Graco ProMix PD2K User manual

Installation
ProMix® PD2K Electronic Proportioner
332457H
EN
Electronic positive displacement proportioner for fast-setting two-component materials. Manual system
with Advanced Display Module. For professional use only.
Important Safety Instructions
Read all warnings and instructions in this manual. Save these
instructions.
See page 3 for model part numbers and
approvals information.
PROVEN QUALITY. LEADING TECHNOLOGY.

Contents
Related Manuals ................................................ 2
Models............................................................... 3
Warnings ........................................................... 6
Important Isocyanate (ISO) Information................ 9
Important Acid Catalyst Information ..................... 11
Acid Catalyst Conditions............................... 11
Moisture Sensitivity of Acid Catalysts ............ 12
System Control Drawing 16P577 ......................... 13
Configuring Your System .................................... 15
1. Select a Base Model ................................ 15
2. Select Hoses ........................................... 20
3. Select Mixing Option ................................ 22
4. Select a Spray Gun.................................. 23
5. Select Color and Catalyst Change
Kits................................................ 24
6. Select Pump Expansion Kits ..................... 25
7. Select Communication Options ................. 25
General Information ............................................ 26
Location............................................................. 26
Install the Display Module.................................... 27
Install the Booth Control...................................... 28
Air Supply .......................................................... 29
Fluid Supply ....................................................... 31
Fluid Requirements ...................................... 31
Single Color Connections ............................. 32
Color Change Connections........................... 32
Solvent Connections .................................... 32
TSL Cup Kit........................................................ 33
Solvent Meter Accessory..................................... 36
Light Tower Accessory........................................ 36
Electrostatic Air Hose Quick Disconnect Kit
24S004................................................. 36
Electrical Supply................................................. 37
Electrical Requirements................................ 37
Electrical Connections.................................. 37
Grounding.......................................................... 38
Electrical Schematics.......................................... 41
Standard Models (MC1000, MC2000,
MC3000, MC4000) ......................... 41
Dual Panel Models (MC1002, MC2002,
MC4002)........................................ 47
Optional Cables and Modules ....................... 53
Dimensions ........................................................ 54
Notes ................................................................ 55
Technical Data ...................................................56
Related Manuals
Manual No. Description
3A2800 PD2K Proportioner Repair-Parts Manual, Manual Systems
332562 PD2K Proportioner Operation Manual, Manual Systems
3A4186 PD2K Dual Panel Proportioner Opertion Manual, Manual Systems
3A2801 Mix Manifold Instructions-Parts Manual
332339 Pump Repair-Parts Manual
332454 Color Change Valve Repair-Parts Manual
332455 Color Change Kits Instructions-Parts Manual
332456 3rd and 4th Pump Kits Instructions-Parts Manual
334512 PD1K Pump Expansion Kits Instructions-Parts Manual
3A4497 Air Control Box Kit Instructions Manual
2332457H

Models
Models
SeeFigs.1–7f
or 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
With low–pressure pumps:
300 psi (2.068 MPa, 20.68 bar)
MC0500
MC0502
A100 psi (0.7 MPa,
7.0 bar)
With high–pressure pumps:
1500 psi (10.34 MPa,
103.4 bar)
MC1000
MC1002
MC3000
Acid-based
Material
A100 psi (0.7 MPa,
7.0 bar)
300 psi (2.068 MPa, 20.68 bar)
MC2000
MC2002
MC4000
M4002
Acid-based
Material
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 Models MC1000, MC1002, & MC3000 (Low
Pressure) Identification Label
Continued on the next page.
332457H 3

Models
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 & 26A188 Control Box Identification
Label
.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 Models MC2000, MC2002, MC4000, &
MC4002 (High Pressure) Identification Label
Figure 4 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 5 Intrinsically Safe Color Change Control
(Accessory) Identification Label
Continued on the next page.
4332457H

Models
Intrinsically safe
equipment for
Class I, Div 1,
Group D, T3
Install per 16P577
Ta = 2°C to 50°C
II 2 G
Ex ia IIA T3 Gb
FM13 ATEX 0026
IECEx FMG 13.0011
www.graco.com/patents
12 VDC FM16US0241
FM16CA0129
Figure 6 Booth Control Identification Label
Figure 7 Pump Expansion Kit (Accessory) Identification Label
332457H 5

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 backtothese
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. Paint
or solvent flowing through the equipment can cause static sparking. 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).
• Ground all equipment in the work area. See Grounding instructions.
• Never spray or flush solvent at high pressure.
• 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.
• Use only grounded hoses.
•Holdgu
n 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.
•Conn
ect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes
and regulations.
6332457H

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 gun, 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 spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
•Donots
top or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop spraying/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.
•Kee
p 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.
332457H 7

Warnings
WARNING
TOXIC FLUID OR FUMES
Toxic fluids or fumes can cause serious injury or death if splashed in the eyesoronskin,
inhaled, or swallowed.
• Read Safety Data Sheet (SDS) for handling instructions and to know the specific hazards of
the fluids you are using, including the effects of long-term exposure.
• When spraying, servicing equipment, or when in the work area, always keepsworkarea
well ventilated and always wear appropriate personal protective equipment. See Personal
Protective Equipment warnings in this manual.
• Store hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Always wear appropriate personal protective equipment and cover all skin when spraying,
servicing equipment, or when in the work area. Protective equipment helps prevent serious
injury, including long-term exposure; inhalation of toxic fumes, mists, or vapors; allergic
reactions; burns; eye injury and hearing loss. This protective equipment includes, but is not
limited to:
• A properly fitting respirator, which may include a supplied-air respirator, chemically
impermeable gloves, protective clothing and foot coverings as recommended by the fluid
manufacturer and local regulatory authority.
•Protect
ive eyewear, and hearing protection.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
•Donoto
perate 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 SDS from distributor or retailer.
•Dono
t 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.
•Dono
t 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 youareusingit.
• Use equipment only for its intended purpose. Call your distributor for information.
•Rou
te 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.
•Co
mply with all applicable safety regulations.
8332457H

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 in the
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
Bwettedparts.
• Never use solvent on one side if it has been
contaminated from the other side.
332457H 9

Important Isocyanate (ISO) Information
Moisture Sensitivity of Isocyanates
Exposure to moisture (such as humidity) will cause
ISO to partially cure; forming small, hard, abrasive
crystals, which become suspended in the fluid.
Eventually a film will form on the surface and the ISO
will begin to gel, increasing in viscosity.
NOTICE
Partially cured ISO will reduce performance and
the life of all wetted parts.
• Always use a sealed container with a desiccant
dryer in the vent, or a nitrogen atmosphere.
Never store ISO in an open container.
• Keep the ISO pump wet cup or reservoir (if
installed) filled with appropriate lubricant. The
lubricant creates a barrier between the ISO and
the atmosphere.
• Use only moisture-proof hoses compatible with
ISO.
• Never use reclaimed solvents, which may
contain moisture. Always keep solvent
containers closed when not in use.
• Always lubricate threaded parts with an
appropriate lubricant when reassembling.
NOTE: The amount of film formation and rate of
crystallization varies depending on the blend of ISO,
the humidity, and the temperature.
Changing Materials
NOTICE
Changing the material types used in your
equipment requires special attention to avoid
equipment damage and downtime.
• When changing materials, flush the equipment
multiple times to ensure it is thoroughly clean.
• Always clean the fluid inlet strainers after
flushing.
•Checkwit
h your material manufacturer for
chemical compatibility.
• When changing between epoxies and urethanes
or polyureas, disassemble and clean all fluid
components and change hoses. Epoxies often
have amines on the B (hardener) side. Polyureas
often have amines on the A (resin) side.
10 332457H