Доки прототиа 332456EN-D

Installation-Parts
Pump Expansion Kits 332456D

EN
To add a third or fourth pump to a ProMix® PD2K, or to add pumps to a PD1K Proportioner. Each kit
includes one pump and associated parts. PD2K is shown with two kits added. For professional use only.
Important Safety Instructions

Read all warnings and instructions in this manual and in your PD2K
manual. Save these instructions.
See page 3 for model part numbers and

approvals information.
PROVEN QUALITY. LEADING TECHNOLOGY.

Contents
Related Manuals ................................................ 2 TSL Cup Kit ................................................. 12
Models............................................................... 3 Fluid Connections ........................................ 15
Electrical Connections .................................. 16
Warnings ........................................................... 3 Grounding ................................................... 18
Important Isocyanate (ISO) Information ................ 6 Complete the Installation .............................. 19
Isocyanate Conditions .................................. 6 Repair................................................................ 21
Material Self-ignition..................................... 6 Dose Valve Tubing Connections ................... 21
Keep Components A and B Separate ............ 6 Replace Pump Control Module ..................... 23
Moisture Sensitivity of Isocyanates................ 6
Changing Materials ...................................... 7 Electrical Schematics.......................................... 24
Standard Models (MC1000, MC2000,
Important Acid Catalyst Information ..................... 8 MC3000, MC4000) ......................... 24
Acid Catalyst Conditions............................... 8 Dual Panel Models (MC1002, MC2002,
Moisture Sensitivity of Acid Catalysts ............ 8 MC4002)........................................ 30
Installation.......................................................... 9 Pump Expansion Kit Parts................................... 36
Before Installing the Kit................................. 9
Install the Frame .......................................... 10 Technical Data ................................................... 39
Install the Wall Bracket ................................. 11 California Proposition 65 ..................................... 39
Related Manuals
Manual No. Description Manual No. Description
3A2800 PD2K Proportioner Repair-Parts 3A4186 PD2K Proportioner Dual Fluid
Manual, Manual Systems Panel Operation Manual, Manual
Systems
332457 PD2K Proportioner Installation
Manual, Manual Systems 3A4486 PD2K Proportioner Dual Fluid
Panel Operation Manual, Automatic
332562 PD2K Proportioner Operation Systems
Manual, Manual Systems
332339 Pump Repair-Parts Manual
3A2801 Mix Manifold Instructions-Parts
Manual 332454 Color Change Valve Repair-Parts
Manual
332709 PD2K Proportioner Repair-Parts
Manual, Automatic Systems 332455 Color Change Kits Instructions-
Parts Manual
332458 PD2K Proportioner Installation
Manual, Automatic Systems
332564 PD2K Proportioner Operation
Manual, Automatic Systems
2 332456D
Models
Models
Kit Part No. Series Description Maximum Fluid Working Pressure
24R968 A 70 cc Low Pressure Color Pump Kit 300 psi (2.068 MPa, 20.68 bar)
24R969 A 70 cc High Pressure Color Pump Kit 1500 psi (10.34 MPa, 103.4 bar)
24R970 A 35 cc Low Pressure Color or 300 psi (2.068 MPa, 20.68 bar)
Catalyst Pump Kit
24R971 A 35 cc High Pressure Color or 1500 psi (10.34 MPa, 103.4 bar)
Catalyst Pump Kit
25M268 A 35 cc Low Pressure Acid Catalyst 300 psi (2.068 MPa, 20.68 bar)
Pump Kit
26A048 A 35 cc High Pressure Acid 1500 psi (10.34 MPa, 103.4 bar)
Catalyst Pump Kit
Figure 1 . Pump Expansion Kit Identification Label 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 symbols refer to procedure-specific risks. When these
symbols appear in the body of this manual, 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.
332456D 3
Warnings
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.
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.
• Do not stop 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.
• 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.
4 332456D
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.
332456D 5
Important Isocyanate (ISO) Information

Isocyanates (ISO) are catalysts used in two Keep Components A and B Separate
component materials.
Isocyanate Conditions
Cross-contamination can result in cured
material in fluid lines which could cause serious
injury or damage equipment. To prevent
cross-contamination:
Spraying or dispensing fluids that contain • Never interchange component A and component
isocyanates creates potentially harmful mists, B wetted parts.
vapors, and atomized particulates
• Never use solvent on one side if it has been
• Read and understand the fluid manufacturer’s contaminated from the other side.
warnings and Safety Data Sheet (SDS) to know
specific hazards and precautions related to
isocyanates.
• Use of isocyanates involves potentially
Moisture Sensitivity of Isocyanates
hazardous procedures. Do not spray with the
equipment unless you are trained, qualified, Exposure to moisture (such as humidity) will cause
and have read and understood the information ISO to partially cure; forming small, hard, abrasive
in this manuals and in the fluid manufacturer’s crystals, which become suspended in the fluid.
application instructions and SDS. Eventually a film will form on the surface and the ISO
will begin to gel, increasing in viscosity.
• Use of incorrectly maintained or mis-adjusted
equipment may result in improperly cured NOTICE
material. Equipment must be carefully
maintained and adjusted according to Partially cured ISO will reduce performance and
instructions in the manual. the life of all wetted parts.
• To prevent inhalation of isocynate mists, vapors, • Always use a sealed container with a desiccant
and atomized particulates, everyone in the dryer in the vent, or a nitrogen atmosphere.
work area must wear appropriate respiratory Never store ISO in an open container.
protection. Always wear a properly fitting
respirator, which may include a supplied-air • Keep the ISO pump wet cup or reservoir (if
respirator. Ventilate the work area according to installed) filled with appropriate lubricant. The
instructions in the fluid manufacturer’s SDS. lubricant creates a barrier between the ISO and
the atmosphere.
• Avoid all skin contact with iscocyanates.
Everyone in the work area must wear chemically • Use only moisture-proof hoses compatible with
impermeable gloves, protective clothing and ISO.
foot coverings as recommended by the fluid • Never use reclaimed solvents, which may
manufacturer and local regulatory authority. contain moisture. Always keep solvent
Follow all fluid manufacturer recommendations, containers closed when not in use.
including those regarding handling of
contaminated clothing. After spraying, wash • Always lubricate threaded parts with an
hands and face before eating or drinking. appropriate lubricant when reassembling.
NOTE: The amount of film formation and rate of

crystallization varies depending on the blend of ISO,
Self--ignition
Material Self the humidity, and the temperature.
Some materials may become self-igniting if applied

too thick. Read material manufacturer’s warnings
and material MSDS.
6 332456D
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.
• Check with 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.
332456D 7
Important Acid Catalyst Information
Important Acid Catalyst Information

Pump Expansion Kit 26A048 is designed for acid catalysts (“acid”) currently used in two-component, wood-finishing
materials. Current acids in use (with pH levels as low as 1) are more corrosive than earlier acids. More
corrosion-resistant wetted materials of construction are required, and must be used without substitution, to withstand
the increased corrosive properties of these acids.
Acid Catalyst Conditions
Acid is flammable, and spraying or dispensing acid creates potentially harmful mists, vapors, and atomized
particulates. To help prevent fire and explosion and serious injury:
• Read and understand the acid manufacturer’s warnings and Safety Data Sheet (SDS) to know specific hazards
and precautions related to the acid.
• Use only genuine, manufacturer’s recommended acid-compatible parts in the catalyst system (hoses, fittings,
etc). A reaction may occur between any substituted parts and the acid.
• To prevent inhalation of acid 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 acid manufacturer’s SDS.
• Avoid all skin contact with acid. Everyone in the work area must wear chemically impermeable gloves, protective
clothing, foot coverings, aprons, and face shields as recommended by the acid manufacturer and local regulatory
authority. Follow all acid manufacturer recommendations, including those regarding handling of contaminated
clothing. Wash hands and face before eating or drinking.
• Regularly inspect equipment for potential leaks and remove spills promptly and completely to avoid direct contact
or inhalation of the acid and its vapors.
• Keep acid away from heat, sparks, and open flames. Do not smoke in the work area. Eliminate all ignition
sources.
• Store acid in the original container in a cool, dry, and well-ventilated area away from direct sunlight and
away from other chemicals in accordance with acid manufacturer’s recommendations. To avoid corrosion of
containers, do not store acid in substitute containers. Reseal the original container to prevent vapors from
contaminating the storage space and surrounding facility.
Moisture Sensitivity of Acid Catalysts NOTICE

Acid build-up will damage the valve seals and
Acid catalysts can be sensitive to atmospheric reduce the performance and life of the catalyst
moisture and other contaminants. It is recommended pump. To prevent exposing acid to moisture:
the catalyst pump and valve seal areas exposed to
atmosphere are flooded with ISO oil, TSL, or other • Always use a sealed container with a desiccant
compatible material to prevent acid build-up and dryer in the vent, or a nitrogen atmosphere.
premature seal damage and failure. Never store acids in an open container.
• Keep the catalyst pump and the valve seals filled
with the appropriate lubricant. The lubricant
creates a barrier between the acid and the
atmosphere.
• Use only moisture-proof hoses compatible with
acids.
• Always lubricate threaded parts with an
appropriate lubricant when reassembling.
8 332456D
Installation
Installation
Before Installing the Kit 1. Flush the system as explained in your PD2K
Operation Manual. Follow the Pressure Relief
Procedure in your PD2K manual.
2. Close the main air shutoff valve on the air supply
line.
3. Remove electrical power from the system.
• Servicing the electrical control box exposes you
to high voltage. To avoid electric shock, turn off NOTE: The pump expansion kit can be mounted
power at the main circuit breaker before opening directly on the PD2K stand, or mounted onto a wall.
the enclosure. Install using the steps in Install the Frame, page 10 or
• All electrical wiring must be done by a qualified the steps in Install the Wall Bracket, page 11.
electrician and comply with all local codes and
regulations.
• Do not substitute or modify system components
as this may impair intrinsic safety.
Follow the Pressure Relief Procedure in

your PD2K manual whenever you see
this symbol.
This equipment stays pressurized until pressure

is manually relieved. To help prevent serious
injury from pressurized fluid such as skin injection,
splashing fluid, and moving parts, follow the
Pressure Relief Procedure in your system manual
when you stop spraying and before cleaning,
checking, or servicing the equipment.
332456D 9
Installation
Install the Frame NOTE: The illustration shows a resin (70cc) pump
expansion kit being installed on the left (color) side
Use these steps if you want to install the kit onto the of the PD2K proportioner. The pump control module
PD2K stand using frame (13). and dual grommet (11) are preassembled at the
factory so the cable (8) is facing to the right, allowing
1. Follow the steps in easier access to connections inside the PD2K
Before Installing the Kit, page 9 . electrical control box (D).
2. Install the frame (13) to the upright of the PD2K Install a catalyst (35cc) pump expansion kit on the
stand (A) using three screws (16) and nuts (18). right side of the proportioner, with the pump control
module and dual grommet (11) preassembled in the
3. Install the back panel/bracket assembly (B) in the
opposite direction so the cable (8) is facing to the left.
outermost position on the frame (13), to allow
clearance for the color change manifold (C).
Fasten the panel to the frame (13) using four
screws (15) and nuts (18). Install the top screws
from the front and the bottom screws from the
back.
Figure 2 Install the Frame and Pump
10 332456D
Installation
Install the Wall Bracket 3. Install the back panel/bracket assembly (B) to
wall bracket (47) using six screws (15) and six
Use these steps if you want to install the kit away nuts (18).
from the PD2K or PD1K stand using wall bracket (47). NOTE: The illustration shows a resin (70cc)
1. Follow the steps in pump expansion kit being installed on the left
Before Installing the Kit, page 9 . (color) side of the PD1K proportioner. The
pump control module and dual grommet (11)
2. Install wall bracket (47) to a wall or other suitable are preassembled at the factory so the cable (8)
vertical surface using four screws or bolts (user is facing to the right, allowing easier access to
provided). connections inside the PD1K electrical control
box (D).
Install a catalyst (35cc) pump expansion kit
on the right side of the proportioner, with the
pump control module and dual grommet (11)
preassembled in the opposite direction so the
cable (8) is facing to the left.
Figure 3 Install the Wall Bracket and Pump
332456D 11
Installation
TSL Cup Kit

The cup is used for either Throat Seal Liquid (TSL) 2. Place the TSL cup (73) into the bracket (73a).
or ISO oil. These liquids prevent exposure of air or
moisture with the resin or catalyst at the pump throat
packings and dosing valves. The PD2K Proportioner
includes two TSL Cup Kits, one for each pump. The
cups supply TSL to the upper throat cartridge of the
color (70 cc) pump, to the upper and lower throat
cartridges of the catalyst (35 cc) pump, and to the
four pump dosing valves. When using isocyanate
catalysts, the cup attached to the catalyst side of the
PD2K Proportioner is used to supply ISO oil to the
upper and lower throat cartridges of the catalyst (35
cc) pump and the catalyst dosing valves.
NOTE: TSL and ISO oil must be ordered separately.
For TSL, order Part No. 206995, one quart (0.95
liter). For ISO oil, order Part No. 217374, one pint
(0.48 liter).
1. Slide the kit mounting bracket onto any side of
the pump’s hex nut.
NOTE: Prior to mounting the cup, use a

Figure 4 Install TSL Cup Kit
permanent black marker to mark a horizontal line
on the front of the cup approximately half way
NOTE: The pump’s upper throat cartridge has
between the top and bottom of the cup. Mark a
three ports (two are plugged). Move a plug (73d)
second horizontal line approximately 1/4 in. (3
if necessary so the barbed fitting (73b) can be
mm) above the first line. Shining a strong light
put in the port closest to the TSL cup.
towards these lines will provide a shadow that
will be visible from inside the TSL cup. 3. Check that the o-ring is in place on the barbed
fitting (73b). Apply low strength thread adhesive
and install the fitting in the upper throat cartridge
port. Be sure the other two ports are plugged
(73d).
12 332456D
Installation
4. Catalyst (35 cc) pumps: Repeat for the lower 6. Cut the tubing (73c) to length as required.
throat cartridge. Connect the TSL cup fittings to the fittings on the
pump and valves. TSL is gravity-fed from the
cup to the pump and valves; position the fittings
and tubing to prevent kinks and enable the TSL
to flow freely down to the valve and air to rise
up and out of the valve.
7. Fill the cup to the level of the lower black
horizontal line with either TSL or ISO oil, as
appropriate for the resin and catalyst materials
being used.
NOTE: If TSL leaks from the rod guard of the
color (70 cc) pump, be sure the lower u-cup seal
is installed in the lower throat cartridge.
NOTE: The fluid levels in the TSL cups should be
checked daily. Fluid levels should remain static
for an extended period of time. Rising or falling
fluid levels in a TSL cup can be an indication of a
condition which needs immediate attention. Refer
5. If you are lubricating the dosing valves, remove to the troubleshooting steps in the repair manual for
the plug (73d) and gasket from the valve port (V) guidance.
closest to the TSL cup.
NOTE: Choose the valve port in the upward
facing position. This will allow liquid to flow into ISO Oil Fill Procedure
the valve while allowing air to rise out of the
When using polyurethane coatings with isocyanate
valve.
catalysts in high-humidity environments, use of ISO
Check that the o-ring is in place on the barbed
oil on the catalyst pump TSL cup is recommended
fitting (73b). Apply low strength thread adhesive
instead of TSL. The ISO oil will present a barrier
and install the fitting in the valve port (V).
that will prevent catalyst hardening from contact with
NOTE: Do not confuse the valve port (V) with the
moisture. When performing the first fill of a cup with
air port (W).
ISO oil, it will be necessary to bleed the air out of the
feed line.
NOTE: If not already present on the TSL cup, draw
the two horizontal lines at, and slightly above, the
vertical center of the front of the cup before filling.
To bleed air:
1. Fill the catalyst pump TSL cup to the lower
horizontal line.
2. Remove one plug (73d) from the upper throat
cartridge and allow air in that area to flow until no
air is being expelled. Replace the plug.
3. Repeat step 2 at the lower throat cartridge.
4. Use absorbent rags to clean up excess ISO oil
that escaped from the plug holes.
5. Replenish the ISO oil level in the TSL cup to the
lower horizontal line.
NOTE: If you are not lubricating the dosing

valves, remove the unused barbed fittings (73b)
from the bottom of the TSL cup (73). Apply low
strength thread adhesive and install the plugs
and gaskets supplied with the kit.
332456D 13
Installation
Air Connections
For PD2K installations: Follow the steps below. NOTE: A 6 ft (1.83 m) length of 1/4 in. (6 mm) OD
polyethylene tubing (35) is supplied with the kit to
For PD1K installations: For the first expansion supply air to the expansion pump’s solenoid manifold
kit, connect the air supply tube (35) directly to the (3).
electrical control box (Z). For the second through
fourth expansion kits, follow steps 2–4 below. 1. See the PD2K Repair-Parts Manual. Remove the
PD2K fluid panel cover to expose the air supply
tubing to the two existing solenoid manifolds.
2. Cut the air supply tubing upstream of the Y-fitting.
3. Install the Y-fitting (36) supplied in the kit as
shown, to restore the air supply to the two
existing solenoid manifolds.
4. Connect the supplied 1/4 in. (6 mm) OD tubing
(35) between the open branch of the Y-fitting
(36) and the air inlet of the solenoid manifold (3).
This supplies air to the expansion pump solenoid
manifold, as shown in the detail of the illustration.
NOTE: If you are installing a fourth pump, make
a second splice in the main solenoid air supply
line and plumb as explained above.
Figure 5 Air Connection for PD1K First Expansion Kit
Figure 6 Supplying Air to the Expansion Pump

Solenoid Manifold
14 332456D
Installation
Fluid Connections
1. Connect a 1/4 npt(f) fluid hose from the fluid
source to the pump’s fluid inlet fitting (S).
2. Connect a 1/4 npt(f) fluid outlet hose from the
pump’s fluid outlet fitting (R) to the gun’s fluid
supply.
Figure 7 Pump Fluid Connections
332456D 15
Installation
Electrical Connections 4. Thread the cable into the electrical control box
and connect to the appropriate connection port
on the enhanced fluid control module. For
NOTICE example, connect Pump 1 to P1 and Pump 2 to
To avoid electrical component damage, remove all P2 (PD1K only); Pump 3 to P3, Pump 4 to P4,
system power before plugging any connectors. and so on.
NOTE: See the Electrical Schematics, page 24.

1. Verify that electrical power is removed from the
system.
2. Remove the cover from the PD2K/PD1K
electrical control box.
3. Remove the knockout (K) from the side of the
electrical control box.
Figure 8 Install Grommet in Electrical Control

Box
Figure 9 Enhanced Fluid Control Module

Connection Points
16 332456D
Installation
NOTICE 5. The PD2K/PD1K fluid panel cover was previously

removed in Air Connections, page 14. Thread
Be sure to keep 48 volt cables isolated from the the 2–wire cable (22) through the grommet (42)
low voltage wiring. All 48 VDC wiring must use on the bottom of the fluid panel and up into
the right-hand wireway (X) inside the electrical the electrical box through an existing grommet
control box. Use grommet (Y) marked in Figure and the wireway. Connect the cable (22) to the
9 to install the Pump Expansion Kit wiring. appropriate terminals on the top of the 48 VDC
power supply: P1 for Pump 1 and P2 for Pump
2 (PD1K only); P3 for Pump 3, P4 for Pump 4.
Connect the red wire to + terminal, black wire to
- terminal.
Figure 11 48 VDC Power Supply Connection

Points
6. Install the dual grommet (11, shipped loose) on
Figure 10 48 VDC Grommet and Wireway the free end of the D-SUB cable (8).
7. Fasten the grommet (11) to the side of the
electrical control box, using two screws (31).
8. Reinstall the covers on the PD2K electrical
control box and on the fluid panel.
332456D 17
Installation
Grounding
This equipment must be grounded to reduce the

risk of static sparking and electric shock. Electric
or static sparking can cause fumes to ignite or
explode. Improper grounding can cause electric
shock. Grounding provides an escape wire for the
electric current.
1. Verify that the PD2K base unit is properly

grounded. See the PD2K installation manual for
complete grounding instructions.
2. Ground the expansion kit pump(s) as follows:
a. If the added pump is mounted to the PD2K
main unit, verify that the added pump is
grounded by taking a resistance reading from
the ground screw (7) on the added pump
kit’s back panel (2) to the system’s true earth
ground. Resistance must be less than 1 ohm.
b. If the added pump is NOT mounted to the Figure 12 Grounding the Pump Expansion Kit
PD2K main unit, connect a ground wire to
the ground screw (7) on the added pump kit’s
back panel (2). Connect the other end of the
ground wire to the same true earth ground
that the main PD2K unit is connected to.
Verify that the added pump is grounded by
taking a resistance reading from the ground
screw (7) on the added pump kit’s back
panel (2) to the system’s true earth ground.
Resistance must be less than 1 ohm.
18 332456D
Installation
Complete the Installation

1. Install the cover (12) on the expansion kit, using
the screw (37) and nut (18). 4. Press and navigate to System Screen 1
on the Advanced Display Module. Change the
number of Color Pumps and Catalyst Pumps as
needed, based on the kit installation.
Figure 15 System Screen 1
Figure 13 Install Expansion Kit Cover (Frame)
Figure 14 Install Expansion Kit Cover (Wall

Mount)
2. Restore electrical power to the PD2K/PD1K.
3. Turn on the control box power switch.
332456D 19
Installation
5. Go to the Pump Screens. The menu bar at the 6. The Home Screen will now show animations and
top of the screen will now show separate tabs information for the added pumps.
for the added pump(s) 3 and 4. Each pump has
three screens. Enter the required information, as
explained in the PD2K Operation Manual.
NOTE: At a minimum, you must enter the
Pump Size on Pump Screen 1 and transducer
calibration data “Outlet Offset Factor” and “Outlet
Sensitivity Factor” on Pump Screen 2 (see your
PD2K Operation Manual). Also, create a recipe
using the new material number, which can be
found on Pump Screen 1 under Available Colors
(or Catalysts).
Figure 18 PD2K Home Screen (Advanced

Display Module)
7. See the PD2K Operation Manual to return the
system to service.
Figure 16 Third (Color) Pump Screen
Figure 17 Fourth (Catalyst) Pump Screen
20 332456D
Repair
Repair
Dose Valve Tubing Connections
NOTE: 5/32 in. (4 mm) tubing connects the solenoid 2. On the side of the solenoid manifold are four
manifold to the pump’s dosing valves. See the Pump ports with 90° tube fittings (not shown): UP
Tubing Schematic on the next page. Tubing lengths OPEN, UP CLOSED, DOWN OPEN, and DOWN
must be 18 in. ± 1/2 in. (457 mm ± 13 mm) for all CLOSED. These ports provide air to open and
connections. Always use equal lengths of tubing, to close the pump’s outlet dosing valves.
balance the timing of the valves. Lengths longer than
18 in. (457 mm) will increase valve response time.
1. On the bottom of the solenoid manifold are four
ports with tube fittings: UP OPEN, UP CLOSED,
DOWN OPEN, and DOWN CLOSED. These
ports provide air to open and close the pump’s
inlet dosing valves.
Figure 21 Tubing Connections at Solenoid

Manifold, to Pump Outlet Manifold
a. Connect blue tubing (B) from the UP OPEN
fitting to the 90° tube fitting on the side of the
OUTLET UP dosing valve.
b. Connect red tubing (R) from the UP CLOSED
fitting to the 90° tube fitting on the end of the
OUTLET UP dosing valve.
Figure 19 Tubing Connections at Solenoid

Manifold, to Pump Inlet Manifold
a. Connect green tubing (G) from the UP OPEN
fitting to the 90° tube fitting on the side of the
INLET UP dosing valve.
b. Connect red tubing (R) from the UP CLOSED
fitting to the 90° tube fitting on the end of the
INLET UP dosing valve.
c. Connect black tubing (K) from the DOWN Figure 22 Outlet Manifold Tubing
OPEN fitting to the 90° tube fitting on the side Connections
of the INLET DOWN dosing valve.
d. Connect red tubing (R) from the DOWN
CLOSED fitting to the 90° tube fitting on the
end of the INLET DOWN dosing valve.
Figure 20 Inlet Manifold Tubing Connections
332456D 21
Repair
c. Connect yellow tubing (Y) from the DOWN See the following table to understand the relationship
OPEN fitting to the 90° tube fitting on the side between pump stroke and dose valve actuation.
of the OUTLET DOWN dosing valve.
d. Connect red tubing (R) from the DOWN Table 1 Dose Valve Actuation
CLOSED fitting to the 90° tube fitting on the
end of the OUTLET DOWN dosing valve. Pump Up Inlet Down Up Down
Stroke Valve Inlet Outlet Outlet
3. Repeat these steps for each pump in your Valve Valve Valve
system.
Up Open Closed Open Closed
Down Closed Open Closed Open
UP EXH
OP EN
INLET UP
Gre e n (G)
Re d (R) CLOS ED
Blue (B)
OP EN
Re d (R)
OUTLET UP
CLOS ED
DOWN EXH
OP EN
INLET DOWN
Bla ck (K)
Re d (R) CLOS ED
Ye llow (Y)
OP EN
Re d (R)
OUTLET DOWN
CLOS ED
Figure 23 Pump Tubing Schematic
22 332456D
Repair
Replace Pump Control Module

If the pump control module needs replacement, install
a new module as follows.
NOTICE
To avoid electrical component damage, remove all
system power before plugging any connectors.
NOTE: See the Electrical Schematics, page 24.

1. Connect the motor cable connectors (25) to
connection ports 2 and 3 on the pump control
module (5) and to the pump motor (N).
NOTE: The wire harness has two cables, one
for the motor control and the other for encoder
feedback. The connectors are keyed differently
to ensure correct installation. Attach the two
ground wires to the ground screw on the pump Figure 25 Pump Control Module Connections
motor (N).
2. Connect the 2–wire cable (22) to connection port
8 on the pump control module (5); red wire to pin
1 and black wire to pin 2.
3. Ensure that the pre-installed D-SUB Cable (8)
is securely attached to connection port 1 on the
pump control module (5).
4. Connect the pump’s outlet pressure transducer
(T) to port 5.
5. Connect the inlet pressure transducer to port 4.
6. Install the valve wiring (V) in port 7. See
Electrical Schematics, page 24.
Figure 24 Pump Control Module Connection

Points
332456D 23
Electrical Schematics
Standard Models (MC1000, MC2000, MC3000, MC4000)
NOTE: The electrical schematic illustrates all possible
wiring expansions in a ProMix PD2K system; models
MC1000, MC2000, and MC4000. Some components
shown are not included with all systems.
NOTE: See Optional Cables and Modules
for a list of cable options.
065161, 065159 2 CABLE 2 CABLE

RELAY (15V206)
(15V206)
2 POSITION POWER MODULE INTEGRATION
SWITCH (24R257)
6
6
CATALYST CHANGE
GATEWAY
6
6
CATALYST CHANGE
6
COLOR CHANGE
(16U725)
COLOR CHANGE
COLOR CHANGE
COLOR CHANGE
MODULE 2
5
MODULE 3
MODULE 6
MODULE 1
MODULE 4
MODULE 5
(24N935)
(24N935)
(24N935)
CABLE
(24N935)
(24N935)
(24N935)
16T658
24V
(121227)
CABLE
(121001)
POWER
3 CABLE
CABLE (15V206)
48V-10APOWER SUPPLY
3
LINEFILTER
(16V446) SUPPLY (16U820)
(16T660)
AWI
CABLE GATEWAY
16H078 (24R910) CABLE CABLE CABLE
2 (15V206) 2 (15V206) 2 (15V206)
5
2
TERMINAL BLOCK
(121227)
(114095)
3 CABLE GUNTRIGGER INPUTS
TERMINAL
BLOCKS WITH FUSES
119159
16W159
119159
16W159
16W159
16W159
POWER IN 119159
16T072 119159
CAN SOLENOID (121324)

IS BOARD GFB
(24M485) PRESSURE SW (121323) INTERF
ACES
FAN FAN GCA
(24P658) (24P658) SOLVENTCUTOFF (121324)
MODULE
(16T280)
CABLE
ENCODER AND MOT OR ENCODERAND MOT OR

(16P036, 16P037) (16P036, 16P037) SWITCH (120278) SOLVENT
WIRE HARNESS WIRE HARNESS
EFCM
BREAKOUT MODULE PUMP 2
(24P684, 24P685) (24P684, 24P685) FLOW

SWITCH (120278) INPUTS
PUMP INLET
TRANSDUCER
(16P289, 16P290)
PUMP INLET
TRANSDUCER
(16P289, 16P290) BARRIER
(24N913)
SPLITTER SOLVENT METER (258718)
BOARD
(16P243)
PUMP OUTLET PUMP OUTLET (248192)
SAFETYINTERLOCK SWITC
H
(24N527)
(24N527)
TRANSDUCER TRANSDUCER
(16P289, 16P290) (16P289, 16P290)
3
ADVANCED LIGHT
PUMP V/P FOR PUMP V/P FOR CABLE
FLUID REG. FLUID REG. DISPLAY MODULE TOWER
(121003) (24E451) (15X472)
MAC SERIES 46
MAC SERIES 46
SOLENOID
SOLENOID
(16P812)
(16P812)
UP UP
FLOW RATE ANALOG IN
FLOW RATE ANALOG IN
FLOW RATE ANALOG IN
FLOW RATE ANALOG IN
DOWN DOWN
FLOW SENSOR FLOW SENSOR

(120278) (120278)
COLOR CHANGE MODULE 7
1
OR G3000 METER OR G3000 METER (24R219)
7
(16V426)
CABLE
(239716, 258718 (239716, 258718
16M510, 16M519) 16M510, 16M519)
4
CABLE (16T659)
CABLE (16T659) COLOR CH
ANGE MODULE 8
CABLE (16T659) (24R219)
CABLE (16T659) 7
(16V426)
1 CABLE
FAN FAN 1
(24P658) (24P658) CABLE (16V429)
ENCODER AND MOT OR ENCODERAND MOT OR BOOTH CO

NTROL(24M731)
(16P036, 16P037) (16P036, 16P037)

(24P684, 24P685) (24P684, 24P685)
PUMP INLET
TRANSDUCER
PUMP INLET
TRANSDUCER
HAZARDOUS LOCATION
(16P289, 16P290) (16P289, 16P290)
PUMP OUTLET PUMP OUTLET

NON-HAZARDOUS LOCATION
(24N527)
(24N527)
(16P289, 16P290) (16P289, 16P290)
PUMP V/P FOR PUMP V/P FOR

FLUID REG. FLUID REG.
MAC SERIES 46
MAC SERIES 46
SOLENOID
SOLENOID
(16P812)
(16P812)
UP UP
DOWN DOWN

(120278) (120278)
OR G3000 METER OR G3000 METER
(239716, 258718 (239716, 258718
16M510, 16M519) 16M510, 16M519)
Figure 26 Electrical Schematic, Sheet 1
24 332456D
CONTINUED ON P
AGE 3 CONTINUED ON P
AGE 3
UNUSED 5
UNUSED 4
3 10
2
UNUSED 1
CABLE (121227) CABLE CABLE
2
3 1 1 1 1 1
2 2 2 2 2
CABLE (16V429)
(15V206)
CABLE 3 P3 P4 3 3 P3 P4 3 3 8
4 4 4 4 4
5 AWI 5 5 5 5
(121227) (121001)
12345
2 CAN IS BOARD
16T072
12345
1
GATEWAY
(24R910)
5
3 INTEGRATION
GATEWAY
5
3
GCAMODULE
EFCM
1
(NONIS)
(IS)
4 (24M485) 3
12345 12345
(24N913)
(16T280)
CABLE
UNUSED
UNUSED
GFB INTERFACE +24VDC 1

(121324) COM 2
UNUSED 3
UNUSED 4
+24VDC 5
123 COM 6
1 +24VDC 7 5
SPLITTER SOLVENT CUTOFF (121324) 8
UNUSED 2 COM
(16P243) 3 PWR (RED) 9
54 3 2 1 SIG (WHITE) 10
BARRIER COM(BLACK) 11
1 2
BOARD SHIELD/GRN UNUSED 12
SOLVENT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
(248192) METER
UNUSED
UNUSED
UNUSED
(258718)
D-SUB CABLE
RED WIRE (06
5161)
GROUND BAR
(16T659)
4
4 25 PIN
BLAC
K WIRE (065159)
25 PIN D-SUB CABLE
(16T659)
24V
POWER
SUPPLY
(16T660)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
1 1
GRND (GRN/YEL)
BREAK
OUT MODULE PUMP 1 (24N527) BREAK
OUT MODULE PUMP 2 (24N527)
2 3 4 5 6 7 8 2 3 4 5 6 7 8
12345 1234 12345 12345 1234 12 34 5678 12 34 12345 1234 12345 12345 1234 12 3 4 5678 12 34
13 A1(+) A2(-)
RELAY
+48V
+48V
+48V
+48V
COM
COM
COM
COM
14
OUTLET TRANSDUCER
OUTLET TRANSDUCER
N L GRND
INLET TRANSDUCER
INLET TRANSDUCER
(16P289 OR 16P290)
(16P289 OR 16P290)
V/P FOR FLUID REG.
V/P FOR FLUID REG.

(16P289 OR 16P290)
(16P289 OR 16P290)
L (BROWN)
48V-10A ENCODER/MOTOR ENCODER/MOTOR

PUMP 1
PUMP 2
N (BLUE)
PUMP 1
PUMP 2
PUMP 1
PUMP 2
POWER SUPPLY AND AND
COM(BLACK)
COM(BLACK)
+24VDC
+24VDC
COM
COM
SHIELD/GRN
COM
COM
SHIELD/GRN
+24VDC
+24VDC
WIRE HARN
ESS WIRE HARN
ESS
SIG (WHITE)
SIG (WHITE)
(16U820)
PWR (RED)
PWR (RED)
PUMP1 PUMP2
+ -
FAN PUMP 1
FAN PUMP 2
(24P658)
(24P658)
SEE DET
AILAOR B SEE DET
AILAOR B
N03 N03
2 POSITION
SWITCH
POWER MODULE
PUMP 1
PUMP 2
PUMP 1
PUMP 2
DOWN
DOWN
UP
UP
(16U725)
(24R257)
N04 N04 MANIF

OLD MANIFOLD
+-+-+-+-
MAC SERIES 46
MAC SERIES 46
(16P812 QTY 2)
(16P812 QTY 2)
F4
G3000 G3000
F3
CABLE
F2
METER METER
F1
(16T658) PUMP 1 PUMP 2

(EITHER, 239716, (EITHER, 239716,
258718,16M510, 258718,16M510,
OR 16M519) OR 16M519)
L N +-+-+-+-
GRND
LINE SCREW GRND
FILTER TWIST
ED PAIR CABLE (16W159) SCREW
(16V446) TWIST
ED PAIR CABLE (16W159)
L GRND N
CABLE
(16H078) DETAILA, LOW PRESSURE PUMPS DETAIL B, HIGH PRESSURE PUMPS
(24M706, 24M714, 24T799) (24M707, 24M71 5, 24T800)
L N GRND BREAKOUT MODULE BREAKOUT MODULE
TERMINAL (24N527) (24N527)
BLOCK 2 3 2 3
(114095) 12345 1234 12345 1234
L N GRND WIRE HARNESS WIRE HARNESS

(24P684) DRAIN/FOIL (24P685) DRAIN/FOIL
DRAIN/FOIL
POWER IN
DRAIN/FOIL
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
DRAIN/FOIL
MOTOR
GROUND 1 2 3 4 5 6 78 9 1011 12 1 2 3 4 5 6 78 9 10 12 1 2 3 4 5 67 8 9 1011 12 1 2 3 4 5 67 8 9 10
SCREW
MOTOR
PUMP ENCODER AND MOTOR MOTOR
MOUNTING
PUMP ENCODER AND MOTOR
MOUNTING
SCREW
(16P037) SCREW (16P036)
Figure 27 Electrical Schematic, Sheet 2, Part 1

CONTINUED ON THE NEXT PAGE
332456D 25
GUN TRIGGER INPUTS

1 SIG
2 COM
3 SIG
119159
4 COM
5 SIG
6 COM
6 7 SIG
8 COM
9 SIG
10 COM GFB PRESSURE SWITCH (121323)
GCAMODULE 11
12
SIG
COM SOLVENT FLOW SWITCH 1 (120278)
EFCM 1
2
3
4
5
FLOW RATE ANALOG IN 1
FLOW RATE ANALOG COMMON 1
(24N913) 7
6
7
8
9
10
SIG
COM SOLVENT FLOW SWITCH 2 (120278)
11 SIG
12 SAFETY INTERLOCK SWITCH
COM
1
CABLE
1 1
2 2 ADVANCED 2 LIGHT
9 3 3 DISPLAY MODULE 3 TOWER
4 4 (15X472)
3 4 5
4 (24E451)
5
5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 (121003)
3
D-SUB CABLE
(16T659)
4
4 25 PIN
25 PIN D-SUB CABLE

(16T659)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
1 1
BREAKOUT MODULE PUMP 3 (24N527) BREAKOUT MODULE PUMP 4 (24N527)
2 3 4 5 6 7 8 2 3 4 5 6 7 8
12345 1234 12345 12345 1234 12 34 5678 12 34 12345 1234 12345 12345 1234 12 34 5678 12 34
+48V
+48V
+48V
+48V
COM
COM
COM
COM
OUTLET TRANSDUCER
OUTLET TRANSDUCER
INLET TRANSDUCER
INLET TRANSDUCER
(16P289 OR 16P290)
(16P289 OR 16P290)
V/P FOR FLUID REG.
V/P FOR FLUID REG.

(16P289 OR 16P290)
(16P289 OR 16P290)
ENCODER/MOTOR ENCODER/MOTOR
PUMP 3
PUMP 4
PUMP 3
PUMP 4
PUMP 3
PUMP 4
AND AND
COM(BLACK)
COM(BLACK)
+24VDC
+24VDC
COM
COM
SHIELD/GRN
COM
COM
SHIELD/GRN
+24VDC
+24VDC
SIG (WHITE)
SIG (WHITE)
PWR (RED)
PWR (RED)
PUMP 3 PUMP 4
FAN PUMP 3
FAN PUMP 4
(24P658)
(24P658)
SEE DETAILAOR B SEE DETAILAOR B
PUMP 3
PUMP 4
PUMP 3
PUMP 4
DOWN
DOWN
UP
UP
MANIFOLD MANIFOLD
MAC SERIES 46
MAC SERIES 46
(16P812 QTY 2)
(16P812 QTY 2)
G3000 G3000
METER METER
PUMP 3 PUMP 4
(EITHER, 239716, (EITHER, 239716,
258718,16M510, 258718,16M510,
OR 16M519) OR 16M519)
GRND
SCREW GRND
SCREW
TWISTED PAIR CABLE (16W159)


26 332456D
FROMCAN IS BOARD (24M485)
2 CABLE(15V206)
12 34 5
COLOR
CHANGE
MANIFOLD MODULE 1 MANIFOLD
1 (COLORS 6
FLUSH +24VDC COM DUMP
COM 2 1 THRU 8) 5 +24VDC
COLOR1 +24VDC 3 4 COM
4 J8 J9 3 COLOR1
COM +24VDC
COLOR2 +24VDC 5 2 COM COLOR2
COM 6 1 +24VDC
6
+24VDC 1 6 COM
COLOR3 COM 2 5 +24VDC COLOR3
+24VDC 3 J15 J16 4 COM
+24VDC 5 2 COM
+24VDC 1 6 COM
+24VDC 3 4 COM
COLOR7 COM 4 J14 J10 3 +24VDC COLOR7
+24VDC 5 2 COM
12 34 5
(15V206)
CABLE
2
12 34 5
COLOR CATALYST
CHANGE CHANGE
MANIFOLD MODULE 2 MANIFOLD MANIFOLD MODULE 5 MANIFOLD
1 (COLORS 6 1 (CATALYST 6
*FLUSH +24VDC COM DUMP* +24VDC COM DUMP
COM 2 9 THRU 16) 5 +24VDC FLUSH COM 2 1 THRU 4) 5 +24VDC
+24VDC 3 4 COM +24VDC 3 4 COM
COLOR9
COM 4 J8 J9 3 +24VDC
COLOR9 CATALYST 1 COM 4 J8 J9 3 +24VDC
CATALYST 1
COLOR10 +24VDC 5 2 COM COLOR10 CATALYST 2 +24VDC 5 2 COM CATALYST 2
COM 6 1 +24VDC COM 6 1 +24VDC
6 6
COLOR11 COM 2 5 +24VDC COLOR11 CATALYST 3 COM 2 5 +24VDC CATALYST 3
+24VDC 3 J15 J16 4 COM 3 J15 4 COM
COLOR12 COM 4 3 +24VDC COLOR12 CATALYST 4
+24VDC
COM 4 J16 3 +24VDC CATALYST 4
+24VDC 5 2 COM UNUSED 5 2 UNUSED
COLOR13 COM 6 1 +24VDC COLOR13 UNUSED 6 1 UNUSED

COLOR15 COM 4 J14 J10 3 +24VDC COLOR15 UNUSED 4 J14 J10 3 UNUSED
12 34 5 12 34 5
(15V206)
(15V206)
CABLE
CABLE
2
12 34 5 12 34 5
COLOR COLOR
CHANGE CHANGE
MANIFOLD MODULE 3 MANIFOLD MANIFOLD MODULE 4 MANIFOLD
1 (COLORS 6 1 (COLORS 6
*FLUSH +24VDC COM DUMP* *FLUSH +24VDC COM DUMP*
COM 2 17 THRU 24) 5 +24VDC COM 2 25 THRU 32) 5 +24VDC
COLOR17
COLOR17 COLOR25
COLOR25
COLOR18 +24VDC 5 2 COM COLOR18 COLOR26 +12VDC 5 2 COM COLOR26
6 6
COLOR19 COM 2 5 +24VDC COLOR19 COLOR27 COM 2 5 +24VDC COLOR27
COLOR20
+24VDC
COM
3
4 J15 J16 43 COM
+24VDC COLOR20 COLOR28 +24VDC
COM
3
4
J15 J16 4
3
COM
+24VDC COLOR28

COLOR23 COM 4 J14 J10 3 +24VDC COLOR23 UNUSED 4 J14 J10 3 UNUSED
54 3 2 1 12 34 5
CABLE(15V206)
2
* May be unused in some configurations.
332456D 27
CATALYST
CHANGE
1 (CATALYST 6
+24VDC COM
FLUSH COM 2 3 THRU 4) 5 +24VDC DUMP
+24VDC 3 4 COM
CATALYST 3 COM 4 J8 J9 3 +24VDC CATALYST 3
+24VDC 5 2 COM
CATALYST 4 6 1 CATALYST 4
COM +24VDC
6
UNUSED 1 6 UNUSED
UNUSED 2 5 UNUSED
UNUSED 3 J15 J16 4 UNUSED
UNUSED 4 3 UNUSED
UNUSED 5 2 UNUSED
UNUSED 6 1 UNUSED
UNUSED 1 6 UNUSED
UNUSED 2 5 UNUSED
UNUSED 3 4 UNUSED
UNUSED 5 2 UNUSED
UNUSED 6 1 UNUSED
12 34 5
(15V206)
CABLE
2
54 3 2 1
CATALYST
CHANGE
1 (CATALYST 6
+24VDC COM
+24VDC 3 4 COM
+24VDC 5 2 COM
COM +24VDC
6
UNUSED 1 6 UNUSED
UNUSED 2 5 UNUSED
3 J15 4 UNUSED
UNUSED
UNUSED 4 J16 3 UNUSED
UNUSED 5 2 UNUSED
UNUSED 6 1 UNUSED
UNUSED 1 6 UNUSED
UNUSED 2 5 UNUSED
UNUSED 3 4 UNUSED
UNUSED 5 2 UNUSED
UNUSED 6 1 UNUSED
12 34 5
(15V206)
CABLE
2
12 34 5
COLOR
CHANGE
MODULE 4
(COLORS
25 THRU 32
)
ALTERNATE CONFIGURATION
FOR CATALYST CHANGE CONTROL
Figure 30 Electrical Schematic, Sheet 3, Alternate
Configuration for Catalyst Change Control
28 332456D
HAZARDOUS LOCATION
12 34 5
COLOR
CHANG E
+12VDC 1 (COLORS 6 COM
COLOR FLUSH COM 2 33 THRU 40) 5 +12VDC CATALYST FLUSH
COLOR 1 +12VDC 3 4 COM CATALYST 1
COM 4
5
J8 J9 3 +12VDC
COLOR 2 +12VDC 2 COM CATALYST 2
COM 6 1 +12VDC
7
+12VDC 1 6 COM
COLOR 3 COM 2 5 +12VDC CATALYST 3
+12VDC 3 4 COM
COLOR 4 COM 4 J15 J16 3 +12VDC CATALYST 4
+12VDC 5 2 COM
COLOR 5 COM 6 1 +12VDC COLOR 9
+12VDC 1 6 COM
+12VDC 3 4 COM
COLOR 7 COM 4 J14 J10 3 +12VDC COLOR 11
+12VDC 5 2 COM
12 34 5
(16V426)
CABLE
1
12 34 5
COLOR
CHANG E
1 (COLORS 6 COM
COLOR 13 +12VDC COLOR 22
COM 2 41 THRU 48) 5 +12VDC
COLOR 14 +12VDC 3 4 COM COLOR 23
COM 6 1 +12VDC
7
+12VDC 1 6 COM
+12VDC 3 J15 J16 4 COM
+12VDC 5 2 COM
COLOR 18 6 1 +12VDC COLOR 27
COM
+12VDC 1 6 COM
+12VDC 3 4 COM
+12VDC 5 2 COM
54 3 2 1
(16V426)
CABLE
1
5 4 3 2 1
BOOTH CONTROL
(24M731)
Figure 31 Electrical Schematic, Sheet 3, Hazardous

Location
332456D 29
Dual Panel Models (MC1002, MC2002, MC4002)

NOTE:The electrical schematic illustrates all possible
NOTE:
wiring expansions in a ProMix PD2K system; models
MC1002, MC2002, and MC4002. Some components
shown are not included with all systems.
NOTE: See Optional Cables and Modules
for a list of cable options.
2 CABLE 2 CABLE
POWERMODULE (15V206) (15V206)
(26A189) INTEGRATION
2 POSITION
6
6
CATALYST CHANGE
6
6
CATALYST CHANGE
6
GATEWAY
COLOR CHANGE
COLOR CHANGE
COLOR CHANGE
COLOR CHANGE
SWITCH
(16U725)
MODULE 2
MODULE 3
MODULE 6
MODULE 1
MODULE 4
5
MODULE 5
(24N935)
(24N935)
(24N935)
(24N935)
(24N935)
(24N935)
24V
CABLE POWER 48V-10APOWER SUPPLY
(121227)
16T658
CABLE
SUPPLY (16U820)
(121001)
3 CABLE
CABLE (15V206)
3
(16T660)
LINE FIL
TER
(16V446)
AWI
GATEWAY CABLE CABLE
CABLE
CABLE (24R910) 2 2 2
(15V206) (15V206) (15V206)
16H078 5
RELAY 1 RELAY 2
(121227)
3 CABLE
TERMINAL BLOCK AIR FLOW SW. 1 (119159)
(114095)
TERMINAL BLOCK WITH FUSES
AIR FLOW SW. 2 (119159)
AIR
POWER IN GFBPRESS. SW. 1 (121323) CONTROL
16W159
16W159
16W159
16W159
CABLE
16T072 15V819 MODULE
GFBPRESS. SW. 2 (121323)
(26A231)
GFBVALVE 1 (121324)
CAN
IS BOARD GFBVALVE 2 (121324)
(24M485)
GCA SOLVENT CUTOFF VALVE (121324)
FAN FAN 17L058
MODUL E SOLVENT CUTOFF VALVE (121324)
(16T280)
CABLE
(24P658) (24P658)
ENCODERAND MOT OR
(16P036, 16P037)
WIRE HARNESS
ENCODERAND MOT OR
(16P036, 16P037)
WIRE HARNESS
EFCM SWITCH (120278)
SWITCH (120278) SOLVENT
(24P684, 24P685)
PUMP INLET
(24P684, 24P685)
PUMP INLET BARRIER

(24N913) SWITCH (120278)
FLOW
INPUTS
TRANSDUCER TRANSDUCER SPLITTER BOARD SWITCH (120278)
(16P289, 16P290) (16P289, 16P290) (16P243) (248192)
PUMP OUTLET PUMP OUTLET SAFETY INTERLOCK SWITCH
(24N527)
(24N527)
(16P289, 16P290) (16P289, 16P290) LIGHT
CABLE ADV
ANCED DISPLA
Y MODULE TOWER
(121003) 3 (24E451)
CABLE 126232 CABLE 126232 (15X472)
OR 17N315 OR 17N315
MAC SERIES 46
MAC SERIES 46
SOLENOID
SOLENOID
(16P812)
(16P812)
UP UP
PLC DISCRETE 1 (4-20mA)
PLC DISCRETE 2 (4-20mA)
DOWN DOWN
COLOR CHANGE 1 BOOTHCONTROL

MODULE 7 CABLE (24M731)
SOLVENT SOLVENT
METER 1 (24R219) (16V426) WITH SHUNT
METER 2
(258718) 7 (17M540)
(258718)
1
COLOR CHANGE BOOTH
MODULE 8 CABLE
(16V426) CONTROL
(24R219) (24M731)
FAN FAN 4 CABLE (16T659) 7
(24P658) (24P658)
ENCODERAND MOT OR ENCODERAND MOT OR
(16P036, 16P037) (16P036, 16P037)

(24P684, 24P685) (24P684, 24P685)
PUMP INLET PUMP INLET CABLE (16V429)

HAZARDOUS LOCA
TION
1
(16P289, 16P290) (16P289, 16P290)
NON-HAZARDOUS LOCA
TION
PUMP OUTLET PUMP OUTLET
(24N527)
(24N527)
(16P289, 16P290) (16P289, 16P290)
PUMPV/PFOR PUMPV/PFOR
FLUID REG. FLUID REG.
MAC SERIES 46
MAC SERIES 46
SOLENOID
SOLENOID
(16P812)
(16P812)
UP UP
DOWN DOWN

(120278) (120278)
OR G3000 ME TER OR G3000 ME TER
(239716, 258718 (239716, 258718
16M510, 16M519) 16M510, 16M519)
30 332456D
UNUSED 5
UNUSED 4
3 1
2
10 2
UNUSED 1 3
CABLE (121227) CABLE CABLE 4
2
3 1 1 1 1 1 5
2 2 2 2 2 6 6
(15V206)
CABLE
3 P3 P4 3 3 P3 P4 3 3 8 7
4 4 4 4 4 8
5 AWI 5 5 5 5 9
(121227) (121001) 10
16T072 GATEWAY 3 INTEGRATION 3
GCAMODULE 11
2X CABLE (16V429)
12345
(24R910) GATEWAY 12
12345
2 CANIS BOARD 5
1 5
(NON IS) 1
4
12345
(IS)
(24M485)
12345
3 EFCM 2
3
4
5
6
7
(24N913) 7
1
1 8
UNUSED
UNUSED
2 +24VDC 1 9
3 SOLVENTCUTOFF VALVE 1 (121324) COM 2
SPLITTER
10
(17L058)
(16T280)
4 +24VDC 3
CABLE
SOLVENTCUTOFF VALVE 2 (121324) 11

5 COM 4 12
GREEN/BLACK +24VDC 5
1 ORANGE/BLACK COM 6
2 GFBOUTPUT VALVE 1 5
BLUE/BLACK +24VDC 7
3 RED/WHITE COM 8 1
4
GFBOUTPUT VALVE 2 2
UNUSED 9
5
SAFETYINTERLOCK SWITCH SIG 10 9 3
11 4
1
123 COM
12 1 2 3 4 5
SPLITTER UNUSED
UNUSED 2 J4 J5
(16P243) 3
54 3 2 1 BARRI ER
BOARD
(248192)
UNUSED
UNUSED
UNUSED
25 PIN D-SUB
4 CABLE(16T659)
GROUND
24V BAR
POWER 1 1
SUPPLY BREAKOUT
MODULEUMP
P 1 (24N527) BREAKOUT
MODULE PUMP 2 (24N527)
(16T660)
2 3 4 5 6 7 8 2 3 4 5 6 7 8
12345 1234 1 2 3 45 12345 1234 12 34 5678 12 34 12345 1234 12345 12345 1234 12 34 5678 12 34
GRND (GRN/YEL)
+48V
+48V
+48V
+48V
COM
COM
COM
COM
(16P289 OR 16P290)
(16P289 OR 16P290)
(16P289 OR 16P290)
(16P289 OR 16P290)
TRANSDUCER
TRANSDUCER
TRANSDUCER
TRANSDUCER
N L GRND BLACK
BLACK
BLACK
BLACK
ENCODER/MOT
OR ENCODER/MOT
OR
RED
RED
RED
RED
OUTLET
OUTLET
PUMP 1
PUMP 2
PUMP 2
PUMP 1
INLET
AND
INLET
AND
COM
COM
48V-10A
GRN SHIELD
GRN SHIELD
SIG
SIG
PWR
PWR
POWER SUPPLY PUMP1 PUMP2

(16U280)
+24VDC
+24VDC
+24VDC
+24VDC
SEE DET
AILAOR B SEE DET
AILAOR B
COM
COM
COM
COM
--++
BLACK
BLACK
WHITE
WHITE
RED
RED
BROWN (UNUSED)
L (BROWN)
FAN PUMP 1
FAN PUMP 2
N (BLUE)
POWER MODULE
15 RELA DRAIN (UNUSED)

(24P658)
(24P658)
Y BLUE
2 A1
18 A2 BLACK
DOWN
DOWN
(26A189)
UP
UP
BROWN (UNUSED)
N03 N03 15 RELA DRAIN (UNUSED)
Y
1 A1 BLUE PUMP1 PUMP2
18 A2 BLACK MANIF
OLD MANIFOLD
2 POSITION CABLE (126232 OR 17N315)
SOLVENT
SOLVENT
MAC SERIES 46
MAC SERIES 46
(16P812 QTY 2)
(16P812 QTY 2)
SWITCH METER2
METER1
(16U725) (258718)
(258718)
N04 N04
+ - + - +- + -
BLACK
4 3 2 1
WHITE
GND
SCREW
CABLE GND
CABLE (126232 OR 17N315) SCREW
(16T658)
L N
RED
BLACK
BLACK
BLACK
BLACK
RED
RED
RED
LINE
FILTER TWISTED PAIR CABLE (16W159)
(16V446) TWISTEDPAIR CABLE (16W159)
L GND N
GRN
BLACK
WHITE
CABLE
(16H078) DETAILA, LOW PRESSURE PUMPS DETAIL B, HIGH PRESSURE PUMPS
(24M706, 24M714, 24T799) (24M707, 24M715, 24T800)
L N GND BREAKOUTMODULE BREAKOUTMODULE
TERMI NAL (24N527) (24N527)
BLOCK 2 3 2 3
(114095) 1 2 34 5 1234 12345 1234
L N GND WIRE HARNESS WIRE HARNESS

(24P684) DRAIN/FOIL (24P685) DRAIN/FOIL
POWER IN
DRAIN/FOIL
DRAIN/FOIL
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
DRAIN/FOIL
MOTOR
GROUND 1 2 34 5 6 7 8 9 1011 12 123456789 10 12 1 2 3 4 5 67 8 9 1011 12 123456789 10
SCREW
MOTOR
PUMP ENCODER AND MOTOR MOTOR
MOUNTING
PUMP ENCODER AND MOTOR
MOUNTING
SCREW
(16P037) SCREW (16P036)

332456D 31
5
4 SIG BLACK AIR FLOW SWITCH 1
3 1
2
10 2 COM WHITE
1 3 SIG RED AIR FLOW SWITCH 2
4 COM GREEN
1 5 SIG
6 COM SOLVENT FLOW SW. 1 (120278) LEFT BRKT
2 6
3 8 7 SIG
COM SOLVENT FLOW SW. 2 (120278) LEFT BRKT
4 8
5 9 SIG
10 COM SOLVENT FLOW SW. 3 (120278) RIGHT BRKT
AIR CONTROL MODULE (26A231)
GCAMODULE 11 SIG
12 COM SOLVENT FLOW SW. 4 (120278) RIGHT BRKT
TERMINAL
1 PLC DISCRETE 4-20mAINPUT 1 BLOCKS
EFCM 2
3
4
5
6
PLC DISCRETE 4-20mACOMMON 1
PLC DISCRETE 4-20mAINPUT 2
PLC DISCRETE 4-20mACOMMON 2
UNUSED
UNUSED
BLACK
WHITE
RED
1
2
3
+ SIG
- COM
+ SIG
AIR FLOW SWITCH 1
119159
AIR FLOW SWITCH 2
7
1
2
3
(24N913) 7
8
9
10
11
UNUSED
UNUSED
SIG ORANGE
COM BLUE
SIG WHITE/BLACK
GFB INPUT PRESSURE SWITCH 1
CABLE
GREEN
ORANGE
BLUE
4
5
6
- COM
+ SIG
- COM
119159
121323
4
15V819 WHITE/BLACK 7 + SIG GFB INPUT PRESSURE SWITCH 2
12 COM RED/BLACK 121323
5 RED/BLACK 8 - COM
6
7 5 CABLE GREEN/BLACK 9 + 24VDC RED GFB OUTPUT VALVE 1
8 1 1 1 ORANGE/BLACK 10 - COM BLACK 121324
9 2 2 ADVANCED 2 LIGHT
10 9 3 3 DISPLAY MODULE 3 TOWER BLUE/BLACK 11 + 24VDC RED GFB OUTPUT VALVE 2
11 4 4 (15X472) RED/WHITE 12 - COM BLACK 121324
12 1 2 3 4 5
4 (24E451)
5
5
(121003)
3
25 PIN D-SUB
CABLE (16T659) 4
1 1
BREAKOUT MODULE PUMP 3 (24N527) BREAKOUT MODULE PUMP 4 (24N527)
2 3 4 5 6 7 8 2 3 4 5 6 7 8
12345 1234 12345 12345 1234 12 34 5678 12 34 12345 1234 12345 12345 1234 12 34 5678 12 34
+48V
+48V
+48V
+48V
COM
COM
COM
COM
V/P FOR FLUID REG.
V/P FOR FLUID REG.

(16P289 OR 16P290)
(16P289 OR 16P290)
(16P289 OR 16P290)
(16P289 OR 16P290)
TRANSDUCER
TRANSDUCER
TRANSDUCER
TRANSDUCER
BLACK
BLACK
BLACK
BLACK
ENCODER/M OTOR ENCODER/M OTOR
RED
RED
RED
RED
OUTLET
OUTLET
PUMP 3
PUMP 3
PUMP 3
PUMP 4
PUMP 4
PUMP 4
AND AND
INLET
INLET
COM
COM
GRN SHIELD
GRN SHIELD
SIG
SIG
PWR
PWR
PUMP 3 PUMP 4
+24VDC
+24VDC
+24VDC
+24VDC
SEE DET
AILAOR B SEE DET
AILAOR B
COM
COM
COM
COM
BLACK
BLACK
WHITE
WHITE
RED
RED
FAN PUMP 3
FAN PUMP 4
(24P658)
(24P658)
DOWN
DOWN
UP
UP
PUMP 3 PUMP 4
MANIFOLD MANIFOLD
G3000 G3000
MAC SERIES 46
MAC SERIES 46
(16P812 QTY 2)
(16P812 QTY 2)
METER METER
PUMP 3 PUMP 4
(EITHER, 239716, (EITHER, 239716,
258718,16M510, 258718,16M510,
OR 16M519) OR 16M519)
GND
SCREW GND
SCREW


32 332456D
2 CABLE(15V206)
12 34 5
COLOR
CHANGE
MAN
IFOLD MODULE 1 MAN
IFOLD
1 (COLORS 6
FLUSH +24VDC COM DUMP
COM 2 1 THRU 8) 5 +24VDC
COLOR 1 +24VDC 3 4 COM
4 J8 J9 3 COLOR 1
COM +24VDC
COM 6 1 +24VDC
6
+24VDC 1 6 COM
+24VDC 3 J15 J16 4 COM
+24VDC 5 2 COM
+24VDC 1 6 COM
+24VDC 3 4 COM
+24VDC 5 2 COM
12 34 5
(15V206)
CABLE
2
12 34 5
COLOR CATALYST
CHANGE CHANGE
MAN
IFOLD MODULE 2 MAN
IFOLD MAN
IFOLD MODULE 5 MAN
IFOLD
1 (COLORS 6 1 (CATALYST 6
*FLUSH +24VDC COM DUMP* +24VDC COM DUMP
COM 2 9 THRU 16) 5 +24VDC FLUSH COM 2 1 THRU 4) 5 +24VDC
COLOR 9
COLOR 9 CATALYST 1 COM 4 J8 J9 3 +24VDC
CATALYST 1
COLOR 10 +24VDC 5 2 COM COLOR 10 CATALYST 2 +24VDC 5 2 COM CATALYST 2
6 6
COLOR 11 COM 2 5 +24VDC COLOR 11 CATALYST 3 COM 2 5 +24VDC CATALYST 3
3 J15 J16 4 COM 3 J15 4 COM
COLOR 12
+24VDC
COM 4 3 +24VDC COLOR 12 CATALYST 4
+24VDC
COM 4 J16 3 +24VDC CATALYST 4
COLOR 13 COM 6 1 +24VDC COLOR 13 UNUSED 6 1 UNUSED

COLOR 15 COM 4 J14 J10 3 +24VDC COLOR 15 UNUSED 4 J14 J10 3 UNUSED
12 34 5 12 34 5
(15V206)
(15V206)
CABLE
CABLE
2
12 34 5 12 34 5
COLOR COLOR
CHANGE CHANGE
MAN
IFOLD MODULE 3 MAN
IFOLD MAN
IFOLD MODULE 4 MAN
IFOLD
1 (COLORS 6 1 (COLORS 6
*FLUSH +24VDC COM DUMP* *FLUSH +24VDC COM DUMP*
COM 2 17 THRU 24) 5 +24VDC COM 2 25 THRU 32) 5 +24VDC
COLOR 17
COLOR 17 COLOR 25
COLOR 25
COLOR 18 +24VDC 5 2 COM COLOR 18 COLOR 26 +24VDC 5 2 COM COLOR 26
6 6
COLOR 19 COM 2 5 +24VDC COLOR 19 COLOR 27 COM 2 5 +24VDC COLOR 27
COLOR 20 +24VDC
COM
3
4 J15 J16 43 COM
+24VDC COLOR 20 COLOR 28 +24VDC
COM
3
4
J15 J16 4
3
COM
+24VDC COLOR 28

COLOR 23 COM 4 J14 J10 3 +24VDC COLOR 23 UNUSED 4 J14 J10 3 UNUSED
54 3 2 1 12 34 5
CABLE(15V206)
2
* May be unused in some configurations.
332456D 33
CABLE (16V429)
1
HAZARDOUS LOCATION
12 34 5
COLOR
CHANGE
RED +12VDC 1 (COLORS 6 COM BLACK
COLOR FLUSH BLACK COM 2 33 THRU 40) 5 +12VDC RED CATALYST FLUSH
COLOR 1 RED +12VDC 3 4 COM BLACK CATALYST 1
BLACK COM 4
5
J8 J9 3 +12VDC RED
COLOR 2 RED +12VDC 2 COM BLACK CATALYST 2
BLACK COM 6 1 +12VDC RED
7
RED +12VDC 1 6 COM BLACK
COLOR 3 BLACK COM 2 5 +12VDC RED CATALYST 3
COLOR 4 BLACK COM 4 J15 J16 3 +12VDC RED
CATALYST 4
COLOR 5 6 1 COLOR 9
BLACK COM +12VDC RED

COLOR 6 BLACK COM 2 5 +12VDC RED COLOR 10
COLOR 7 BLACK COM 4 J14 J10 3 +12VDC RED COLOR 11
COLOR 8 6 1 +12VDC RED
COLOR 12
BLACK COM
54 32 1
(16V426)
CABLE
1
12 34 5
COLOR
54 32 1 CHANGE
BOOTH CONTROL (COLORS
(24M731) RED +12VDC 1 6 COM BLACK
COLOR 13 2 41 THRU 48) 5 COLOR 22
WITH SHUNT RED +12VDC 3 4 COM BLACK
(17M540) COLOR 14 4 J8 J9 COLOR 23
BLACK COM 3 +12VDC RED
COLOR 15 RED +12VDC 5 2 COM BLACK COLOR 24
BLACK COM 6 1 +12VDC RED
7
17M540

3 J15 4
COLOR 17 RED
BLACK
+12VDC
COM 4 J16 3
COM BLACK
+12VDC RED
COLOR 26
12 34 5 5 2
COLOR 18 RED +12VDC COM BLACK COLOR 27
J1 BLACK COM 6 1 +12VDC RED

COLOR 20 BLACK COM 4 J14 J10 3 +12VDC RED COLOR 29
COLOR 21 6 1 COLOR 30
54 3 2 1
(16V426)
CABLE
1
5 4 3 2 1
BOOTH CONTROL
(24M731)

34 332456D
CATALYST
CHANGE
MANIFOLD MODUL E6 MANIFOLD
1 (CATALYST 6
+24VDC COM
+24VDC 3 4 COM
+24VDC 5 2 COM
COM +24VDC
6
UNUSED 1 6 UNUSED
UNUSED 2 5 UNUSED
UNUSED 4 3 UNUSED
UNUSED 5 2 UNUSED
UNUSED 6 1 UNUSED
UNUSED 1 6 UNUSED
UNUSED 2 5 UNUSED
UNUSED 3 4 UNUSED
UNUSED 5 2 UNUSED
UNUSED 6 1 UNUSED
12 34 5
(15V206)
CABLE
2
54 3 2 1
CATALYST
CHANGE
MANIFOLD MODUL E5 MANIFOLD
+24VDC 1 (CATALYST 6 COM
+24VDC 3 4 COM
+24VDC 5 2 COM
COM +24VDC
1
6 6
UNUSED UNUSED
UNUSED 2 5 UNUSED
3 J15 4 UNUSED
UNUSED
UNUSED 4 J16 3 UNUSED
UNUSED 5 2 UNUSED
UNUSED 6 1 UNUSED
UNUSED 1 6 UNUSED
UNUSED 2 5 UNUSED
UNUSED 3 4 UNUSED
UNUSED 5 2 UNUSED
UNUSED 6 1 UNUSED
12 34 5
(15V206)
CABLE
2
12 34 5
COLOR
CHANGE
MODUL E4
(COLORS
25 THRU 32)
ALTERNATE CONFIGURATION
FOR CATALYST CHANGE CONTROL
INNON-HA ZARDOUS LOCATION
Figure 37 Electrical Schematic, Sheet 4, Alternate
Configuration for Catalyst Change Control
332456D 35
Pump Expansion Kit Parts
36 332456D
Part No. 24R968, 70 cc Low Pressure Color Pump Kit

Part No. 24R969, 70 cc High Pressure Color Pump Kit
Part No. 24R970, 35 cc Low Pressure Catalyst Pump Kit
Part No. 24R971, 35 cc High Pressure Catalyst Pump Kit
Part No. 25M268, 35 cc Low Pressure Acid Catalyst Pump Kit
Part No. 26A048, 35 cc High Pressure Acid Catalyst Pump Kit
Ref Part Description Qty Ref Part Description Qty
1 ——— BRACKET, 1 18 ——— NUT, lock; 3/8–16 10
mounting, pump 19 ——— PLUG, tube, square 4
2 ——— PANEL, back 1
22 ——— CABLE, 2–wire 1
3 24T772 MANIFOLD, solenoid 1
25 24P684 WIRE HARNESS; 1
4 24T770 KIT, fan 1 for Kits 24R968 and
5 24N527 MODULE, control, 1 24R970
pump 24P685 WIRE HARNESS; 1
6 ——— SCREW, cap, socket 4 for Kits 24R969,
head; 10–32 x 1.5 in. 24R971, and 26A048
(38 mm) 27 ——— TIE WRAP (not 3
7 ——— SCREW, ground; M5 1 shown)
x 0.8 30 101550 SCREW, cap, socket 2
8 16V659 CABLE, D-SUB; 25 1 head; 1/4–20 x 1/2 in.
pin; 6 ft (1.83 m) (13 mm)
9 24T790 PUMP, 70 cc, A side, 1 31 105209 SCREW, cap, socket 4
low pressure; for Kit head; 10–32 x 7/8 in.
24R968; see manual (22 mm)
332339 32 114231 NUT, lock; 10–32 4
24T791 PUMP, 70 cc, A side, 1 33 ——— TUBE, nylon, red; for 6 ft
high pressure; for Kit control air to turn inlet (1.83
24R969; see manual and outlet valves off; m)
332339 5/32 in. (4 mm) OD
24T788 PUMP, 35 cc, B side, 1 34 ——— TUBE, nylon, green; 1.5 ft
low pressure; for Kit for control air to turn (457
24R970; see manual inlet up valve on; 5/32 mm)
332339 in. (4 mm) OD
24T789 PUMP, 35 cc, B side, 1 35 ——— TUBE, polyethylene; 6 ft
high pressure; for Kit 1/4 in. (6 mm) OD x 6 (1.83
24R971; see manual ft (1.83 m) m)
332339
36 115287 Y-FITTING; 1/4 in. (6 1
24T818 PUMP, 35 cc, B side, 1
mm) OD tubing
low pressure; for Kit ———
25M268; see manual 37 SCREW, cap, hex 1
332339 head; 3/8–16 x 2.75
24T819 PUMP, 35 cc, B side, 1 in. (70 mm)
high pressure; for Kit 41 16X048 LABEL, notice 2
26A048; see manual 42 ——— GROMMET 3
332339 ———
——— 46 WASHER; 3/8 3
10 BRACKET, 1
mounting, pump 47 ——— BRACKET, wall (use 1
11 ——— GROMMET, dual 2 with PD1K)
cable 48 ——— TUBE, nylon, black; 1.5 ft
12 16V858 COVER 1 for control air to turn (457
——— inlet down valve on; mm)
13 FRAME 1 5/32 in. (4 mm) OD
14 C19798 SCREW, cap, socket 6 49 ——— TUBE, nylon, blue; 1.5 ft
head; 1/4–20 x 3/8 in. for control air to turn (457
(10 mm) outlet up valve on; mm)
15 ——— SCREW, cap, hex 7 5/32 in. (4 mm) OD
head; 3/8–16 x 7/8 in. 50 ——— TUBE, nylon, yellow; 1.5 ft
(22 mm) for control air to turn (457
16 ——— SCREW, cap, hex 3 outlet down valve on; mm)
head; 3/8–16 x 3.75 5/32 in. (4 mm) OD
in. (95 mm)
332456D 37
Ref Part Description Qty Ref Part Description Qty

73 24T302 KIT, cup, TSL; 1 73d ——— PLUG, screw; 10–32; 4
includes items to replace unused
73a-73e item 73b at TSL cup;
73a ——— BRACKET 1 not shown
73e ——— GASKET; for item 4
73b 24U617 KIT, barbed fittings; 1
includes o-rings; 73d; not shown
package of 12
73c ——— TUBE, polyurethane; 1
1/4 in. (6 mm) OD; 10 Items marked — — — are not available separately.
ft (3.05 m); cut to fit
38 332456D
Technical Data
Technical Data
Pump Expansion Kit U.S. Metric
Maximum fluid working
pressure:
Kits 24R968, 24R970, 300 psi 2.1 MPa, 21 bar
and 25M268
Kits 24R969, 24R971, 1500 psi 10.5 MPa, 105 bar
and 26A048
Maximum working air 100 psi 0.7 MPa, 7.0 bar
pressure:
Wetted parts: See Pump manual 332339.
California Proposition 65
CALIFORNIA RESIDENTS
WARNING: Cancer and reproductive harm — www.P65warnings.ca.gov.
332456D 39
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its
name to be free from defects in material and workmanship on the date of sale to the original purchaser for
use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a
period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained
in accordance with Graco’s written recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction,
damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper
maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall
Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied
by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an
authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco
will repair or replace free of charge any defective parts. The equipment will be returned to the original
purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material
or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of
parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY
OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The
buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for
lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be
available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT,
MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but
not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if
any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim
for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from
Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods
sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents,
notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly
hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente
document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou
intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
To place an order, contact your Graco Distributor or call to identify the nearest distributor.
Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
For patent information, see www.graco.com/patents.
Original Instructions. This manual contains English. MM 332456
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
2020,, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
Copyright 2020
www.graco.com
Revision D, May 2020

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Installation-Parts

Pump Expansion Kits 332456D

Important Safety Instructions

See page 3 for model part numbers and

PROVEN QUALITY. LEADING TECHNOLOGY.

Figure 1 . Pump Expansion Kit Identification Label Warnings

SKIN INJECTION HAZARD

TOXIC FLUID OR FUMES

Important Isocyanate (ISO) Information

NOTE: The amount of film formation and rate of

Some materials may become self-igniting if applied

Important Acid Catalyst Information

Acid Catalyst Conditions

Moisture Sensitivity of Acid Catalysts NOTICE

Follow the Pressure Relief Procedure in

This equipment stays pressurized until pressure

Figure 2 Install the Frame and Pump

Figure 3 Install the Wall Bracket and Pump

TSL Cup Kit

NOTE: Prior to mounting the cup, use a

NOTE: If you are not lubricating the dosing

Figure 5 Air Connection for PD1K First Expansion Kit

Figure 6 Supplying Air to the Expansion Pump

Figure 7 Pump Fluid Connections

NOTE: See the Electrical Schematics, page 24.

Figure 8 Install Grommet in Electrical Control

Figure 9 Enhanced Fluid Control Module

NOTICE 5. The PD2K/PD1K fluid panel cover was previously

Figure 11 48 VDC Power Supply Connection

This equipment must be grounded to reduce the

1. Verify that the PD2K base unit is properly

Complete the Installation

Figure 15 System Screen 1

Figure 13 Install Expansion Kit Cover (Frame)

Figure 14 Install Expansion Kit Cover (Wall

Figure 18 PD2K Home Screen (Advanced

Figure 16 Third (Color) Pump Screen

Figure 17 Fourth (Catalyst) Pump Screen

Figure 21 Tubing Connections at Solenoid

Figure 19 Tubing Connections at Solenoid

Figure 20 Inlet Manifold Tubing Connections

Replace Pump Control Module

NOTE: See the Electrical Schematics, page 24.

Figure 24 Pump Control Module Connection

065161, 065159 2 CABLE 2 CABLE

CAN SOLENOID (121324)

ENCODER AND MOT OR ENCODERAND MOT OR

(24P684, 24P685) (24P684, 24P685) FLOW

FLOW RATE ANALOG IN

FLOW RATE ANALOG IN

FLOW RATE ANALOG IN

FLOW SENSOR FLOW SENSOR

ENCODER AND MOT OR ENCODERAND MOT OR BOOTH CO

WIRE HARNESS WIRE HARNESS

(24P684, 24P685) (24P684, 24P685)

PUMP OUTLET PUMP OUTLET

PUMP V/P FOR PUMP V/P FOR

FLOW SENSOR FLOW SENSOR

Figure 26 Electrical Schematic, Sheet 1