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
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3A2800PD2KProportionerRepair-Parts
Manual,ManualSystems
332457PD2KProportionerInstallation
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332562PD2KProportionerOperation
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3A2801MixManifoldInstructions-Parts
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332709PD2KProportionerRepair-Parts
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332458PD2KProportionerInstallation
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332564PD2KProportionerOperation
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ManualNo. No. No.Description Description Description
3A4186PD2KProportionerDualFluid
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3A4486PD2KProportionerDualFluid
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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