Graco 24R968 User manual

Installation-Parts
Pump Pump
PumpExpansion Expansion ExpansionKits Kits Kits332456D
EN
To To
Toadd add adda a athird third thirdor or orfourth fourth fourthpump pump pumpto to toa a aProMix® ProMix® ProMix®PD2K, PD2K, PD2K,or or orto to toadd add addpumps pumps pumpsto to toa a aPD1K PD1K PD1KProportioner. Proportioner. Proportioner.Each Each Eachkit kit kit
includes includes
includesone one onepump pump pumpand and andassociated associated associatedparts. parts. parts.PD2K PD2K PD2Kis is isshown shown shownwith with withtwo two twokits kits kitsadded. added. added.For For Forprofessional professional professionaluse use useonly. only. only.
Important Important
ImportantSafety Safety SafetyInstructions Instructions Instructions
ReadallwarningsandinstructionsinthismanualandinyourPD2K
manual.Savetheseinstructions.
See page 3 for model part numbers andapprovals information.
PROVENQUALITY.LEADINGTECHNOLOGY.

Contents Contents
Contents
RelatedManuals................................................2
Models...............................................................3
Warnings...........................................................3
ImportantIsocyanate(ISO)Information................6
IsocyanateConditions..................................6
MaterialSelf-ignition.....................................6
KeepComponentsAandBSeparate............6
MoistureSensitivityofIsocyanates................6
ChangingMaterials......................................7
ImportantAcidCatalystInformation.....................8
AcidCatalystConditions...............................8
MoistureSensitivityofAcidCatalysts............8
Installation..........................................................9
BeforeInstallingtheKit.................................9
InstalltheFrame..........................................10
InstalltheWallBracket.................................11
TSLCupKit.................................................12
FluidConnections........................................15
ElectricalConnections..................................16
Grounding...................................................18
CompletetheInstallation..............................19
Repair................................................................21
DoseValveTubingConnections...................21
ReplacePumpControlModule.....................23
ElectricalSchematics..........................................24
StandardModels(MC1000,MC2000,
MC3000,MC4000).........................24
DualPanelModels(MC1002,MC2002,
MC4002)........................................30
PumpExpansionKitParts...................................36
TechnicalData...................................................39
CaliforniaProposition65.....................................39
Related Related
RelatedManuals Manuals Manuals
Manual Manual
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3A2800PD2KProportionerRepair-Parts
Manual,ManualSystems
332457PD2KProportionerInstallation
Manual,ManualSystems
332562PD2KProportionerOperation
Manual,ManualSystems
3A2801MixManifoldInstructions-Parts
Manual
332709PD2KProportionerRepair-Parts
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332458PD2KProportionerInstallation
Manual,AutomaticSystems
332564PD2KProportionerOperation
Manual,AutomaticSystems
Manual Manual
ManualNo. No. No.Description Description Description
3A4186PD2KProportionerDualFluid
PanelOperationManual,Manual
Systems
3A4486PD2KProportionerDualFluid
PanelOperationManual,Automatic
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332339PumpRepair-PartsManual
332454ColorChangeValveRepair-Parts
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332455ColorChangeKitsInstructions-
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2
332456D

Models
Models Models
Models
Kit Kit
KitPart Part PartNo. No. No.Series Series
SeriesDescription Description
DescriptionMaximum Maximum MaximumFluid Fluid FluidWorking Working WorkingPressure Pressure Pressure
24R968A70ccLowPressureColorPumpKit300psi(2.068MPa,20.68bar)
24R969A70ccHighPressureColorPumpKit1500psi(10.34MPa,103.4bar)
24R970A35ccLowPressureColoror
CatalystPumpKit
300psi(2.068MPa,20.68bar)
24R971A35ccHighPressureColoror
CatalystPumpKit
1500psi(10.34MPa,103.4bar)
25M268A35ccLowPressureAcidCatalyst
PumpKit
300psi(2.068MPa,20.68bar)
26A048A35ccHighPressureAcid
CatalystPumpKit
1500psi(10.34MPa,103.4bar)
Figure1.PumpExpansionKitIdenti󰘰cationLabelWarnings Warnings
Warnings
Thefollowingwarningsareforthesetup,use,grounding,maintenance,andrepairofthisequipment.Theexclamation
pointsymbolalertsyoutoageneralwarningandthehazardsymbolsrefertoprocedure-speci󰘰crisks.Whenthese
symbolsappearinthebodyofthismanual,referbacktotheseWarnings.Product-speci󰘰chazardsymbolsand
warningsnotcoveredinthissectionmayappearthroughoutthebodyofthismanualwhereapplicable.
332456D 3

Warnings
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,andplastic
dropcloths(potentialstaticarc).
•Keepworkareafreeofdebris,includingsolvent,ragsandgasoline.
•Donotplugorunplugpowercords,orturnpowerorlightswitchesonoroffwhen󰘱ammable
fumesarepresent.
•Groundallequipmentintheworkarea.SeeGrounding Grounding
Groundinginstructions.
•Useonlygroundedhoses.
•Holdgun󰘰rmlytosideofgroundedpailwhentriggeringintopail.Donotusepaillinersunlessthey
areantistaticorconductive.
•Stop Stop
Stopoperation operation operationimmediately immediately immediatelyifstaticsparkingoccursoryoufeelashock,Donotuseequipmentuntil
youidentifyandcorrecttheproblem.
•Keepaworking󰘰reextinguisherintheworkarea.
SKIN SKIN
SKININJECTION INJECTION INJECTIONHAZARD HAZARD HAZARD
High-pressure󰘱uidfromgun,hoseleaks,orrupturedcomponentswillpierceskin.Thismaylooklike
justacut,butitisaseriousinjurythatcanresultinamputation.Get Get
Getimmediate immediate immediatesurgical surgical surgicaltreatment. treatment. treatment.
•Donotspraywithouttipguardandtriggerguardinstalled.
•Engagetriggerlockwhennotspraying.
•Donotpointgunatanyoneoratanypartofthebody.
•Donotputyourhandoverthespraytip.
•Donotstoporde󰘱ectleakswithyourhand,body,glove,orrag.
•FollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenyoustopspraying/dispensingandbeforecleaning,
checking,orservicingequipment.
•Tightenall󰘱uidconnectionsbeforeoperatingtheequipment.
•Checkhosesandcouplingsdaily.Replacewornordamagedpartsimmediately.
MOVING MOVING
MOVINGPARTS PARTS PARTSHAZARD HAZARD HAZARD
Movingpartscanpinch,cutoramputate󰘰ngersandotherbodyparts.
•Keepclearofmovingparts.
•Donotoperateequipmentwithprotectiveguardsorcoversremoved.
•Pressurizedequipmentcanstartwithoutwarning.Beforechecking,moving,orservicingequipment,
followthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedureanddisconnectallpowersources.
TOXIC TOXIC
TOXICFLUID FLUID FLUIDOR OR ORFUMES FUMES FUMES
Toxic󰘱uidsorfumescancauseseriousinjuryordeathifsplashedintheeyesoronskin,inhaled,or
swallowed.
•ReadMSDSstoknowthespeci󰘰chazardsofthe󰘱uidsyouareusing.
•Storehazardous󰘱uidinapprovedcontainers,anddisposeofitaccordingtoapplicableguidelines.
•Alwayswearchemicallyimpermeablegloveswhenspraying,dispensing,orcleaningequipment.
4
332456D

Warnings
WARNING WARNING
WARNING
PERSONAL PERSONAL
PERSONALPROTECTIVE PROTECTIVE PROTECTIVEEQUIPMENT EQUIPMENT EQUIPMENT
Wearappropriateprotectiveequipmentwhenintheworkareatohelppreventseriousinjury,including
eyeinjury,hearingloss,inhalationoftoxicfumes,andburns.Thisprotectiveequipmentincludesbut
isnotlimitedto:
•Protectiveeyewear,andhearingprotection.
•Respirators,protectiveclothing,andglovesasrecommendedbythe󰘱uidandsolventmanufacturer.
EQUIPMENT EQUIPMENT
EQUIPMENTMISUSE MISUSE MISUSEHAZARD HAZARD HAZARD
Misusecancausedeathorseriousinjury.
•Donotoperatetheunitwhenfatiguedorunderthein󰘱uenceofdrugsoralcohol.
•Donotexceedthemaximumworkingpressureortemperatureratingofthelowestratedsystem
component.SeeTechnical Technical
TechnicalData Data Datainallequipmentmanuals.
•Use󰘱uidsandsolventsthatarecompatiblewithequipmentwettedparts.SeeTechnical Technical
TechnicalData Data Datainall
equipmentmanuals.Read󰘱uidandsolventmanufacturer’swarnings.Forcompleteinformation
aboutyourmaterial,requestMSDSfromdistributororretailer.
•Donotleavetheworkareawhileequipmentisenergizedorunderpressure.
•TurnoffallequipmentandfollowthePressure Pressure
PressureRelief Relief ReliefProcedure Procedure Procedurewhenequipmentisnotinuse.
•Checkequipmentdaily.Repairorreplacewornordamagedpartsimmediatelywithgenuine
manufacturer’sreplacementpartsonly.
•Donotalterormodifyequipment.Alterationsormodi󰘰cationsmayvoidagencyapprovalsand
createsafetyhazards.
•Makesureallequipmentisratedandapprovedfortheenvironmentinwhichyouareusingit.
•Useequipmentonlyforitsintendedpurpose.Callyourdistributorforinformation.
•Routehosesandcablesawayfromtraf󰘰careas,sharpedges,movingparts,andhotsurfaces.
•Donotkinkoroverbendhosesorusehosestopullequipment.
•Keepchildrenandanimalsawayfromworkarea.
•Complywithallapplicablesafetyregulations.
332456D 5

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.
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.
6 332456D

ImportantIsocyanate(ISO)Information
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.
332456D
7

ImportantAcidCatalystInformation
Important Important
ImportantAcid Acid AcidCatalyst Catalyst CatalystInformation Information Information
PumpExpansionKit26A048isdesignedforacidcatalysts(“acid”)currentlyusedintwo-component,wood-󰘰nishing
materials.Currentacidsinuse(withpHlevelsaslowas1)aremorecorrosivethanearlieracids.More
corrosion-resistantwettedmaterialsofconstructionarerequired,andmustbeusedwithoutsubstitution,towithstand
theincreasedcorrosivepropertiesoftheseacids.
Acid Acid
AcidCatalyst Catalyst CatalystConditions Conditions Conditions
Acidis󰘱ammable,andsprayingordispensingacidcreatespotentiallyharmfulmists,vapors,andatomized
particulates.Tohelpprevent󰘰reandexplosionandseriousinjury:
•Readandunderstandtheacidmanufacturer’swarningsandSafetyDataSheet(SDS)toknowspeci󰘰chazards
andprecautionsrelatedtotheacid.
•Useonlygenuine,manufacturer’srecommendedacid-compatiblepartsinthecatalystsystem(hoses,󰘰ttings,
etc).Areactionmayoccurbetweenanysubstitutedpartsandtheacid.
•Topreventinhalationofacidmists,vapors,andatomizedparticulates,everyoneintheworkareamustwear
appropriaterespiratoryprotection.Alwayswearaproperly󰘰ttingrespirator,whichmayincludeasupplied-air
respirator.Ventilatetheworkareaaccordingtoinstructionsintheacidmanufacturer’sSDS.
•Avoidallskincontactwithacid.Everyoneintheworkareamustwearchemicallyimpermeablegloves,protective
clothing,footcoverings,aprons,andfaceshieldsasrecommendedbytheacidmanufacturerandlocalregulatory
authority.Followallacidmanufacturerrecommendations,includingthoseregardinghandlingofcontaminated
clothing.Washhandsandfacebeforeeatingordrinking.
•Regularlyinspectequipmentforpotentialleaksandremovespillspromptlyandcompletelytoavoiddirectcontact
orinhalationoftheacidanditsvapors.
•Keepacidawayfromheat,sparks,andopen󰘱ames.Donotsmokeintheworkarea.Eliminateallignition
sources.
•Storeacidintheoriginalcontainerinacool,dry,andwell-ventilatedareaawayfromdirectsunlightand
awayfromotherchemicalsinaccordancewithacidmanufacturer’srecommendations.Toavoidcorrosionof
containers,donotstoreacidinsubstitutecontainers.Resealtheoriginalcontainertopreventvaporsfrom
contaminatingthestoragespaceandsurroundingfacility.
Moisture Moisture
MoistureSensitivity Sensitivity Sensitivityof of ofAcid Acid AcidCatalysts Catalysts Catalysts
Acidcatalystscanbesensitivetoatmospheric
moistureandothercontaminants.Itisrecommended
thecatalystpumpandvalvesealareasexposedto
atmosphereare󰘱oodedwithISOoil,TSL,orother
compatiblematerialtopreventacidbuild-upand
prematuresealdamageandfailure.
NOTICE NOTICE
NOTICE
Acidbuild-upwilldamagethevalvesealsand
reducetheperformanceandlifeofthecatalyst
pump.Topreventexposingacidtomoisture:
•Alwaysuseasealedcontainerwithadesiccant
dryerinthevent,oranitrogenatmosphere.
Neverstoreacidsinanopencontainer.
•Keepthecatalystpumpandthevalveseals󰘰lled
withtheappropriatelubricant.Thelubricant
createsabarrierbetweentheacidandthe
atmosphere.
•Useonlymoisture-proofhosescompatiblewith
acids.
•Alwayslubricatethreadedpartswithan
appropriatelubricantwhenreassembling.
8 332456D

Installation
Installation Installation
Installation
Before Before
BeforeInstalling Installing Installingthe the theKit Kit Kit
•Servicingtheelectricalcontrolboxexposesyou
tohighvoltage.Toavoidelectricshock,turnoff
poweratthemaincircuitbreakerbeforeopening
theenclosure.
•Allelectricalwiringmustbedonebyaquali󰘰ed
electricianandcomplywithalllocalcodesand
regulations.
•Donotsubstituteormodifysystemcomponents
asthismayimpairintrinsicsafety.
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.
NOTE: NOTE:
NOTE:Thepumpexpansionkitcanbemounted
directlyonthePD2Kstand,ormountedontoawall.
InstallusingthestepsinInstalltheFrame,page10or
thestepsinInstalltheWallBracket,page11.
332456D 9

Installation
Install Install
Installthe the theFrame Frame Frame
Usethesestepsifyouwanttoinstallthekitontothe
PD2Kstandusingframe(13).
1.Followthestepsin
BeforeInstallingtheKit,page9.
2.Installtheframe(13)totheuprightofthePD2K
stand(A)usingthreescrews(16)andnuts(18).
3.Installthebackpanel/bracketassembly(B)inthe
outermostpositionontheframe(13),toallow
clearanceforthecolorchangemanifold(C).
Fastenthepaneltotheframe(13)usingfour
screws(15)andnuts(18).Installthetopscrews
fromthefrontandthebottomscrewsfromthe
back.
NOTE: NOTE:
NOTE:Theillustrationshowsaresin(70cc)pump
expansionkitbeinginstalledontheleft(color)side
ofthePD2Kproportioner.Thepumpcontrolmodule
anddualgrommet(11)arepreassembledatthe
factorysothecable(8)isfacingtotheright,allowing
easieraccesstoconnectionsinsidethePD2K
electricalcontrolbox(D).
Installacatalyst(35cc)pumpexpansionkitonthe
rightsideoftheproportioner,withthepumpcontrol
moduleanddualgrommet(11)preassembledinthe
oppositedirectionsothecable(8)isfacingtotheleft.
Figure2InstalltheFrameandPump
10 332456D

Installation
Install Install
Installthe the theWall Wall WallBracket Bracket Bracket
Usethesestepsifyouwanttoinstallthekitaway
fromthePD2KorPD1Kstandusingwallbracket(47).
1.Followthestepsin
BeforeInstallingtheKit,page9.
2.Installwallbracket(47)toawallorothersuitable
verticalsurfaceusingfourscrewsorbolts(user
provided).
3.Installthebackpanel/bracketassembly(B)to
wallbracket(47)usingsixscrews(15)andsix
nuts(18).
NOTE: NOTE:
NOTE:Theillustrationshowsaresin(70cc)
pumpexpansionkitbeinginstalledontheleft
(color)sideofthePD1Kproportioner.The
pumpcontrolmoduleanddualgrommet(11)
arepreassembledatthefactorysothecable(8)
isfacingtotheright,allowingeasieraccessto
connectionsinsidethePD1Kelectricalcontrol
box(D).
Installacatalyst(35cc)pumpexpansionkit
ontherightsideoftheproportioner,withthe
pumpcontrolmoduleanddualgrommet(11)
preassembledintheoppositedirectionsothe
cable(8)isfacingtotheleft.
Figure3InstalltheWallBracketandPump
332456D
11

Installation
TSL TSL
TSLCup Cup CupKit Kit Kit
ThecupisusedforeitherThroatSealLiquid(TSL)
orISOoil.Theseliquidspreventexposureofairor
moisturewiththeresinorcatalystatthepumpthroat
packingsanddosingvalves.ThePD2KProportioner
includestwoTSLCupKits,oneforeachpump.The
cupssupplyTSLtotheupperthroatcartridgeofthe
color(70cc)pump,totheupperandlowerthroat
cartridgesofthecatalyst(35cc)pump,andtothe
fourpumpdosingvalves.Whenusingisocyanate
catalysts,thecupattachedtothecatalystsideofthe
PD2KProportionerisusedtosupplyISOoiltothe
upperandlowerthroatcartridgesofthecatalyst(35
cc)pumpandthecatalystdosingvalves.
NOTE: NOTE:
NOTE:TSLandISOoilmustbeorderedseparately.
ForTSL,orderPartNo.206995,onequart(0.95
liter).ForISOoil,orderPartNo.217374,onepint
(0.48liter).
1.Slidethekitmountingbracketontoanysideof
thepump’shexnut.
NOTE: NOTE:
NOTE:Priortomountingthecup,usea
permanentblackmarkertomarkahorizontalline
onthefrontofthecupapproximatelyhalfway
betweenthetopandbottomofthecup.Marka
secondhorizontallineapproximately1/4in.(3
mm)abovethe󰘰rstline.Shiningastronglight
towardstheselineswillprovideashadowthat
willbevisiblefrominsidetheTSLcup.
2.PlacetheTSLcup(73)intothebracket(73a).
Figure4InstallTSLCupKit
NOTE: NOTE:
NOTE:Thepump’supperthroatcartridgehas
threeports(twoareplugged).Moveaplug(73d)
ifnecessarysothebarbed󰘰tting(73b)canbe
putintheportclosesttotheTSLcup.
3.Checkthattheo-ringisinplaceonthebarbed
󰘰tting(73b).Applylowstrengththreadadhesive
andinstallthe󰘰ttingintheupperthroatcartridge
port.Besuretheothertwoportsareplugged
(73d).
12
332456D

Installation
4.Catalyst Catalyst
Catalyst(35 (35 (35cc) cc) cc)pumps: pumps: pumps:Repeatforthelower
throatcartridge.
5.Ifyouarelubricatingthedosingvalves,remove
theplug(73d)andgasketfromthevalveport(V)
closesttotheTSLcup.
NOTE: NOTE:
NOTE:Choosethevalveportintheupward
facingposition.Thiswillallowliquidto󰘱owinto
thevalvewhileallowingairtoriseoutofthe
valve.
Checkthattheo-ringisinplaceonthebarbed
󰘰tting(73b).Applylowstrengththreadadhesive
andinstallthe󰘰ttinginthevalveport(V).
NOTE: NOTE:
NOTE:Donotconfusethevalveport(V)withthe
airport(W).
NOTE: NOTE:
NOTE:Ifyouarenotlubricatingthedosing
valves,removetheunusedbarbed󰘰ttings(73b)
fromthebottomoftheTSLcup(73).Applylow
strengththreadadhesiveandinstalltheplugs
andgasketssuppliedwiththekit.
6.Cutthetubing(73c)tolengthasrequired.
ConnecttheTSLcup󰘰ttingstothe󰘰ttingsonthe
pumpandvalves.TSLisgravity-fedfromthe
cuptothepumpandvalves;positionthe󰘰ttings
andtubingtopreventkinksandenabletheTSL
to󰘱owfreelydowntothevalveandairtorise
upandoutofthevalve.
7.Fillthecuptothelevelofthelowerblack
horizontallinewitheitherTSLorISOoil,as
appropriatefortheresinandcatalystmaterials
beingused.
NOTE: NOTE:
NOTE:IfTSLleaksfromtherodguardofthe
color(70cc)pump,besuretheloweru-cupseal
isinstalledinthelowerthroatcartridge.
NOTE: NOTE:
NOTE:The󰘱uidlevelsintheTSLcupsshouldbe
checkeddaily.Fluidlevelsshouldremainstatic
foranextendedperiodoftime.Risingorfalling
󰘱uidlevelsinaTSLcupcanbeanindicationofa
conditionwhichneedsimmediateattention.Refer
tothetroubleshootingstepsintherepairmanualfor
guidance.
ISO ISO
ISOOil Oil OilFill Fill FillProcedure Procedure Procedure
Whenusingpolyurethanecoatingswithisocyanate
catalystsinhigh-humidityenvironments,useofISO
oilonthecatalystpumpTSLcupisrecommended
insteadofTSL.TheISOoilwillpresentabarrier
thatwillpreventcatalysthardeningfromcontactwith
moisture.Whenperformingthe󰘰rst󰘰llofacupwith
ISOoil,itwillbenecessarytobleedtheairoutofthe
feedline.
NOTE: NOTE:
NOTE:IfnotalreadypresentontheTSLcup,draw
thetwohorizontallinesat,andslightlyabove,the
verticalcenterofthefrontofthecupbefore󰘰lling.
Tobleedair:
1.FillthecatalystpumpTSLcuptothelower
horizontalline.
2.Removeoneplug(73d)fromtheupperthroat
cartridgeandallowairinthatareato󰘱owuntilno
airisbeingexpelled.Replacetheplug.
3.Repeatstep2atthelowerthroatcartridge.
4.UseabsorbentragstocleanupexcessISOoil
thatescapedfromtheplugholes.
5.ReplenishtheISOoillevelintheTSLcuptothe
lowerhorizontalline.
332456D 13

Installation
Air Air
AirConnections Connections Connections
ForPD2Kinstallations:Followthestepsbelow.
ForPD1Kinstallations:Forthe󰘰rstexpansion
kit,connecttheairsupplytube(35)directlytothe
electricalcontrolbox(Z).Forthesecondthrough
fourthexpansionkits,followsteps2–4below.
Figure5AirConnectionforPD1KFirstExpansionKit
NOTE: NOTE:
NOTE:A6ft(1.83m)lengthof1/4in.(6mm)OD
polyethylenetubing(35)issuppliedwiththekitto
supplyairtotheexpansionpump’ssolenoidmanifold
(3).
1.SeethePD2KRepair-PartsManual.Removethe
PD2K󰘱uidpanelcovertoexposetheairsupply
tubingtothetwoexistingsolenoidmanifolds.
2.CuttheairsupplytubingupstreamoftheY-󰘰tting.
3.InstalltheY-󰘰tting(36)suppliedinthekitas
shown,torestoretheairsupplytothetwo
existingsolenoidmanifolds.
4.Connectthesupplied1/4in.(6mm)ODtubing
(35)betweentheopenbranchoftheY-󰘰tting
(36)andtheairinletofthesolenoidmanifold(3).
Thissuppliesairtotheexpansionpumpsolenoid
manifold,asshowninthedetailoftheillustration.
NOTE: NOTE:
NOTE:Ifyouareinstallingafourthpump,make
asecondspliceinthemainsolenoidairsupply
lineandplumbasexplainedabove.
Figure6SupplyingAirtotheExpansionPump
SolenoidManifold
14
332456D

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.
Figure7PumpFluidConnections
332456D 15

Installation
Electrical Electrical
ElectricalConnections Connections Connections
NOTICE NOTICE
NOTICE
Toavoidelectricalcomponentdamage,removeall
systempowerbeforeplugginganyconnectors.
NOTE: NOTE:
NOTE:SeetheElectricalSchematics,page24.
1.Verifythatelectricalpowerisremovedfromthe
system.
2.RemovethecoverfromthePD2K/PD1K
electricalcontrolbox.
3.Removetheknockout(K)fromthesideofthe
electricalcontrolbox.
4.Threadthecableintotheelectricalcontrolbox
andconnecttotheappropriateconnectionport
ontheenhanced󰘱uidcontrolmodule.For
example,connectPump1toP1andPump2to
P2(PD1Konly);Pump3toP3,Pump4toP4,
andsoon.
Figure8InstallGrommetinElectricalControl
Box
Figure9EnhancedFluidControlModule
ConnectionPoints
16 332456D

Installation
NOTICE NOTICE
NOTICE
Besuretokeep48voltcablesisolatedfromthe
lowvoltagewiring.All48VDCwiringmustuse
theright-handwireway(X)insidetheelectrical
controlbox.Usegrommet(Y)markedinFigure
9toinstallthePumpExpansionKitwiring.
Figure1048VDCGrommetandWireway
5.ThePD2K/PD1K󰘱uidpanelcoverwaspreviously
removedinAirConnections,page14.Thread
the2–wirecable(22)throughthegrommet(42)
onthebottomofthe󰘱uidpanelandupinto
theelectricalboxthroughanexistinggrommet
andthewireway.Connectthecable(22)tothe
appropriateterminalsonthetopofthe48VDC
powersupply:P1forPump1andP2forPump
2(PD1Konly);P3forPump3,P4forPump4.
Connecttheredwireto+terminal,blackwireto
-terminal.
Figure1148VDCPowerSupplyConnection
Points
6.Installthedualgrommet(11,shippedloose)on
thefreeendoftheD-SUBcable(8).
7.Fastenthegrommet(11)tothesideofthe
electricalcontrolbox,usingtwoscrews(31).
8.ReinstallthecoversonthePD2Kelectrical
controlboxandonthe󰘱uidpanel.
332456D
17

Installation
Grounding Grounding
Grounding
Thisequipmentmustbegroundedtoreducethe
riskofstaticsparkingandelectricshock.Electric
orstaticsparkingcancausefumestoigniteor
explode.Impropergroundingcancauseelectric
shock.Groundingprovidesanescapewireforthe
electriccurrent.
1.VerifythatthePD2Kbaseunitisproperly
grounded.SeethePD2Kinstallationmanualfor
completegroundinginstructions.
2.Groundtheexpansionkitpump(s)asfollows:
a.If If
Ifthe the theadded added addedpump pump pumpis is ismounted mounted mountedto to tothe the thePD2K PD2K PD2K
main main
mainunit, unit, unit,verifythattheaddedpumpis
groundedbytakingaresistancereadingfrom
thegroundscrew(7)ontheaddedpump
kit’sbackpanel(2)tothesystem’strueearth
ground.Resistancemustbelessthan1ohm.
b.If If
Ifthe the theadded added addedpump pump pumpis is isNOT NOT NOTmounted mounted mountedto to tothe the the
PD2K PD2K
PD2Kmain main mainunit, unit, unit,connectagroundwireto
thegroundscrew(7)ontheaddedpumpkit’s
backpanel(2).Connecttheotherendofthe
groundwiretothesame same
sametrueearthground
thatthemainPD2Kunitisconnectedto.
Verifythattheaddedpumpisgroundedby
takingaresistancereadingfromtheground
screw(7)ontheaddedpumpkit’sback
panel(2)tothesystem’strueearthground.
Resistancemustbelessthan1ohm.
Figure12GroundingthePumpExpansionKit
18 332456D

Installation
Complete Complete
Completethe the theInstallation Installation Installation
1.Installthecover(12)ontheexpansionkit,using
thescrew(37)andnut(18).
Figure13InstallExpansionKitCover(Frame)
Figure14InstallExpansionKitCover(Wall
Mount)
2.RestoreelectricalpowertothePD2K/PD1K.
3.Turnonthecontrolboxpowerswitch.
4.PressandnavigatetoSystemScreen1
ontheAdvancedDisplayModule.Changethe
numberofColorPumpsandCatalystPumpsas
needed,basedonthekitinstallation.
Figure15SystemScreen1
332456D 19

Installation
5.GotothePumpScreens.Themenubaratthe
topofthescreenwillnowshowseparatetabs
fortheaddedpump(s)3and4.Eachpumphas
threescreens.Entertherequiredinformation,as
explainedinthePD2KOperationManual.
NOTE: NOTE:
NOTE:Ataminimum,youmustenterthe
PumpSizeonPumpScreen1andtransducer
calibrationdata“OutletOffsetFactor”and“Outlet
SensitivityFactor”onPumpScreen2(seeyour
PD2KOperationManual).Also,createarecipe
usingthenewmaterialnumber,whichcanbe
foundonPumpScreen1underAvailableColors
(orCatalysts).
Figure16Third(Color)PumpScreen
Figure17Fourth(Catalyst)PumpScreen
6.TheHomeScreenwillnowshowanimationsand
informationfortheaddedpumps.
Figure18PD2KHomeScreen(Advanced
DisplayModule)
7.SeethePD2KOperationManualtoreturnthe
systemtoservice.
20 332456D