
protection.Alwayswearaproperly󰘰tting
respirator,whichmayincludeasupplied-air
respirator.Ventilatetheworkareaaccordingto
instructionsinthe󰘱uidmanufacturer’sSDS.
•Avoidallskincontactwithiscocyanates.
Everyoneintheworkareamustwearchemically
impermeablegloves,protectiveclothingand
footcoveringsasrecommendedbythe󰘱uid
manufacturerandlocalregulatoryauthority.
Followall󰘱uidmanufacturerrecommendations,
includingthoseregardinghandlingof
contaminatedclothing.Afterspraying,wash
handsandfacebeforeeatingordrinking.
Material Material
MaterialSelf Self Self- - -ignition ignition ignition
Somematerialsmaybecomeself-ignitingifapplied
toothick.Readmaterialmanufacturer’swarnings
andmaterialMSDS.
Keep Keep
KeepComponents Components ComponentsA A Aand and andB B BSeparate Separate Separate
Cross-contaminationcanresultincured
materialin󰘱uidlineswhichcouldcauseserious
injuryordamageequipment.Toprevent
cross-contamination:
•Never Never
NeverinterchangecomponentAandcomponent
Bwettedparts.
•Neverusesolventononesideifithasbeen
contaminatedfromtheotherside.
334512C7

ImportantIsocyanate(ISO)Information
Moisture Moisture
MoistureSensitivity Sensitivity Sensitivityof of ofIsocyanates Isocyanates Isocyanates
Exposuretomoisture(suchashumidity)willcause
ISOtopartiallycure;formingsmall,hard,abrasive
crystals,whichbecomesuspendedinthe󰘱uid.
Eventuallya󰘰lmwillformonthesurfaceandtheISO
willbegintogel,increasinginviscosity.
NOTICE NOTICE
NOTICE
PartiallycuredISOwillreduceperformanceand
thelifeofallwettedparts.
•Alwaysuseasealedcontainerwithadesiccant
dryerinthevent,oranitrogenatmosphere.
Never Never
NeverstoreISOinanopencontainer.
•KeeptheISOpumpwetcuporreservoir(if
installed)󰘰lledwithappropriatelubricant.The
lubricantcreatesabarrierbetweentheISOand
theatmosphere.
•Useonlymoisture-proofhosescompatiblewith
ISO.
•Neverusereclaimedsolvents,whichmay
containmoisture.Alwayskeepsolvent
containersclosedwhennotinuse.
•Alwayslubricatethreadedpartswithan
appropriatelubricantwhenreassembling.
NOTE: NOTE:
NOTE:Theamountof󰘰lmformationandrateof
crystallizationvariesdependingontheblendofISO,
thehumidity,andthetemperature.
Changing Changing
ChangingMaterials Materials Materials
NOTICE NOTICE
NOTICE
Changingthematerialtypesusedinyour
equipmentrequiresspecialattentiontoavoid
equipmentdamageanddowntime.
•Whenchangingmaterials,󰘱ushtheequipment
multipletimestoensureitisthoroughlyclean.
•Alwayscleanthe󰘱uidinletstrainersafter
󰘱ushing.
•Checkwithyourmaterialmanufacturerfor
chemicalcompatibility.
•Whenchangingbetweenepoxiesandurethanes
orpolyureas,disassembleandcleanall󰘱uid
componentsandchangehoses.Epoxiesoften
haveaminesontheB(hardener)side.Polyureas
oftenhaveaminesontheA(resin)side.
8334512C

Installation
Installation Installation
Installation
Before Before
BeforeInstalling Installing Installingthe the theKit Kit Kit
•Servicingtheelectricalcontrolboxexposesyou
tohighvoltage.Toavoidelectricshock,turnoff
poweratthemaincircuitbreakerbeforeopening
theenclosure.
•Allelectricalwiringmustbedonebyaquali󰘰ed
electricianandcomplywithalllocalcodesand
regulations.
•Thisequipmentmustbegroundedtoreducethe
riskofstaticsparkingandelectricshock,which
couldcausefumestoigniteorexplode.See
Grounding,page16.
FollowthePressureReliefProcedurein
yourPD2Kmanualwheneveryousee
thissymbol.
Thisequipmentstayspressurizeduntilpressure
ismanuallyrelieved.Tohelppreventserious
injuryfrompressurized󰘱uidsuchasskininjection,
splashing󰘱uid,andmovingparts,followthe
Pressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedureinyoursystemmanual
whenyoustopsprayingandbeforecleaning,
checking,orservicingtheequipment.
1.FlushthesystemasexplainedinyourPD2K
OperationManual.FollowthePressureRelief
ProcedureinyourPD2Kmanual.
2.Closethemainairshutoffvalveontheairsupply
line.
3.Removeelectricalpowerfromthesystem.
Install Install
Installthe the thePump Pump Pump
Theelectronicportionofthepumpkitmustremain
outsidethehazardouslocation.SeeFigure2.
1.FollowthestepsinBefore Before
BeforeInstalling Installing Installingthe the theKit, Kit, Kit,inthe
previoussection.
2.Planyourinstallationsothatallpumpsare
locatedwithin6ft.ofthePD2Kelectricalcontrol
box(D).Eachmulti-conductorcable(10)must
beabletoreachfromthedualcablegrommet
(9)tooneoftheportsonthecontrolbox.See
ElectricalConnections,page14.SeealsoFigure
2.
NOTE: NOTE:
NOTE:Tomountpumpsonbothsidesofthe
controlbox,turnthepumpcontrolmodule(6)
over,andconnectthedualcablegrommet(9)on
theothersideoftherearmountingbracket.
3.Installthepumpassemblysecurelybybolting
therearmountingbracket(4)todesiredwallor
sturdysurface.SeeDimensions,page32.
4.Applyapproved󰘰reproofsealanttothemating
surfaceofthemountingplate(1),toensure
anairtightseal.Mounttheplateonthe
horizontalsurfacethatisthebarrierbetween
thehazardousandnon-hazardousareas.See
Dimensions,page32.
334512C9

Installation
Non Non
Non- - -Hazardous Hazardous HazardousLocation Location Location
Hazardous Hazardous
HazardousLocation Location LocationHazardous Hazardous HazardousLocation Location Location
Figure2
10334512C

Installation
TSL TSL
TSLCup Cup CupKit Kit Kit
ThroatSealLiquid(TSL)lubricatesthepumpthroat
packingsanddosingvalves.TheTSLCupKit
suppliesTSLtotheupperandlowerthroatcartridges
ofthepump,andtothefourpumpdosingvalves.
NOTE: NOTE:
NOTE:TSLmustbeorderedseparately.OrderPart
No.206995,1quart(0.95liter).
1.Slidethekitmountingbracketontoanysideof
thepump’shexnut.
2.PlacetheTSLcup(51)intothebracket(51a).
Routingofthethroatsealtubing(51c)should
always always
alwaysslopeuptothereservoir.
NOTE: NOTE:
NOTE:Thepump’supperthroatcartridgehas
threeports(twoareplugged).Installthebarbed
󰘰tting(51b)intheportclosesttotheTSLcup,by
movingaplugifnecessary.
3.Checkthattheo-ringisinplaceonthebarbed
󰘰tting(51b).Applylowstrengththreadadhesive
andinstallthe󰘰ttingintheupperthroatcartridge
port.
4.Repeatforthelowerthroatcartridge.
5.Ifyouarelubricatingthedosingvalves,remove
theplugandgasketfromthevalveportclosest
totheTSLcup.Checkthattheo-ringisinplace
onthebarbed󰘰tting(51b).Applylowstrength
threadadhesiveandinstallthe󰘰ttinginthevalve
port.
NOTE: NOTE:
NOTE:Ifyouarenotlubricatingthedosing
valves,removetheunusedbarbed󰘰ttings(51b)
fromthebottomoftheTSLcup(51).Applylow
strengththreadadhesiveandinstalltheplugs
andgasketssuppliedwiththekit.
6.Cutthetubing(51c)tolengthasrequired.
ConnecttheTSLcup󰘰ttingstothe󰘰ttingsonthe
pumpandvalves.TSLisgravity-fedfromthe
cuptothepumpandvalves;positionthe󰘰ttings
andtubingtopreventkinksandenabletheTSL
to󰘱owfreely.
7.FillthecupwithTSL.
Figure3InstallTSLCupKit
334512C11

Installation
Air Air
AirConnections Connections Connections
Connectthemainairsupplylinetotheairinletofthe
solenoidmanifold(40).
NOTE: NOTE:
NOTE:A6ft(1.83m)lengthof1/4in.(6mm)OD
polyethylenetubing(35)issuppliedwiththekitto
supplyairtotheexpansionpump’ssolenoidmanifold
(40).
1.Cuttheairsupplytubingthatleadsintothe
electricalcontrolbox(D).
2.InstalltheY-󰘰tting(55)suppliedinthekitto
restoreairsupplytotheelectricalcontrolbox(D).
3.Connectthesupplied1/4in.(6mm)ODtubing
(35)betweentheopenbranchoftheY-󰘰tting(55)
andtheairinletofthesolenoidmanifold(40).
Thislinesuppliesairtotheexpansionpump
solenoidmanifold,asshownintheillustration.
NOTE: NOTE:
NOTE:Ifyouareinstallingasecond,third,or
fourthpump,makeadditionalsplicesinthemain
airsupplylineandconnectinsamemanner.
Figure4SupplyingAirtotheExpansionPump
SolenoidManifold
12334512C

Installation
Fluid Fluid
FluidConnections Connections Connections
1.Connecta1/4npt(f)󰘱uidhosefromthe󰘱uid
sourcetothepump’s󰘱uidinlet󰘰tting(S).
2.Connecta1/4npt(f)󰘱uidoutlethosefromthe
pump’s󰘱uidoutlet󰘰tting(R)tothegun’s󰘱uid
supply.
Figure5PumpFluidConnections
334512C13

Installation
Electrical Electrical
ElectricalConnections Connections Connections
NOTICE NOTICE
NOTICE
Toavoidelectricalcomponentdamage,removeall
systempowerbeforeplugginganyconnectors.
NOTE: NOTE:
NOTE:SeetheElectricalSchematics,page22.
1.Verifythatelectricalpowerisremovedfromthe
system.
2.Removethecoverfromtheelectricalcontrolbox.
3.Removetheknockout(K)fromthesideofthe
electricalcontrolbox.
4.Threadthecableintotheelectricalcontrolbox
andconnecttotheappropriateconnectionport
ontheenhanced󰘱uidcontrolmodule(Pump1
toP1,Pump2toP2,Pump3toP3,andPump
4toP4).
Figure6InstallGrommetinElectricalControl
Box
Figure7EnhancedFluidControlModule
ConnectionPoints
14334512C

Installation
5.Threadthe2–wirecable(52)upintothe
electricalboxthroughanexistinggrommetand
thewireway.Connectthecable(52)tothe
appropriateterminalsonthetopofthe48Vdc
powersupply(P1forpump1,P2forpump2,
P3forpump3,P4forpump4);redwireto+
terminal,blackwireto-terminal.
Figure848VdcPowerSupplyConnection
Points
6.Installthedualgrommet(9,shippedloose)on
thefreeendoftheD-SUBcable(10).
7.Fastenthegrommet(9)tothesideofthe
electricalcontrolbox,usingtwoscrews(11).
8.Reinstallthecoverontheelectricalcontrolbox.
334512C15

Installation
Grounding Grounding
Grounding
Thisequipmentmustbegroundedtoreducethe
riskofstaticsparkingandelectricshock.Electric
orstaticsparkingcancausefumestoigniteor
explode.Impropergroundingcancauseelectric
shock.Groundingprovidesanescapewireforthe
electriccurrent.
1.Verifythatthebaseunitisproperlygrounded.
SeethePD2Kinstallationmanualforcomplete
groundinginstructions.
2.Groundtheexpansionkitpump(s)asfollows:
a.Connectagroundwiretothegroundscrew
(8)ontheaddedpumpkit’sbackpanel(4).
Connecttheotherendofthegroundwireto
thesame same
sametrueearthgroundthatthemainunit
isconnectedto.Verifythattheaddedpump
isgroundedbytakingaresistancereading
fromthegroundscrew(8)ontheadded
pumpkit’sbackpanel(4)tothesystem’s
trueearthground.Resistancemustbeless
than1ohm.
Figure9GroundingthePumpExpansionKit
16334512C

Installation
Complete Complete
Completethe the theInstallation Installation Installation
1.Installthecover(29)ontheexpansionkit,using
thescrew(31).
Figure10InstallExpansionKitCover
2.Restoreelectricalpower.
3.Turnonthecontrolboxpowerswitch.
4.Press
andnavigatetoSystemScreen1
ontheAdvancedDisplayModule.Changethe
numberofColorPumpsandCatalystPumpsas
needed,basedonthekitinstallation.
Figure11SystemScreen1
334512C17

Installation
5.GotothePumpScreens.Themenubaratthe
topofthescreenwillnowshowseparatetabs
forallinstalledpumps.Eachpumphasthree
screens.Entertherequiredinformation,as
explainedinthePD2KOperationManual.
NOTE: NOTE:
NOTE:Ataminimum,youmustenterthe
PumpSizeonPumpScreen1andtransducer
calibrationdata“OutletOffsetFactor”and“Outlet
SensitivityFactor”onPumpScreen2(seeyour
PD2KOperationManual).Also,createarecipe
usingthenewmaterialnumber,whichcanbe
foundonPumpScreen1underAvailableColors
(orCatalysts).
Figure12Third(Color)PumpScreen
Figure13Fourth(Catalyst)PumpScreen
6.TheHomeScreenwillnowshowanimationsand
informationfortheaddedpumps.
Figure14PD2KHomeScreen(Advanced
DisplayModule)
7.SeethePD2KOperationManualtoreturnthe
systemtoservice.
18334512C

Repair
Repair Repair
Repair
Dose Dose
DoseValve Valve ValveTubing Tubing TubingConnections Connections Connections
NOTE: NOTE:
NOTE:5/32in.(4mm)tubingconnectsthesolenoid
manifoldtothepump’sdosingvalves.SeethePump
TubingSchematiconthenextpage.Tubinglengths
mustbe18in.±1/2in.(457mm±13mm)forall
connections.Alwaysuseequallengthsoftubing,to
balancethetimingofthevalves.Lengthslongerthan
18in.(457mm)willincreasevalveresponsetime.
1.Onthebottomofthesolenoidmanifoldarefour
portswithtube󰘰ttings:UPOPEN,UPCLOSED,
DOWNOPEN,andDOWNCLOSED.These
portsprovideairtoopenandclosethepump’s
inletdosingvalves.
Figure15TubingConnectionsatSolenoid
Manifold,toPumpInletManifold
a.Connectgreentubing(G)fromtheUPOPEN
󰘰ttingtothe90°tube󰘰ttingonthesideofthe
INLETUPdosingvalve.
b.Connectredtubing(R)fromtheUPCLOSED
󰘰ttingtothe90°tube󰘰ttingontheendofthe
INLETUPdosingvalve.
c.Connectblacktubing(K)fromtheDOWN
OPEN󰘰ttingtothe90°tube󰘰ttingontheside
oftheINLETDOWNdosingvalve.
d.Connectredtubing(R)fromtheDOWN
CLOSED󰘰ttingtothe90°tube󰘰ttingonthe
endoftheINLETDOWNdosingvalve.
Figure16InletManifoldTubingConnections
2.Onthesideofthesolenoidmanifoldarefour
portswith90°tube󰘰ttings(notshown):UP
OPEN,UPCLOSED,DOWNOPEN,andDOWN
CLOSED.Theseportsprovideairtoopenand
closethepump’soutletdosingvalves.
Figure17TubingConnectionsatSolenoid
Manifold,toPumpOutletManifold
a.Connectbluetubing(B)fromtheUPOPEN
󰘰ttingtothe90°tube󰘰ttingonthesideofthe
OUTLETUPdosingvalve.
b.Connectredtubing(R)fromtheUPCLOSED
󰘰ttingtothe90°tube󰘰ttingontheendofthe
OUTLETUPdosingvalve.
Figure18OutletManifoldTubing
Connections
334512C19

Repair
c.Connectyellowtubing(Y)fromtheDOWN
OPEN󰘰ttingtothe90°tube󰘰ttingontheside
oftheOUTLETDOWNdosingvalve.
d.Connectredtubing(R)fromtheDOWN
CLOSED󰘰ttingtothe90°tube󰘰ttingonthe
endoftheOUTLETDOWNdosingvalve.
3.Repeatthesestepsforeachpumpinyour
system.
Seethefollowingtabletounderstandtherelationship
betweenpumpstrokeanddosevalveactuation.
Table Table
Table1 1 1Dose Dose DoseValve Valve ValveActuation Actuation Actuation
Pump Pump
Pump
Stroke Stroke
Stroke
Up Up
UpInlet Inlet Inlet
Valve Valve
Valve
Down Down
Down
Inlet Inlet
Inlet
Valve Valve
Valve
Up Up
Up
Outlet Outlet
Outlet
Valve Valve
Valve
Down Down
Down
Outlet Outlet
Outlet
Valve Valve
Valve
UpOpenClosedOpenClosed
DownClosedOpenClosedOpen
INLET UP
OUTLET UP
OPEN
CLOSED
Green (G)
Red (R)
Blue (B)
Red (R)
CLOSED
OPEN
UP EXH
INLET DOWN
OUTLET DOWN
OPEN
CLOSED
Black (K)
Red (R)
Yellow (Y)
Red (R)
CLOSED
OPEN
DOWN EXH
Figure19PumpTubingSchematic
20334512C