Graco ProMix PD2K Use and care manual

Repair-Parts
ProMix® PD2K Proportioner for
Automatic Spray Applications 332709D
EN
Electronic positive displacement proportioner for fast-setting two-component materials. System for
automatic dispense, with Advanced Display Modules. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual and in your
installation, operation, and associated component manuals. Save
these instructions.
See page 3 for model part numbers and
approvals information.
PROVEN QUALITY. LEADING TECHNOLOGY.

Contents
Models............................................................... 3
Related Manuals ................................................ 6
Warnings ........................................................... 7
Important Isocyanate (ISO) Information................ 10
Material Self-ignition..................................... 10
Important Acid Catalyst Information ..................... 12
Troubleshooting.................................................. 14
System Troubleshooting............................... 14
Error Code Troubleshooting.......................... 15
Power Barrier Board Diagnostics .................. 28
Isolation Board Diagnostics .......................... 29
Enhanced Fluid Control Module (EFCM)
Diagnostics .................................... 30
Pump Module Diagnostics ............................ 31
Advanced Display Module Diagnostics........... 32
Notes ................................................................ 33
Electrical Schematics.......................................... 34
Standard Models (AC1000, AC2000)............. 34
Dual Panel Models (AC1002, AC2002)........... 40
Optional Cables and Modules ....................... 46
Communications Options (for PLC and
AWI) ....................................... 47
Repair................................................................ 48
Before Servicing .......................................... 48
Pressure Relief Procedure............................ 49
Repairing the Advanced Display Module
(ADM)............................................ 50
Servicing the Control Box ............................. 51
Servicing the Fluid Section ........................... 60
Parts.................................................................. 64
Proportioner Parts (Standard Models) ........... 64
Proportioner Parts (Dual Panel
Models).......................................... 67
Control Box Parts......................................... 70
Control Box Parts (Dual Panel Models)........... 73
Solenoid Manifold Parts................................ 76
Technical Data ...................................................77
2332709D

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
Location of PD2K and
Electrical Control Box
(ECB) Labels
AC0500
AC0502
A100 psi (0.7 MPa,
7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
AC1000
AC1002
A100 psi (0.7 MPa,
7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
AC2000
AC2002
A100 psi (0.7 MPa,
7.0 bar)
1500 psi (10.34 MPa,
103.4 bar)
0359 II 2 G
.7 7 100
MAX AIR WPR
MPa bar PSI
2.068 20.68 300
MAX FLUID WPR
MPa bar PSI
PART NO. SERIES
Artwork No. 294021 Rev. F
Read Instruction Manual
Warning: Substitution of components
may impair intrinsic safety.
SERIAL
ProMix® PD2K / PD1K
Electronic Proportioner
MAX TEMP 50°C (122°F)
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
MFG. YR.
Intrinsically Safe (IS) System. Install
per IS Control Drawing No. 16P577.
Control Box IS Associated
Apparatus for use in non hazardous
location, with IS Connection to color
change and booth control modules
Apparatus for use in:
Class I, Division 1, Group D T3
Hazardous Locations
II 2 G
Ex ia IIA T3
FM13 ATEX 0026
IECEx FMG 13.0011
FM16US0241
FM16CA0129
Intrinsically safe
equipment for Class I,
Div 1, Group D, T3
Ta = 2°C to 50°C
Figure 1 Model AC1000 and AC1002 (Low Pressure)
Identification Label
Artwork No. 294024 Rev. D
SERIES NO. MFG. YR.
PART NO.
AMPS
VOLTS 90-250 ~
7 AMPS MAX
POWER REQUIREMENTS
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
II (2) G
[Ex ia] IIA Gb
FM13 ATEX 0026
IECEx FMG 13.0011
Intrinsically safe connections
for Class I, Div 1, Group D
Ta = 2°C to 50°C
Install per 16P577 50/60 Hz
ProMix®PD2K / PD1K
Um: 250 V
FM16US0241
FM16CA0129
Figure 2 24M672 and 26A188 Control Box
Identification Label
Continued on the next page.
332709D 3

Models
.7 7 100
MAX AIR WPR
MPa bar PSI
10.34 103.4 1500
MAX FLUID WPR
MPa bar PSI
PART NO. SERIES
Artwork No. 294022 Rev. F
Read Instruction Manual
Warning: Substitution of components
may impair intrinsic safety.
SERIAL
ProMix® PD2K / PD1K
Electronic Proportioner
MAX TEMP 50°C (122°F)
Intrinsically Safe (IS) System. Install
per IS Control Drawing No. 16P577.
Control Box IS Associated
Apparatus for use in non hazardous
location, with IS Connection to color
change and booth control modules
Apparatus for use in:
Class I, Division 1, Group D T3
Hazardous Locations
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
MFG. YR.
II 2 G
Ex ia IIA T3
FM13 ATEX 0026
IECEx FMG 13.0011
FM16US0241
FM16CA0129
Intrinsically safe
equipment for Class I,
Div 1, Group D, T3
Ta = 2°C to 50°C
Figure 3 Model AC2000 and AC2002 (High
Pressure) Identification Label
.7 7 100
MAX AIR WPR
MPa bar PSI PART NO. SERIES
Artwork No. 294280 Rev. E
Read Instruction Manual
Warning: Substitution of components
may impair intrinsic safety.
SERIAL
ProMix® PD2K / PD1K
Electronic Proportioner
MAX TEMP 50°C (122°F)
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
MFG. YR.
Intrinsically Safe (IS) System. Install
per IS Control Drawing No. 16P577.
Control Box IS Associated
Apparatus for use in non hazardous
location, with IS Connection to color
change and booth control modules
Apparatus for use in:
Class I, Division 1, Group D T3
Hazardous Locations
II 2 G
Ex ia IIA T3
FM13 ATEX 0026
IECEx FMG 13.0011
FM16US0241
FM16CA0129
Intrinsically safe
equipment for Class I,
Div 1, Group D, T3
Ta = 2°C to 50°C
POWER REQUIREMENTS
AMPSVOLTS
90-250 ~ 7 AMPS MAX
50/60 Hz Um: 250 V
Figure 4 Model AC0500 and AC0502 Identification Label
Figure 5 Non-Intrinsically Safe Color Change Control (Accessory) Identification Label
Artwork No. 294055 Rev. C
GRACO INC.
P.O. Box 1441
Minneapolis, MN
55440 U.S.A.
.7 7
MAX AIR WPR
MPa bar PSI
COLOR CHANGE CONTROL
ProMix®PD2K / PD1K
100
PART NO. SERIES SERIAL MFG. YR.
Intrinsically safe equipment
for Class I, Div 1, Group D, T3
Ta = 2°C to 50°C
Install per 16P577
II 2 G
Ex ia IIA T3 Gb
FM13 ATEX 0026
IECEx FMG 13.0011
FM16US0241 FM16CA0129
Figure 6 Intrinsically Safe Color Change Control (Accessory) Identification Label
4332709D

Models
Figure 7 Pump Expansion Kit (Accessory) Identification Label
332709D 5

Related Manuals
Related Manuals
Current manuals are available at www.graco.com.
Manual No. Description
332458 PD2K Proportioner Installation
Manual, Automatic Systems
332564 PD2K Proportioner Operation
Manual, Automatic Systems
3A4486 PD2K Dual Panel Proportioner
Operation Manual, Automatic
Systems
332339 Pump Repair-Parts Manual
332454 Color Change Valve Repair-Parts
Manual
332455 Color Change Kits Instructions-
Parts Manual
Manual No. Description
333282 Remote Mix Manifold
Instructions-Parts Manual
332456 Pump Expansion Kits
Instructions-Parts Manual
334183 Modbus TCP Gateway Module
Instructions-Parts Manual
334494 ProMix PD2K CGM Installation Kits
Instructions-Parts Manual
334512 Isolated Pump Expansion Kits
Instructions-Parts Manual
6332709D

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.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help
prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic
drop cloths (potential static arc).
• 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.
• Ground all equipment in the work area. See Grounding instructions.
• 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 operation immediately if static sparking occurs or you feel a shock, Do not use equipment until
you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
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.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
332709D 7

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.
• Be sure your installation complies with national, state, and local codes for the installation of
electrical apparatus in a Class I, Group D, Division 1 (North America) or Class I, Zones 1 and 2
(Europe) Hazardous Location, including all of the local safety fire codes (for example, NFPA 33,
NEC 500 and 516, OSHA 1910.107, etc.).
• 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 substitute system components as this may impair intrinsic safety.
• 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 dispensing device, 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 point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
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.
• 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 chemically impermeable gloves when spraying, dispensing, or cleaning equipment.
8332709D

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.
• 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.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
• 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 equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• 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 you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• 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.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
332709D 9

Important Isocyanate (ISO) Information
Important Isocyanate (ISO) Information
Isocyanates (ISO) are catalysts used in two
component materials.
Isocyanate Conditions
Spraying or dispensing fluids that contain
isocyanates creates potentially harmful mists,
vapors, and atomized particulates
• Read and understand the fluid manufacturer’s
warnings and Safety Data Sheet (SDS) to know
specific hazards and precautions related to
isocyanates.
• Use of isocyanates involves potentially
hazardous procedures. Do not spray with the
equipment unless you are trained, qualified,
and have read and understood the information
in this manuals and in the fluid manufacturer’s
application instructions and SDS.
• Use of incorrectly maintained or mis-adjusted
equipment may result in improperly cured
material. Equipment must be carefully
maintained and adjusted according to
instructions in the manual.
• To prevent inhalation of isocynate mists, vapors,
and atomized particulates, everyone inthe
work area must wear appropriate respiratory
protection. Always wear a properly fitting
respirator, which may include a supplied-air
respirator. Ventilate the work area according to
instructions in the fluid manufacturer’s SDS.
• Avoid all skin contact with iscocyanates.
Everyone in the work area must wear chemically
impermeable gloves, protective clothing and
foot coverings as recommended by the fluid
manufacturer and local regulatory authority.
Follow all fluid manufacturer recommendations,
including those regarding handling of
contaminated clothing. After spraying, wash
hands and face before eating or drinking.
Material Self-ignition
Some materials may become self-igniting if applied
too thick. Read material manufacturer’s warnings
and Safety Data Sheet (SDS).
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.
10 332709D