Graco 332709B manual

Repair-Parts ProMix® PD2K Pr oportioner for Automatic Spr ay Applications 332709B EN Electronic positive displacement proportioner for fast-setting two-co mponent materials. System for automatic dispense, with Advanced Display Modules. For professional use only. Importan t Safety Instru ctions Read all warni ngs and inst ruction s in this manu al [...]

Contents Mo del s ............................................................... 3 Re la te d Man ual s ................................................ 5 Wa rni ng s ........................................................... 6 Im por tan t Is o cy ana te (I SO) I nf or mat io n ................ 9 Tr ou bl esh oot in g............................[...]

Models Models S e eF i g s . 1 – 7f or component ident ification la bels, including app roval informat ion and c ertification. Part No. Series Maxi mum Air Wo rking Pressure Maximum Flui d Work ing Pressure Location of PD2K and Electric al Control Box (ECB) Labels AC1000 A 100 psi (0.7 MPa, 7.0 bar) 300 psi (2.0 68 MPa, 20.68 bar) AC2000 A 100 [...]

Models Figure 3 Model AC2000 (High Pressure) Identificat ion Label Figure 4 Non-Intrin sically Safe Color C hange Control ( Accessory) Identificati on Label Figure 5 Intrinsically Safe Co lor Change C ontrol (Accessory) Identificat ion Label Figure 6 Pump Exp ansion Kit (Ac cessory ) Identification Label 4 332709B[...]

Related M anuals Related Manuals Current manua l s are available at www.graco. com. Manual No. Description 332458 PD2K Proportioner In stallati on Manual, Automat ic Systems 332564 PD2K Proport i oner Operation Manual, Aut omati c Systems 332339 Pump Repair -Parts Manual 332454 Color C han ge Valve Repair -Parts Manual Manual No. Description 332455[...]

Warnings Warnings The following warnings are for the setu p, use, grounding , maintenance and r epair of thi s equipme nt. The exclamat ion p oint symbol alert s you to a general warning and t he hazard symbol refers t o p rocedure-specific risks. W hen th ese symbols a ppear in the b ody of this manual or on warnin g labels, ref er bac kt ot h e [...]

Warnings WARNING INTRINSIC SAFETY Intrinsical ly sa fe equipment that i s install ed improper ly or connected to non- intrin sically safe equipment wi l l create a hazard ous condition an d can cause fire, e xplosion, or el ectric s hock. Follow loc al regulatio ns and the follo wing safety req uirements. • Be sure your insta llation complies wi[...]

Warnings WARNING PERSONAL PROTECTIVE EQUIPMENT Wear appropri ate protect ive equipme nt when in the w ork area to hel p preven t serious injury, including eye injury, hea ring loss, inh alation of toxic fume s, and burns . Th is protective equipment in cludes but i s not limit ed to: •P r o t e c t i v e e yewear, and heari ng protectio n. • Re[...]

Important Isocy anate (ISO) Informati on Important Iso cyanate (ISO) Information Isocyana tes (ISO) are catalys ts used in two component materi als. Isocyanate Conditions Spraying or di spensing mat erials co ntaining isocyanates cr eates potenti ally harmfu l mists, vapors, and atomized parti culates. Read and understand mat erial manufact urer’[...]

Troubleshootin g Troubleshooting NOTE: Check all possib le remedies before disassembl ing the system. System Troubleshooting Problem Cause S olution Inadequate power suppl y. See Techni cal Data, page 61 . Power switch is off. Turn switch on. Main power is shut off. Turn main power swit ch on. Exhausted fluid sup ply. Refill and re prime pump. Cl[...]

Troubleshootin g Error Code Tro ubleshooting System errors alert y ou of a problem and help prevent off-rat io spraying. There are three typ es: Advisory, Deviation, and Alarm. An Adviso ry r ecords an event in t he system, and will clear itself after 60 second s. A Deviation records an error in the system but does not shut down t he equipme nt. Th[...]

Troubleshootin g Code Type De scription Pro blem Cause Solution B9S0 Advi- sory Volume Rollover Solvent Current Batch counter for solvent rolle do v e r . The totaliz er has reached maximum capable value and started over at z ero. n/a B9SX Advi- sory Volume Rollover Solvent Lifetime Grand total c ounter for solvent rolled ove r. The totali ze r has[...]

Troubleshootin g Code Type Description Problem Cause Solution CDDX Alarm Duplicat e Fluid Module System sees tw o or more identi cal Enhanced Flui d Control Mo dul es EFCM). More than on e E FCM is connected i nt h e system. Check the syst em and remove the extra EFCM. System has a leak or open valve th at is allowin g unrestric ted flow. Inspect [...]

Troubleshootin g Code Type De scription Pro blem Cause Solution DG0# Alar m No Stall Down Pump # Pump failed th es t a l l t e s t ;d i dn o ts tall on the downstro ke. Valve failure ,s e a l failure, worn rod or cylinder. Replace inlet and outlet valve a nd seal for down stroke. Replace piston and throat seals. Replace rod and cylinder as necessar[...]

Troubleshootin g Code Type Description Problem Cause Solution Pump dose valves did not actuate. Verify air pre ssure to solenoid va lves. Verify the val ves are actuating. Motor could not drive pumps and linea r actuator. Verify motor is driving the pump. EF0# Alarm Timeout Startup Pump # Pump tried b ut was not able to move to the home position wi[...]

Troubleshootin g Code Type De scription Pro blem Cause Solution EQU2 Record USB Sys. Settings Uploaded Settings were uploaded from USB drive. User installe dU S B device in ADM U SB port. n/a EQU3 Record USB Cus- tom Lang. Down- loaded Custom Language was downloaded to USB drive. User installed USB device in ADM USB port. n/a EQU4 Record USB Custom[...]

Troubleshootin g Code Type Description Problem Cause Solution F7D# Alarm Flow Detected Pump # T h ep u m pfl o w exceeded 20 cc /min flow coming i nt oI d l e mode. There is a leak in the system or the gun was open when the system went into Idle mo de. Verify there a re no leaks in the sy stem. Make sure the a ir flow switch is actu at ing prope[...]

Troubleshootin g Code Type De scription Pro blem Cause Solution P3F# Devia - tion Pressure High Inlet Pump # The inlet pressu re on pump # is greater than the user-ente red deviation limit. Decrease inlet pressure. P4D# Alarm Pressure High Outlet Pump # The outlet pr essure on pump # is grea ter t han the user ente red alarm limit. Relieve syst em [...]

Troubleshootin g Code Type Description Problem Cause Solution Purge pro cess was not completed. Make sure purge process is completed. QPD1 Devia- tion Potlife Expired Potlife time h as expired befor et h e system has m ov ed the required a mou nt of material ( potlife volume) t hro ugh the mixed materi al line. Solvent supply shut off or empty. Ver[...]

Troubleshootin g Maintenance Error Co des Perform t he re quired maintenance if the f ollowing codes occur. Code Type Name Descript ion END# Record Calibration P ump # A calibration test was run on the pump . ENS0 Record Calibration Solvent Meter A calibrati on test was run on the sol vent meter. ENT# Record Calibration St all Test Pump # A stall t[...]

Troubleshootin g Power Barrier Board Diagnostics Figure 7 Power Barrier Board Table 1 . Power Barrier Board Diagnostics ID Component or Indicator Function D4 LED (green) IS Power D5 LED (green) Power F3 Fuse, 400 mA, 250 V F4 Fuse, 400 mA, 250 V If either F 3 or F4 is blown, there is no po wer to the IS locati on. D4 is out. J4 Connector 24 Vdc pow[...]

Troubleshootin g Isolation Board Diagnostics Figure 8 Isolation Board Table 2 . Isolation Board Diagnostics ID Compo nent or Indi cator Funct ion D6 LED (yellow) IS Communicati on D7 LED (green) IS Power D8 LED (green) Non -IS Power D14 LED (yellow) Non-IS C ommunication J1 Connector Non-IS, Gateway J2 Co nnector No n-IS, Opti onal Color Change Mod[...]

Troubleshootin g Enhanced Flui d Control Module (EFCM) Diagnostics Figure 9 Enhanced Fluid Control Module Table 3 . Enhanced Fluid Control Module Diagnostics ID Component or Indicator Function 1 25 pin connect or Pump 1 Module 2 25 pin connect or Pump 2 Module 3 25 pin connect or Pump 3 Module (accessory) 4 25 pin connect or Pump 4 Module (accessor[...]

Troubleshootin g Pump Module Diagnostics Figure 10 Pump Mo dule Table 4 . P ump Module Diagnostics ID Component or Indicator Function 1 25 pin connect or Input from EFCM 2 5 pin connector Pump connecti on 3 5 pin conne ctor Motor encoder connection 4 5 pin conne ctor Pump Inlet Transducer 5 5 pin connector Pump Outlet Transduce r 6 4 pin connector [...]

Troubleshootin g Advanced Display Module Diagnostics Figure 11 Advanced Display M odule Table 5 . Advanced Display Module Diagnostics ID Compone nt or Indicator Function D1 LED (yellow/green) Green: USB inserted Yellow : USB communication D6 LED (red/yel low/green) Green: Power Yello w: Communication Red: Erro r J1 8 pin connector Token port J2 8 p[...]

Notes Notes 26 332709B[...]

Electrical Sche matics Electrical Sc hematics NOTE: The electrical s chematic illus trates all po ssible wiring expansio ns in a ProMix P D2K system. Some components shown are not i ncluded with all s ystems. NOTE: See Optional Cable s and Modules, page 33 for a list of cable options. 2 POSITION SWITCH (16U725) TERMINAL BLOCK (114095) LINE FILTER ([...]

Electrical Sche matics +24VDC COM +24VDC COM PWR (RED) SIG (WHITE) COM (BLACK) SHIELD/GRN MANIFOLD GROUND BAR INLET TRANSDUCER PUMP 1 (16P289 OR 16P290) OUTLET TRANSDUCER PUMP 1 (16P289 OR 16P290) MAC SERIES 46 (16P812 QTY 2) PUMP 1 UP PUMP 1 DOWN G3000 METER PUMP 1 (EITHER, 239716, 258718,16M510, OR 16M519) 24V POWER SUPPL Y (16T660) 1 2 3 1 2 3 4[...]

Electrical Sche matics GUN TRIGGER INPUTS GFB PRESSURE SWITCH (121323) SOL VENT FLOW SWITCH 1 (120278) 1 2 3 4 5 1 2 3 4 5 LIGHT TOWER (15X472) ADV ANCED DISPLA Y MODULE (24E451) 25 24 23 22 21 20 19 18 17 16 14 13 12 11 10 15 9 8 7 6 5 4 3 2 1 25 24 23 22 21 20 19 18 17 16 14 13 12 11 10 15 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11 12 SIG COM GCA [...]

Electrical Sche matics COLOR CHANGE MODULE 1 (COLORS 1 THRU 8) J8 J15 J14 J9 J10 J16 1 2 34 5 1 2 34 5 COLOR CHANGE MODULE 2 (COLORS 9 THRU 16) J8 J15 J14 J9 J10 J16 1 2 34 5 1 2 34 5 COLOR CHANGE MODULE 3 (COLORS 17 THRU 24) J8 J15 J14 J9 J10 J16 1 2 34 5 COLOR CHANGE MODULE 4 (COLORS 25 THRU 32) J8 J15 J14 J9 J10 J16 1 2 34 5 1 2 3 4 5 FLUSH COLO[...]

Electrical Sche matics CA TAL YST CHANGE MODULE 5 (CA TAL YST 1 THRU 2) J8 J15 J14 J9 J10 J16 1 2 3 4 5 1 2 34 5 CA TAL YST CHANGE MODULE 6 ( C ATA LYS T 3 THRU 4) J8 J15 J14 J9 J10 J16 CABLE (15V206) FLUSH C ATA LYS T 1 C ATA LYS T 2 DUMP C ATA LYS T 1 C ATA LYS T 2 FLUSH C ATA LYS T 3 C ATA LYS T 4 DUMP C ATA LYS T 3 C ATA LYS T 4 1 2 34 5 1 2 34[...]

Electrical Sche matics NON-HAZARDOUS LOCA TION HAZARDOUS LOCA TION FROM CAN IS BOARD (24M485) ON P AGE 2 BOOTH CONTROL (24M731) COLOR CHANGE MODULE 7 (COLORS 33 THRU 40) J8 J15 J14 J9 J10 J16 1 2 34 5 1 2 34 5 COLOR CHANGE MODULE 8 (COLORS 41 THRU 48) J8 J15 J14 J9 J10 J16 1 2 34 5 1 2 3 4 5 1 2 3 4 5 CABLE (16V426) CABLE (16V426) COLOR FLUSH COLOR[...]

Electrical Sche matics Optional Cabl es and Modules NOTE: The total lengt h of all cable used i n the system must not exceed 150 ft (45 m). See the Electrical Schemat ics, page 27 . M12 CAN Cables, for Hazardous Locations NOTE: The total length of cabl e used in the hazardous locat ion must not exceed 12 0 ft (36 m). Cable Part N o. Length ft (m ) [...]

Repair Repair Before Servi cing • Servicing the elect rical control box ex poses you to high voltage . To avoid electric shock, turn off power at the mai n circuit br eaker befor e opening the enclos ure. • All electrical wi ring must be done by a q ualified electri cian and compl y with al l local co des and regulati ons. • Do not substitut[...]

Repair Pressure Reli ef Procedure Follow the Pressure Relief Pr ocedure whenever you se e this symbol . This equipment stays pressuri zed until pressure is manuall y relieved. To help prevent seri ous injury from pressuriz ed fluid, such as skin injection , splashing fluid and moving par ts, follow the Pressure Relief Procedure w h e ny o us t o [...]

Repair Repairing the Advanced Display Module (ADM) Replace the AD M To replace the Advan ced Display Modul e, disconnect the cable f rom the module an d remove the modul e from the bra cket. Install the new m odule on the bracket and attach the cab le. Figure 19 Replace t he Advanced Displ ay Module Install Key Token or Upgrade Token 1. Shut off th[...]

Repair Replace the Battery A lithiu m battery main tains the A DM clock when the power is not connect ed. Sparking can occur w hen changing t he battery. Replace the bat tery only in a non- hazardous location, away f rom flammable fluid or fumes. 1. Turn off the PD2K power switch. 2. Remove the rear access panel. Figure 22 Remove Battery Pa nel 3[...]

Repair Servicing the Control Box Replacing the Isolation Board NOTICE To avoid damaging the circui t boards when servicing the control box, wear Part No. 112190 grounding strap on y our wrist and ground appropriat ely. To avoid electri cal component damage, r emove all system power before p lugging any connect ors. 1. Follo w the steps in Before Se[...]

Repair Figure 2 4 Detail of Isolation Board Ca ble Connect ions 332709B 39[...]

Repair Replacing the Barrier Board NOTICE To avoid damaging the circui t boards when servicing the control box, wear Part No. 112190 grounding strap on y our wrist and ground appropriat ely. To avoid electri cal component damage, r emove all system power before p lugging any connect ors. 1. Follo w the steps in Before Servicing, page 34 . 2. Loosen[...]

Repair Replacing the Barrier Board Fuses NOTICE To avoid damaging the circui t boards when servicing the contro l box, wear Part No. 112190 grounding strap on y our wrist and ground appropriate ly. To avoid ele ctrical component damage, remove a ll system power before pl ugging any conn ectors. 1. Follow steps 1–4 under Replacing the Barrie r Boa[...]

Repair Replacin g the 24 Vdc Power Su pply NOTICE To avoid damaging the circui t boards when servicing the control box, wear Part No. 112190 grounding strap on y our wrist and ground appropriat ely. To avoid electri cal component damage, r emove all system power before p lugging any connect ors. 1. Follo w the steps in Before Servicing, page 34 . 2[...]

Repair Replacing the 48 Vdc Pump Power Su pply NOTICE To avoid damaging the circui t boards when servicing the contro l box, wear Part No. 112190 grounding strap on y our wrist and ground appropriate ly. To avoid ele ctrical component damage, remove a ll system power before pl ugging any conn ectors. 1. Follo w the steps in Before Servicing, page 3[...]

Repair Replacing a Pump Control Module NOTICE To avoid damaging the circui t boards when servicing the control box, wear Part No. 112190 grounding strap on y our wrist and ground appropriat ely. To avoid electri cal component damage, r emove all system power before p lugging any connect ors. 1. Follo w the steps in Before Servicing, page 34 . 2. Lo[...]

Repair Replacing a Communication Gateway Mod ule NOTICE To avoid damaging the circui t boards when servicing the contro l box, wear Part No. 112190 grounding strap on y our wrist and ground appropriate ly. To avoid ele ctrical component damage, remove a ll system power before pl ugging any conn ectors. 1. Follo w the steps in Before Servicing, page[...]

Repair Replacing the Line Filter NOTICE To avoid damaging the circui t boards when servicing the control box, wear Part No. 112190 grounding strap on y our wrist and ground appropriat ely. To avoid electri cal component damage, r emove all system power before p lugging any connect ors. 1. Follo w the steps in Before Servicing, page 34 . 2. Loosen t[...]

Repair Replacing the Power Switch NOTICE To avoid damaging the circui t boards when servicing the contro l box, wear Part No. 112190 grounding strap on y our wrist and ground appropriate ly. To avoid ele ctrical component damage, remove a ll system power before pl ugging any conn ectors. 1. Follo w the steps in Before Servicing, page 34 . 2. Loosen[...]

Repair Servicing the Fluid Section R e m o v i n gaP u m p 1. Follo w the steps in Before Servicing, page 34 . 2. Remove the screws (56) holdi ng the cover (8) to the fron t of the un it. 3. Disconnect the cab le from the pump dr iver (101) . 4. Disconnect the air lines from t he dosing valves (V). 5. Disconnect the fluid inlet an d outlet lines f[...]

Repair Replacing a Solenoid NOTICE To avoid damaging the circui t boards when servicing the contro l box, wear Part No. 112190 grounding strap on y our wrist and ground appropriate ly. To avoid ele ctrical component damage, remove a ll system power before pl ugging any conn ectors. 1. Follo w the steps in Before Servicing, page 34 . 2. Remove the s[...]

Repair Replacing a Fan NOTICE To avoid damaging the circui t boards when servicing the control box, wear Part No. 112190 grounding strap on y our wrist and ground appropriat ely. To avoid electri cal component damage, r emove all system power before p lugging any connect ors. 1. Follo w the steps in Before Servicing, page 34 . 2. Remove the screws [...]

Repair Figure 35 Replacing a F an 332709B 51[...]

Repair Replacing a Solvent Flow Switch 1. Follo w the steps in Before Servicing, page 34 . 2. Remove the screws (56) holdi ng the cover (8) to the fron t of the un it. 3. Disconnect the solvent flow switch wires from J6 pins 11–12 (Switch 1) or J7 pins 9–10 (Swit ch 2) on the EFCM. See Electrical Schematics, page 27 . 4. Disconnect the solvent[...]

Notes Notes 332709B 53[...]

Parts Parts Proportioner Parts Part No. A C10 00 Low Pressure Proportioner Part No. AC20 00 High Pressure Propor tioner 54 332709B[...]

Parts Part No. AC1000 Low Pressure Proport ioner Part No. AC200 0 High Pressure Propo rtioner Ref Part Description Qty 1 ——— FRAME 1 2 ——— CONTROL BOX, electric al; see Control Box Parts, page 57 1 3 ——— PANEL, fluid 1 4 ——— BRACKET, mo unting 2 5 24T790 PUMP, 70 cc, A side, low pressure; f or Model MC 1000; see manual 3323[...]

Parts Ref Part Description Qty 30 ——— WASHER; 3/8 40 31 ——— SCREW, cap, hex head; 3/8–16 x 2.75 in. (70 mm) 4 32 ——— SCREW, cap, h ex head; 3/ 8–16 x7 / 8i n . (22 mm) 10 33 ——— NUT, lock; 3/8–16 10 34 ——— SCREW, cap, hex head; 3/8–16 x 3 in . (76 mm) 8 43 ——— WIRE HARNESS; for Model MC1000 (not shown) 2 [...]

Parts Control Box Pa rts Electrical Contr ol Box 332709B 57[...]

Parts Electrical Control Box (conti nued) Ref Part Description Qty 101 ——— ENCLOS URE 1 102 ——— PANEL, back 1 103 24T769 POWER SUPPLY; 48 Vdc; 1 0A ;4 8 0W 1 104 ——— WASH ER, lock; no. 6 3 105 ——— SPAC ER, standoff 3 106 255786 BOAR D, barrie r; incl udes item 106a 1 106 a 15D979 FUS E; 400 mA, q uic k act ing 2 107 ——?[...]

Parts Ref Part Description Qty 121 ——— CONNECTOR, bar , ground 1 122 ——— SCREW, groun d; M5 x 0.8 3 123 ——— NUT, hex, flange head; 1/4–20 4 124 ——— SCREW, flanged, hex head; 1/4–20 x 0.75 in. (19 mm) 4 125 ——— SCREW, machine, pan head; 10–24 x 0.375 in. (10 mm) 2 126 ——— SCREW, ma chine, pan head; 10 –3[...]

Parts Solenoid Mani fold Par ts Part No. 24T772 Solenoid Manif old Ref Part Descrip tion Qty 301 ——— PLATE 1 302 ——— MANIFOLD 1 303 ——— SCREW, cap, socket head; 1/4–20 x 0.375 in. (10 mm) 4 304 115671 CONNECTOR; 1/8 npt(m) x 1 /4 in. (6 mm) OD tube 1 305 16P812 VALVE, solenoid 2 307 114151 FITTING, el bow, swivel; 1 /8 npt (m) x[...]

Technical Data Technical Data Positive Di splacement Proportioner U.S. Metric Maximum fluid worki ng pressure: AC1000 Air Spray Systems 300 psi 2.1 MPa, 21 ba r AC2000 Air-Assisted Spray Systems 1500 psi 10.5 MPa, 10 5b a r Maximum wo rking air pressure: 100 psi 0.7 MPa, 7. 0b a r Air supply: 85–100 psi 0.6–0.7 M Pa, 6.0–7.0 bar) Air filter[...]

Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufac tured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale t o the original purchaser for use. With the exception of any special, extended, or limited w arranty publishe d by Graco, Graco w ill, for a pe[...]