Graco 309909H User Manual

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Page 1

Repair - Parts

Self-contained, single color, electronic plural component paint proportioner. For professional use only.

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

See page 3 for model information, including maximum working pressure and approvals.

309909H

ENG

TI4909a

Page 2

Manual Conventions

Contents

Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . 2

ProMix Easy Models . . . . . . . . . . . . . . . . . . . . . . . . 3

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 7

Fluid Manifold to Gun . . . . . . . . . . . . . . . . . . . . . 7

Pump to Fluid Manifold . . . . . . . . . . . . . . . . . . . . 8

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Preventive Maintenance Schedule . . . . . . . . . . . 9

Mix Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Dispense Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Turbine Alternator . . . . . . . . . . . . . . . . . . . . . . . . 9

Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Pump Test/Meter Calibration . . . . . . . . . . . . . . . . 9

Wet Cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Icing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Replacing Air Filter Element . . . . . . . . . . . . . . . 15

User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Pneumatic Control . . . . . . . . . . . . . . . . . . . . . . 19

Dispense Valve/Mix Manifold Assembly . . . . . . 21

Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . 21

Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . 22

248349 Main Control Board Schematic . . . . . . . . 23

246899 Pump Solenoid Expansion Board

Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Part No. 234596 Series A, Pump-based,

Cart-mounted Air Spray Unit . . . . . . . . . . . . 24

Pump and Meter-based, Wall-mounted

Air Spray Units . . . . . . . . . . . . . . . . . . . . . . 27

Pump-based, Wall-mounted Air Spray Units . . . 30 Meter-based, Wall-mounted High Pressure

Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Pump-based, Wall-mounted High Pressure

Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Pump and Meter-based, Wall-mounted High

Pressure Units . . . . . . . . . . . . . . . . . . . . . . 40

Tube Connections, Low Pressure Pumps . . . . . 44

Tube Connections, High Pressure Pumps . . . . . 45

Tube Connections, Meters . . . . . . . . . . . . . . . . . 46

Pneumatic Schematic . . . . . . . . . . . . . . . . . . . . 47

248270 Intrinsically Safe Pneumatic Control . . . 48 248316 Non-intrinsically Safe

Pneumatic Control . . . . . . . . . . . . . . . . . . . 50

User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . 52

287230 Pump Air Control . . . . . . . . . . . . . . . . . 53

287231 Meter Air Control . . . . . . . . . . . . . . . . . 53

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 56

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 56

Manual Conventions

WARNING

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in property damage or

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Warnings included in instructions generally have a symbol indicating the hazard. Follow the instructions and read the hazard section on warning pages 5 to 6 for additional information.

2 309909H

destruction of equipment.

Note

A note indicates additional helpful information.

CAUTION

Page 3

ProMix Easy Models

WARNING

Do not install equipment approved only for non-hazardous location in a hazardous area. Substitution of components may impair intrinsic safety and cause personal injury. Read page 5.

Approved for Hazardous Location

Class I, Div 1, Group D (North America); Class I, Zones 1 and 2 (Europe)

ProMix Easy Models

ProMix

Easy

Part No. Series Description

234596 A

234597 A 234598 A 234599 A 234601 A 234602 A

234603 A 234604 A 234605 A 234606 A 234608 A 234609 A 234611 A 234612 A 234613 A 234618 A 234619 A

Cart mount, UltraMix Wall mount, UltraMix cst* Pump/G3000 Meter Wall mount, UltraMix sst** Pump/G3000 Meter Wall mount, UltraMix cst* Pumps Wall mount, UltraMix sst** Pumps

Wall mount, HydraMix Wall mount, HydraMix 500 sst** Pump/G3000 Meter Wall mount, HydraMix 600 cst* Pump/G3000 Meter Wall mount, HydraMix 600 sst** Pump/G3000 Meter Wall mount, HydraMix 500 cst* Pumps Wall mount, HydraMix 500 sst** Pumps Wall mount, HydraMix 600 cst* Pumps Wall mount, HydraMix 600 sst** Pumps Wall mount, HydraMix 700 cst* Pumps Wall mount, HydraMix 700 sst** Pumps Wall mount, G3000 Meter, cst* mix manifold Wall mount, G3000 Meter, sst** mix manifold

™

cst* Pumps, hose and gun

™

500 cst* Pump/G3000 Meter

Approved for Non-hazardous Location

234600 A 234825 A 234607 A 234826 A 234610 A 234827 A

Wall mount, UltraMix cst* Pumps Wall mount, UltraMix sst** Pumps Wall mount, HydraMix 500 cst* Pumps Wall mount, HydraMix 500 sst** Pumps Wall mount, HydraMix 600 cst* Pumps Wall mount, HydraMix 600 sst** Pumps

Maximum Working

Pressure

psi (MPa, bar) Approvals

250 (1.7, 17)

250 (1.7, 17) 250 (1.7, 17) 250 (1.7, 17) 250 (1.7, 17)

Conforms to

FM std 3600 & 3610

for use in

Class I Div 1

Group D T3

Hazardous Locations

2400 (16, 166)

2400 (16, 166) 3400 (23, 234) 3400 (23, 234)

ISSeP 04 ATEX 020X

EEx ia p IIA T3

2400 (16, 166) 2400 (16, 166) 3400 (23, 234) 3400 (23, 234) 4700 (32, 324) 4700 (32, 324) 4000 (28, 280)

CAN/CSA

22.2 No. 157-92 & No. 1010.1-92

4000 (28, 280)

250 (1.7, 17)

250 (1.7, 17) 2400 (16, 166) 2400 (16, 166) 3400 (23, 234) 3400 (23, 234)

9902471 Conforms to UL61010A-1

Certified to

CAN/CSA

22.2 No. 1010.1-92

0359

* cst=carbon steel. ** sst=stainless steel.

309909H 3

Page 4

Related Manuals

Component Manuals in English This manual available in the following languages:

Manual Description

309908 ProMix Easy Operation 309909 ProMix Easy Repair-Parts 310654 Fluid Mix Manifold 310655 Dispense Valve 310662 UltraMix and HydraMix Displacement

Pumps 310671 UltraMix Pumps 310672 HydraMix Pumps 310673 Circulation Kits 310674 Stand and Caster Kits 310675 AC Power Supply 310676 Remote Manifold Kit 310677 Heater Installation Kit 310678 TSL Pump Kits 309192 ISO Supply Kit 309623 Data Download Kits

Manual Language

309909 English 310680 French 310682 Spanish 310684 German 310686 Italian 310688 Chinese 310690 Japanese 310769 Dutch 310771 Finnish 310773 Swedish

308778 G3000 Flowmeter 308034 Turbine Alternator Repair Kit

4 309909H

Page 5

Warnings

The following general warnings are related to the safe setup, use, grounding, maintenance, and repair of this equipment. Additional more specific warnings may be found throughout the text 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. 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 lights on or off when flammable fumes are present.

• Ground equipment and conductive objects in work area. See Setup instructions in ProMix Easy Operation manual 309908.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

• Keep a 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 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.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

MOVING PARTS HAZARD

Moving parts can pinch 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 in this manual. Disconnect power or air supply.

309909H 5

Page 6

Warnings

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• 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.

• Check equipment daily. Repair or replace worn or damaged parts immediately.

• Do not alter or modify equipment.

• For professional use only.

• Use equipment only for its intended purpose. Call your Graco distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kind or overbend hoses or use hoses to pull equipment.

• Comply with all applicable safety regulations.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDS’s 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.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

•Gloves

• Hearing protection

6 309909H

Page 7

Pressure Relief Procedure

WARNING

Relieve pressure from fluid manifold to gun whenever you stop spraying and before servicing gun or removing spray tip.

In addition, relieve pressure from pump to fluid manifold at end of day and before cleaning, checking, or servicing pump, manifold, or fluid line accessories or transporting equipment.

Read warnings, page 5.

Fluid Manifold to Gun

1. Engage trigger lock.

3. Disengage trigger lock.

4. Hold a metal part of the gun firmly to a grounded

metal pail. Trigger gun to relieve pressure.

5. Engage trigger lock.

2. Press .

309909H 7

Page 8

Pressure Relief Procedure

Pump to Fluid Manifold

1. Close shutoff valves G

2. Place waste container under sampling valves H

and H

3. Turn function knob to pressure relief/park .

and GB.

TI4699a

5. Open sampling valve A slowly to bleed off pressure.

Indicator A will stay on for 5 sec after Pump A reaches Park position, then go off.

Pump air supply pressure must be sufficient to cause pumps to stroke to bottom-most position when function knob to is set to pressure relief/park

6. Indicator B comes on and Pump B pressurizes.

7. Open sampling valve B slowly to bleed off pressure.

Indicator B will stay on for 5 sec after Pump B reaches Park position, then go off.

4. Press . Indicator A comes on, and Pump A pres-

surizes.

If both pumps are not parked after 1 min, Alarm 26 will sound.

8. Close sampling valves A and B before restarting

system.

8 309909H

Page 9

Maintenance

Preventive Maintenance Schedule

Establish a preventive maintenance schedule, based on the pump’s repair history.

Mix Manifold

See mix manifold manual 310654.

Dispense Valve

See dispense valve manual 310655.

Pump

See applicable pump manual 310671, 310672, or

310662.

Turbine Alternator

Replace bearings every 2000 hours. See page 19.

Air Filters

Check daily. Drain and clean as necessary. See page

15.

Pump Test/Meter Calibration

See ProMix Easy Operation manual. If pumps/meters fail test, see Troubleshooting, page 10.

Wet Cup

Check pump and dispense valve wet-cups daily. Keep filled with Graco Throat Seal Liquid (TSL), Part No.

206995.

Storage

Before storing the pump, always flush it, see ProMix Easy Operation manual. Relieve the pressure, page 7.

Icing

If you experience icing at the pump air manifold:

• Reduce pump input air pressure below 80 psi (0.56 MPa, 5.6 bar), if required spray pressure allows.

• Reduce moisture in compressed air supply, or use heated air.

If icing persists, see table below.

Problem Solution

Pump slows on both up and down stroke.

Pump slows on down stroke.

Pump slows on up stroke. Turn U port bleed screw 90° (1/4 turn) counter-

309909H 9

Turn D port bleed screw 60° (1/6 turn) counterclockwise, to bleed 1 cfm air to melt ice.

Turn D port bleed screw 60° (1/6 turn) counterclockwise, to bleed 1 cfm air to melt ice. If icing continues, turn screw to 90° (1/4 turn) to increase air flow to 2 cfm. If necessary, increase air flow to 3 cfm by turning screw to 270° (3/4 turn). Do not exceed 3 cfm (3/4 turn maximum).

clockwise, to bleed 1 cfm air to melt ice. If icing continues, turn screw to 120° (1/3 turn) to increase air flow to 2 cfm. If necessary, increase air flow to 3 cfm by turning screw to 180° (1/2 turn). Do not exceed 3 cfm (1/2 turn maximum).

TI5294a

Page 10

Troubleshooting

WARNING

If an alarm code displays, see page 13.

Read warnings, page 5-6.

Problem Cause Solution

Display not lit. No electric power.

Pumps do not run. Air pressure to pumps too low. Increase pressure to 50 psi (0.35 MPa,

Pump test volume is not correct. Air pressure to pumps too low Increase pressure to 50 psi (0.35 MPa,

Air valve not turned on. Turn on main air valve to system. Air supply pressure too low. Increase pressure to 60 psi (0.42 MPa,

4.2 bar) or greater.

Air supply filters plugged. Clean filter bowls; replace filter elements.

Page 15. Turbine air regulator set too low. Adjust to proper setting. Turbine alternator failure. Repair or replace turbine. Page 19. Power supply not connected to main

board. Main board not connected to display

board.

Display board failure. Replace display board. Page 18. Power not connected to unit (non-IS units

only).

Solenoid valve stuck. Actuate solenoid manually, if it does not

Dispense valve(s) not opening. Service or replace valve(s). See 310655.

Sensors not functioning properly. Check position of sensors. See ProMix

Pump cavitating excessively. Check for air in lines caused by loose fit-

Check power connections to main board.

See Electrical Schematic, page 22.

Check electrical connections between

display and main board. See Electrical

Schematic, page 22, and 248349 Main

Control Board Schematic, page 23.

Ensure that power cord is plugged in.

Check that cord is connected properly;

see ProMix Easy Operation manual.

3.5 bar).

operate, replace solenoid. Page 20.

3.5 bar).

Easy Operation manual, and applicable

pump manual.

Check board calibration and recalibrate if

necessary. See ProMix Easy Operation

manual.

Replace sensors. See pump manual

310671 or 310672.

ting or use of agitator.

Material too viscous. Use heater.

10 309909H

Page 11

Troubleshooting

Problem Cause Solution

Paint does not cure consistently. Ratio not set correctly. Check that correct ratio is set and set by

volume. See ProMix Easy Operation manual.

Material not mixing correctly. Test pump. Page 9.

Make sure mixer is clean; flush as needed. See ProMix Easy Operation manual.

Pump not operating correctly. Observe whether pumps are loading and

checking correctly, if not, clean and repair pump. See displacement pump manual

310662.

Poor spray pattern. Fluid pressure too low. Increase pump pressure.

Spray tip dirty or worn. Relieve pressure. Clean or replace tip.

Follow gun manual instructions. Fluid A or B filters plugged. Clean filters. Mixer or hoses partially plugged or too

restrictive.

System runs erratically. Air filter(s) clogged. Replace elements. Clean. Replace element(s). See page 15.

Air supply hoses undersized. Replace hoses with appropriate size. Air compressor undersized. Use larger air compressor. Air supply pressure tank undersized. Use larger pressure tank.

Air supply relief valve opens. Turbine air regulator set too high. Lower setting to 23-25 psi (172-241 kPa,

Turbine alternator makes high-pitched whining noise.

Display shows 88888 or unit reboots unexpectedly.

ProMix Easy does not start when start button is pressed.

Dispense valves leaking. Loose or worn packings. Tighten packing nut. If leak continues,

Turbine bearings worn. (Setting turbine air regulator too high, wears bearings.)

Turbine is not supplying enough power to board.

Faulty start switch or wire harness. Check start switch and wiring harness

Faulty stop switch or wiring harness. Check stop switch and wiring harness

Bad I/O port on display board. Replace board. Page 18. Bad I/O port on main board. Replace board. Page 17.

Inspect parts for cured material. Clean or

replace, or use larger hoses and mixer.

1.7-2.4 bar).

Replace bearings. Page 19.

Increase turbine regulator setting to

23-25 psi (172-241 kPa, 1.7-2.4 bar).

Check turbine and electrical control

exhaust air for restrictions.

Replace turbine bearings. Page 19.

continuity; switch is normally open circuit.

See Electrical Schematic, page 22.

continuity; stop switch is normally closed

circuit. See Electrical Schematic, page

22.

replace packings. See 310655.

309909H 11

Page 12

Troubleshooting

Problem Cause Solution

Flow rate too low. Inadequate air supply. Use larger CFM compressor.

Air pressure to pumps too low. Increase pressure. Fluid A or B filters plugged. Clean filters. Spray tip too small. Relieve pressure. Install larger tip. Follow

gun manual instructions.

Mixer or hoses partially plugged or too restrictive.

Insufficient dispense valve travel. Increase travel. See 310655. Shutoff valves are not fully open. Ensure that shutoff valves are fully open

Inspect parts for cured material. Clean or replace, or use larger hoses and mixer.

and sampling valves are closed.

Pump stops after 12 cycles.

Pump cycle rate slows and eventually stops.

Knob is set to Run pump A

or B

Turn knob to spray rial.

independently.

Icing at pump air manifold. See Icing, page 9.

if spraying mate-

12 309909H

Page 13

Alarms

* Indicates error where audible alarm sounds once briefly. ** Indicates error where audible alarm sound pulses.

Code Alarm Active Problem Cause

Startup Errors

01 Sensor Error A* Always No signal from pump A

sensor

02 Sensor Error B* Always No signal from pump B

sensor

03 Communication Error* Always Loss of communication

between main and display boards

Operating Errors

04 not used 05 not used 06 Pump Error A** Spray 07 Pump Error B**

08 Sensor Code Error Always Sensor values reverted to

09 Metering Error A** Spray A dose too great Dispense valve A leak

Te st

Batch

Pump does not stall after top change over

Pump cavitating excessively

default

Loose cable, failed sensor or cable, failed magnet assembly

Loose cable, failed board

Intake valve leak

Air in lines caused by loose fitting or use of agitator

Empty fluid supply Sensor value data corrupt; board needs replacement

and /or recalibration

Empty B fluid supply

Alarms

Clogged flow meter

10 Metering Error B** Spray B dose too great Dispense valve B leak

Empty A fluid supply

Clogged flow meter 11 Sensor Reading Low A* Spray 12 Sensor Reading Low B*

13 Sensor Reading High A* Spray 14 Sensor Reading High B*

21 Pot Life Error Spray

Te st

Batch

Te st

Batch

first, then

Always

Pump stroke travels beyond sensor range at top change over

Pump stroke travels beyond sensor range at bottom change over

Pot life timer timed out Not enough material sprayed after last reset

Sensor or bracket loose

Sensor magnet dirty

Sensor or bracket loose

Sensor magnet dirty

309909H 13

Page 14

Alarms

Code Alarm Active Problem Cause

Operating Errors

(continued)

22 High Ratio (units with

meter[s] only)

23 Low Ratio (units with

meter[s] only)

24 Dose Timeout A (units

with meter[s] only)

25 Dose Timeout B (units

with meter[s] only)

26 Park Timeout

(pump-based units only)

Testing Error

15 Piston packing/ball A* Test Pump does not com16 Piston packing/ball B* 17 Inlet Ball A* Test Pump does not com18 Inlet Ball B* 19 Dispense Valve A* Test Pump does not com20 Dispense Valve B*

27 Pump Calibration

Timeout A

28 Pump Calibration

Timeout B

Spray Mix ratio higher than

Tar g et + Tole r anc e

Spray Mix ratio lower than

Target - Tolerance

Spray Air flow switch indicates

more than 40 sec of air flow without dose completing

Park Pumps not at bottom of

stroke

pletely stall in up stroke

pletely stall in downstroke

pletely stall in both up and down strokes

Run A Pump doesn’t run

through calibration.

Run B

Flow rate too high

Slow actuation of dispense valve A or B

Clogged flow meter Air flow switch stuck open.

Atomizing air leak downstream of air flow switch.

Clogged flow meter.

Gun triggered without fluid (dusting parts) Sampling valves closed, or gun not triggered.

Piston packing or ball check failure

Intake valve ball check failure

Throat packing or dispense valve failure

Sampling valves closed.

14 309909H

Page 15

Repair

Flush before repairing equipment, if possible. See ProMix Easy Operation manual.

WARNING

Read warnings, page 5.

Follow Pressure Relief Procedure, page 7, if service time may exceed pot life time, before servicing fluid components, and before transporting equipment to a service area.

Replacing Air Filter Element

There are 2 air filters on the unit: the 5 micron air manifold filter (7) and 40 micron pump air filter (9). Check filters daily and replace element as needed. Order 15D909 5 micron filter and 15D890 40 micron filter.

WARNING

Removing the bowl of a pressurized air filter could cause serious injury. Do not service air filter until air line is depressurized.

1. Close main air shutoff valve on air supply line and on unit.

2. Remove left side plate (21).

3. Unlock filter bowl guard and remove.

4. Unscrew filter bowl.

5. Remove and replace element.

6. Screw filter bowl on securely.

7. Reassemble.

309909H 15

Page 16

Repair

User Interface

Removal

1. Close main air shutoff valve on air supply line and on unit.

2. Remove side panels (21).

3. Remove fasteners (45). Gently pull user interface (11) away from pneumatic control (10).

315

Software Upgrades

CAUTION

To avoid damaging circuit board, wear a grounding strap.

1. Remove User Interface cover. See above.

2. Use a chip remover (D) to remove software chip (C). F

IG. 2.

C D

IG. 2

TI4901a

IG. 1

4. To completely remove user interface (11), disconnect ground wire (315), and wires (416 and 406) from main control board (301). See Electrical Schematic, page 22.

3. Install new chip (beveled corner down).

4. Reassemble.

5. Recalibrate main circuit board. See ProMix Easy Operation Manual.

16 309909H

Page 17

Replacing Main Circuit Board

CAUTION

To avoid damaging circuit board, wear a grounding strap.

1. Remove User Interface cover. See page 16.

2. Disconnect all wire connectors from board (301). F

IG. 3.

3. Remove four screws (302) and replace board (301).

4. Reassemble. Refer to Electrical Schematic, page

22.

5. Recalibrate system. See ProMix Easy Operation Manual.

NOTE: If the main control board is replaced on units that use a flow meter, the flow meter calibration data must be set using a PC and a Data Download Kit (Graco P/N 248403 for hazardous locations or Graco P/N 248404 for non-hazardous locations).

Repair

320

301

TI4561a

IG. 3

309909H 17

Page 18

Repair

Replacing Display Circuit Board

CAUTION

To avoid damaging circuit board, wear a grounding strap.

1. Remove User Interface cover. See page 16.

2. Disconnect wires from display board (410). F

404

413 418

407

3. Remove two screws (411).

4. Loosen setscrew (419) from knob (405) and remove knob assembly. Remove jam nut (N).

5. Remove and replace display board (410).

6. Reassemble. Refer to Electrical Schematic, page

22.

IG. 4.

410

411

406 405

419

FIG. 4

403

401

TI4755a TI4756a

406

416

407

403

416

18 309909H

Page 19

Repair

Pneumatic Control

Alternator Repair

Turbine Alternator Repair Kit 223688 is available to replace turbine bearings.

1. Remove User Interface cover. See page 16.

306r

301

310

304

• Lightly lubricate turbine o-ring before installing turbine in housing.

• Connect alternator red wire to + side and black wire to – side of main circuit board.

• Connect turbine to 3-pin connector on main circuit board.

305

310

IG. 6

304

304d

313

TI4561a

IG. 5

2. Disconnect power supply wires (P). F

IG. 5.

3. Disconnect two air lines (310) from alternator (304). F

IG. 6.

4. Remove top nut (305) and loosen bottom nut. Slide alternator up and off bottom nut.

5. Remove four screws (304d) to separate alternator housings. F

IG. 7.

6. Disconnect turbine (304e) from board (A). Follow instructions in turbine kit manual 308034 to remove and repair turbine.

7. Replace gasket (304a) if damaged. Place between housings before securing with screws (304d).

304d

Torque to 20 in-lbs (2 N•m)

IG. 7

304a

304e

8. Reassemble. Refer to Electrical Schematic, page

22.

309909H 19

Page 20

Repair

Replacing Solenoids

Follow this procedure to replace a single solenoid.

1. Remove User Interface cover. See page 16.

2. Disconnect two solenoid wires (V) from main board. F

IG. 8.

3. Disconnect dispense valve pilot lines (A1, A2, B1, B2). F

IG. 8.

4. Remove two screws (S).

5. Remove and replace solenoid (306b).

From left to right, solenoid functions are as follows:

• Component A

• Component B

6. Reassemble. Solenoid wires are polarized (red +, black –). Refer to Electrical Schematic, page 22.

Replacing Alternator Regulator

1. Remove User Interface cover. See page 16.

3. Disconnect supply and exhaust air lines (310). F

IG.

5, page 19.

4. Disconnect solenoid wires 12 position Phoenix connector (306r) from main board.

5. Remove solenoid module (306) with regulator (306e). F

IG. 8.

6. Unscrew and replace regulator (306e).

7. Reassemble. Refer to Electrical Schematic, page

22.

Make sure gaskets (306j, 306k) are in place when reinstalling solenoid module.

8. Set regulator to 24 psi (160 kPa, 1.6 bar).

Replacing Alarm

1. Remove User Interface cover. See page 16.

2. Disconnect alarm wires from main board.

3. Unscrew alarm (313) and replace. F

IG. 5, page 19.

2. Remove two screws (309) from the back of the control box.

Dispense Valve Pilot Lines

A1 (off), clear tube

Set regulator pressure to 24 psi (160 kPa, 16 bar).

Safety relief valve (306t) is required on all IS units.

A2 (on), black tube B1 (off), green tube B2 (on), red tube

306k

306j

TI4699a

IG. 8

4. Reassemble. Refer to Electrical Schematic, page

22.

310

306e

306t

306b

TI4558a

20 309909H

Page 21

Repair

Dispense Valve/Mix Manifold Assembly

WARNING

Read warnings, page 5.

See the Parts drawing for your model.

1. Follow Pressure Relief Procedure, page 7.

2. Label all air and fluid lines, and disconnect from fittings on manifold assembly.

3. Remove fasteners.

4. Remove mix manifold (2).

5. To repair mix manifold, see manual 310654. To repair dispense valves, see manual 310655.

6. Reassemble.

Pump Assembly

WARNING

Read warnings, page 5.

See the Parts drawing for your model.

1. Follow Pressure Relief Procedure, page 7.

2. Remove side plates (21).

3. Remove wire harnesses from sensor and solenoids.

Refer to Electrical Schematic, page 22.

4. Disconnect fluid inlet and outlet lines from pump lower. Disconnect air supply from pump.

5. Label all tubing and disconnect from fittings on pump assembly.

6. Remove mounting hardware and slide pump out of frame.

7. Repair as instructed in pump manuals 310671, 310672, or 310662.

8. Reassemble.

309909H 21

Page 22

Electrical Schematic

AIR INPUT

COM PORT PIN LOCATIONS

FRONT SIDE VIEW

(OPPOSITE SIDE OF SOLDER CUPS)

GND

FRONT PANEL

COM PORT

RS232

CONNECTOR

START

15A851

START/STOP

SWITCH ASSY

STOP

GND

LIGHT

KEY SWITCH ASSY

15A852

GND

KEY SWITCH

MOM.

POWER SUPPLY ASSEMBLY 245223

POWER

SUPPLY

BARRIER

WHITE

245706

BROWN

GREEN

BLACK

53412

12345

RED

BLACK

GREEN

152

RED

MOTOR B DOWN

MOTOR A DOWN

MOTOR B UP

MOTOR A UP

125

246899

RED

BLACK

RED

15D794

BLACK

ALARM COM

ALARM +

WHITE

COMM PORT ASSY

15A850

ALARM ASSY 15A849

6378412

BOARD

239790

SOLENOID

BOARD

DISPLAY BOARD

METER A

243678

OPT. SOLENOID, RECIRC. 552180

FLUID

VALVES

431

"B"

SENSOR

243678

"A"

SENSOR

METER B

526

234628

AIR FLOW SWITCH

119159

GREEN

WHITE_W/GRN

ORANGE

WHITE_W/ORANGE

458117

CABLE # 15D607 (X2)

BLUE

WHITE_W/BLUE

GREEN

WHITE_W/ORANGE

WHITE_W/GRN

10714

ORANGE

RED

BLACK

WHITE

SIGNAL A

COM

12VDC

SIGNAL B

123456788

123

ORANGE

567

BLUE

WHITE_W/BLUE

BLACK

WHITE

CABLE # 15A854 (MAIN TO DISPLAY)

RED

SHIELD

526

1234567

12345

CABLE # 114213

- SOLENOID VALVE A +

- SOLENOID VALVE B

SHIELD

15VDC

RED

BLACK

COM

12VDC

RED

BLACK

RED

ORANGE

RED

BLACK

12VDC

72811412

JUMPER (15V)

11712

Under operating conditions, voltage

at J6 will be approximately 12 Vdc.

123

1234568

248349

MAIN CONTROL

BOARD

22 309909H

Page 23

248349 Main Control Board Schematic

Pin 1 Pin 1

D12 D6 D13 D5 D10

Pin 1

Pin 1 Pin 1 Pin 1

TI11316a

248349 Main Control Board LEDs

LED Description

D2 In normal operation D2 flashes on and off in 1

second intervals. If D2 is off (not flashing), software is not booting; check for power to the board or a short circuit.

D5 On: Dispense valve B is on (open).

Off: Dispense valve B is off (closed).

D6 Active only on units with recirculation option.

On: Recirculation solenoid is on. Off: Recirculation solenoid is off.

D10 On: Dispense valve A is on (open).

Off: Dispense valve A is off (closed).

D12 On: Remote alarm output on.

Off: Remote alarm output off.

D13 D13 is always off. Output powers the 246899

Expansion Board, turning the board on and off.

246899 Pump Solenoid Expansion Board Schematic

246899 Pump Solenoid Expansion Board LEDs

LED Description

D1 D2 D3 D4

Pin 1

TI11229a

D1 On: Pump B is on the downstroke. D2 On: Pump B is on the upstroke. D3 On: Pump A is on the downstroke. D4 On: Pump A is on the upstroke.

309909H 23

Page 24

Parts

Part No. 234596 Series A, Pump-based, Cart-mounted Air Spray Unit

21, 28

103 104

102

100

101 (Ref)

24 309909H

101

101 (Ref)

TI4769a

Page 25

Part No. 234596 Series A, Pump-based, Cart-mounted Air Spray Unit, continued

Parts

40 47

32 33

16 17

65 (Ref)

32 33

24 (Ref)

Pump Solenoid

Cable Connections

2 1

Downstroke solenoid is on the outside.

Upstroke solenoid is on the inside.

TI11228a

78 (Ref)

TI4770a

309909H 25

Page 26

Parts

Part No. 234596 Series A, Pump-based, Cart-mounted Air Spray Unit, continued

Ref. No. Part No. Description Qty.

1 15D771 FRAME, wall mount 2 234593 MIX MANIFOLD; see 310654 3 287230 CONTROL, air; see page 53 4 109544 ELBOW, pipe; 3/8 npt (mbe) 5 116756 ELBOW, street, 45°; 3/8 npt (m x f) 6 155665 UNION, adapter; 3/8 npsm(f) x

3/8 npt(m) 7 117629 FILTER, air; 5 micron 8 114316 ELBOW; 3/8 npt(m) x

3/8 in. (10 mm) OD tube fitting 9 15D795 FILTER, air; 40 micron 10 248270 PNEUMATIC CONTROL,

intrinsically safe; see page 54 11 234620 USER INTERFACE; see page 52 12 248570 PUMP, UltraMix; see 310671 14 15D873 BRACKET, support, fluid manifold 15 C38211 ELBOW; 1/2 npt(m) x

3/8 in. (10 mm) OD tube 16 C19038 WASHER, lock; 1/4 17 112925 SCREW, cap, button hd;

1/4-20 x 3/8 in. (10 mm) 20 103196 SCREW, machine, phillips;

8-32 x 7/16 in. (11 mm) 21 15D767 PLATE, side 22 119291 SCREW, self-tapping 23 113802 SCREW, hex hd, flanged;

3/8-16 x 5/8 in. (16 mm) 24 220598 HOSE, air; nitrile; 1/2 in. (13 mm)

ID; 1/2 npt (mbe); 18 in. (457 mm);

see also pages 44 and 47 25 C19024 ELBOW, swivel; 1/2 npt(m) x

1/2 npsm(f) 26 15D607 CABLE, sensor; see Electrical

Schematic, page 22 27 15D794 HARNESS, connector; see Electri-

cal Schematic, page 22 28▲ 290331 LABEL, warning 30 15D775 CART 31 101765 GROMMET 32 100451 COUPLING; 1/8 npt (fbe) 33 115671 CONNECTOR; 1/8 npt(m) x

1/4 in. (6 mm) OD tube 37 244524 GROUND WIRE 38 113279 PLUG, tube fitting;

5/32 in. (4 mm) OD tube 39 113505 NUT, keps, hex hd; 10-24 40 551787 SCREW, cap, button hd;

10-32 x 3/8 in. (10 mm) 41 111218 CAP 44 114104 SCREW, machine; 1/4-20 x

1-1/2 in. (38 mm) 45 115942 NUT, hex, flange hd; 1/4-20

Ref. No. Part No. Description Qty.

46 113319 FITTING, air; 1/4 npt(m) x

1 1

47 115841 ELBOW; 1/4 npt(m) x

1 1

48 114158 FITTING, Y-adapter;

1 1

49 115743 ADAPTER; 3/8 in (10 mm) tube x

51 116780 SCREW, hex hd flanged;

56 598095 TUBE; nylon; 5/32 in. (4 mm) OD;

1 1

57 054753 TUBE; nylon; 5/32 in. (4 mm) OD;

58 054754 TUBE; nylon; 5/32 in. (4 mm) OD;

2 1

59 054757 TUBE; nylon; 5/32 in. (4 mm) OD;

60 590385 TUBE; polyethylene; 3/8 in. (10 mm)

5 5

63 162453 NIPPLE; 1/4 npsm x 1/4 npt 65 104641 FITTING, bulkhead

67 100840 ELBOW, street; 1/4 npt (m x f) 70 054123 TUBE; nylon; 1/4 in. (6 mm) OD;

71 112958 NUT, hex, flange hd; 3/8-16

72 116935 SCREW, cap; 3/8-16 x 3 in. (76 mm) 73 198720 WHEEL

74 116513 REGULATOR, air 75 108190 GAUGE, pressure, air 76 116514 NUT, regulator

78 206966 HOSE, fluid; 1/4 npsm (fbe); PTFE;

79 195889 BUSHING, strain relief

81 113436 RING, retaining 82 160701 ELBOW, street; 1/8 npt (m x f)

84 15E106 BUSHING, wheel

85 15D986 PLATE, rear

98 154628 WASHER

100 239561 GUN, spray, HVLP; see 308741

101 233498 HOSE ASSEMBLY; 3/8 npsm (f) 1 2

102 162485 NIPPLE; 3/8 npt x 3/8 npsm

103 155495 ELBOW, swivel; 3/8 npt(m) x

2 4

104 214706 REGULATOR, pressure, fluid; 2

▲ Replacement Danger and Warning labels, tags, and cards

are available at no cost.

3/8 in. (10 mm) OD tube

1/4 in. (6 mm) OD tube

1/4 in. (6 mm) tube

3/8-16 x 1-3/4 in. (44 mm)

clear; see pages 44 and 47

black; see pages 44 and 47

red; see pages 44 and 47

green; see pages 44 and 47

OD; see pages 44 and 47

see pages 44 and 47

1/4 in. (6 mm) ID; 18 in. (457 mm); see also pages 44 and 47

nylon fluid hose; 1/4 npsm(f) air hose; 25 ft (7.6 m)

1/4 npsm(f)

see 307212

2 ft

9 ft

3 1 1

4.2 ft 4 2 2 1 1 1 2

2 2 1 2 1 2 1 1

1 1

26 309909H

Page 27

Pump and Meter-based, Wall-mounted Air Spray Units

Part No. 234597 Series A, UltraMix carbon steel pump and G3000 Meter Part No. 234598 Series A, UltraMix stainless steel pump and G3000 Meter

Parts

21, 28

TI4901b

309909H 27

Page 28

Parts

Pump and Meter-based, Wall-mounted Air Spray Units, continued

65 (Ref)

16 17

17169

32 33

5 4

32 33

89 86

45 16

78 (Ref)

14 44

24 (Ref)

Pump Solenoid

Cable Connections

Downstroke solenoid is on the outside.

Upstroke solenoid is on the inside.

TI4902a

TI11262a

28 309909H

Page 29

Pump and Meter-based, Wall-mounted Air Spray Units, continued

See page 27 for model numbers and descriptions.

Ref. No. Part No. Description Qty.

1 15D771 FRAME, wall mount 2 234593 MIX MANIFOLD; cst; carbon steel

models only; see 310654

234451 MIX MANIFOLD; sst; stainless steel

models only; see 310654 3 287230 CONTROL, air; see page 53 4 109544 ELBOW, pipe; 3/8 npt (mbe) 5 116756 ELBOW, street, 45°; 3/8 npt (mxf) 6 155665 UNION, adapter; 3/8 npsm(f) x

3/8 npt(m) 7 117629 FILTER, air; 5 micron 8 114316 ELBOW; 3/8 npt(m) x 3/8 in.

(10 mm) OD tube fitting 9 15D795 FILTER, air; 40 micron 10 248270 PNEUMATIC CONTROL,

intrinsically safe; see page 48 11 234620 USER INTERFACE; see page 52 12 248570 PUMP, UltraMix, cst; carbon steel

models only; see 310671

248571 PUMP, UltraMix, sst; stainless steel

models only; see 310671 13 100361 PLUG, pipe; 1/2 npt 14 15D873 BRACKET, support, fluid manifold 15 C38211 ELBOW; 1/2 npt(m) x

3/8 in. (10 mm) OD tube fitting 16 C19038 WASHER, lock; 1/4 17 112925 SCREW, cap, button hd;

1/4-20 x 3/8 in. (10 mm) 20 103196 SCREW, machine, phillips;

8-32 x 7/16 in. (11 mm) 21 15D767 PLATE, side 22 119291 SCREW, self-tapping 23 113802 SCREW, hex hd, flanged;

3/8-16 x 5/8 in. (16 mm) 24 220598 HOSE, air; nitrile; 1/2 in. (13 mm)

ID; 1/2 npt (mbe); 18 in. (457 mm);

see also pages 44, 46, and 47 25 C19024 ELBOW, swivel; 1/2 npt(m) x

1/2 npsm(f) 26 15D607 CABLE, sensor; see Electrical

Schematic, page 22 27 15D794 HARNESS, connector; see Electri-

cal Schematic, page 22 28▲ 290331 LABEL, warning 31 101765 GROMMET 32 100451 COUPLING; 1/8 npt (fbe) 33 115671 CONNECTOR; 1/8 npt(m) x

1/4 in. (6 mm) OD tube 37 244524 GROUND WIRE

Ref. No. Part No. Description Qty.

38 113279 PLUG, tube fitting;

1 1

39 113505 NUT, keps, hex hd; 10-24 40 551787 SCREW, cap, button hd;

44 114104 SCREW, machine; 1/4-20 x

45 115942 NUT, hex, flange hd; 1/4-20

46 113319 FITTING, air; 1/4 npt(m) x

47 115841 ELBOW; 1/4 npt(m) x

1 1

48 114158 FITTING, Y-adapter;

49 115743 ADAPTER; 3/8 in (10 mm) tube x

53 111763 ELBOW; 1/4 npt (mbe)

56 598095 TUBE; nylon; 5/32 in. (4 mm) OD;

57 054753 TUBE; nylon; 5/32 in. (4 mm) OD;

58 054754 TUBE; nylon; 5/32 in. (4 mm) OD;

1 1

59 054757 TUBE; nylon; 5/32 in. (4 mm) OD;

60 590385 TUBE; polyethylene; 3/8 in. (10 mm)

5 5

63 162453 NIPPLE; 1/4 npsm x 1/4 npt 65 104641 FITTING, bulkhead

67 100840 ELBOW, street; 1/4 npt (m x f) 70 054123 TUBE; nylon; 1/4 in. (6 mm) OD;

78 206966 HOSE, fluid; 1/4 npsm (fbe); PTFE;

79 195889 BUSHING, strain relief 80 100206 BUSHING; 1/2 npt(m) x 1/4 npt(f) 83 501867 CHECK VALVE

86 114339 UNION, swivel; 1/4 npsm(f) x

87 15D957 HARNESS, wire 88 119159 SWITCH, air flow

89 166846 ADAPTER; 1/4 npsm x

90 239716 METER, G3000; see 308778

91 195283 SHIELD, ESD, G3000

2 2

▲ Replacement Danger and Warning labels, tags, and cards

are available at no cost.

5/32 in. (4 mm) OD tube

10-32 x 3/8 in. (10 mm)

1-1/2 in. (38 mm)

3/8 in. (10 mm) OD tube

1/4 in. (6 mm) OD tube

1/4 in. (6 mm) tube

clear; see pages 44, 46, and 47

black; see pages 44, 46, and 47

red; see pages 44, 46, and 47

green; see pages 44, 46, and 47

OD; see pages 44, 46, and 47

see pages 44, 46, and 47

1/4 in. (6 mm) ID; 18 in. (457 mm); see also pages 44 and 47

1/4 npt(m)

1/4 npt (mbe)

Parts

2 4

7 1

2 ft

4.7 ft

2 1 1

4.2 ft

1 1 1 1

1 1 1

1 1

309909H 29

Page 30

Parts

Pump-based, Wall-mounted Air Spray Units

Part No. 234599 Series A, carbon steel, intrinsically safe Part No. 234600 Series A, carbon steel, non-intrinsically safe Part No. 234601 Series A, stainless steel, intrinsically safe Part No. 234825 Series A, stainless steel, non-intrinsically safe

21, 28

TI4904b

30 309909H

Page 31

Pump-based, Wall-mounted Air Spray Units, continued

Parts

32 33

24 (Ref)

1716

32 33

Pump Solenoid

Cable Connections

2 1

63 78 (Ref)

TI4905a

Downstroke solenoid is on the outside.

Upstroke solenoid is on the inside.

TI11228a

309909H 31

Page 32

Parts

Pump-based, Wall-mounted Air Spray Units, continued

See page 30 for model numbers and descriptions.

Ref. No. Part No. Description Qty.

1 15D771 FRAME, wall mount 2 234593 MIX MANIFOLD; cst; carbon steel

models only; see 310654

234451 MIX MANIFOLD; sst; stainless steel

models only; see 310654 3 287230 CONTROL, air; see page 53 4 109544 ELBOW, pipe; 3/8 npt (mbe); intrin-

sically safe models only

114316 ELBOW; 3/8 npt(m) x 3/8 in.

(10 mm) OD tube fitting; non-intrin-

sically safe models only 5 116756 ELBOW, street, 45°; 3/8 npt (mxf);

intrinsically safe models only 6 155665 UNION, adapter; 3/8 npsm(f) x

3/8 npt(m); intrinsically safe models

only 7 117629 FILTER, air; 5 micron; intrinsically

safe models only 8 114316 ELBOW; 3/8 npt(m) x 3/8 in.

(10 mm) OD tube fitting;

intrinsically safe models only 9 15D795 FILTER, air; 40 micron 10 248270 PNEUMATIC CONTROL;

intrinsically safe models only;

see page 48

248316 PNEUMATIC CONTROL; non-intrin-

sically safe models only; see page

50 11 234620 USER INTERFACE; see page 52 12 248570 PUMP, UltraMix, cst; carbon steel

models only; see 310671

248571 PUMP, UltraMix, sst; stainless steel

models only; see 310671 13 100361 PLUG, pipe; 1/2 npt 14 15D873 BRACKET, support, fluid manifold 15 C38211 ELBOW; 1/2 npt(m) x

3/8 in. (10 mm) OD tube fitting 16 C19038 WASHER, lock; 1/4 17 112925 SCREW, cap, button hd;

1/4-20 x 3/8 in. (10 mm) 20 103196 SCREW, machine, phillips;

8-32 x 7/16 in. (11 mm) 21 15D767 PLATE, side 22 119291 SCREW, self-tapping 23 113802 SCREW, hex hd, flanged;

3/8-16 x 5/8 in. (16 mm) 24 220598 HOSE, air; nitrile; 1/2 in. (13 mm)

ID; 1/2 npt (mbe); 18 in. (457 mm);

see also pages 44 and 47 25 C19024 ELBOW, swivel; 1/2 npt(m) x

1/2 npsm(f)

Ref. No. Part No. Description Qty.

26 15D607 CABLE, sensor; see Electrical

1 1

27 15D794 HARNESS, connector; see Electri-

28▲ 290331 LABEL, warning 31 101765 GROMMET

32 100451 COUPLING; 1/8 npt (fbe);

33 115671 CONNECTOR; 1/8 npt(m) x

37 244524 GROUND WIRE 38 113279 PLUG, tube fitting;

39 113505 NUT, keps, hex hd; 10-24 40 551787 SCREW, cap, button hd;

1 1

44 114104 SCREW, machine; 1/4-20 x

45 115942 NUT, hex, flange hd; 1/4-20

48 114158 FITTING, Y-adapter;

49 115743 ADAPTER; 3/8 in (10 mm) tube x

1 2

56 598095 TUBE; nylon; 5/32 in. (4 mm) OD;

57 054753 TUBE; nylon; 5/32 in. (4 mm) OD;

58 054754 TUBE; nylon; 5/32 in. (4 mm) OD;

1 2

59 054757 TUBE; nylon; 5/32 in. (4 mm) OD;

60 590385 TUBE; polyethylene; 3/8 in. (10 mm)

63 162453 NIPPLE; 1/4 npsm x 1/4 npt

70 054123 TUBE; nylon; 1/4 in. (6 mm) OD;

78 206966 HOSE, fluid; 1/4 npsm (fbe); PTFE;

79 195889 BUSHING, strain relief

▲ Replacement Danger and Warning labels, tags, and cards

100451 COUPLING; 1/8 npt (fbe);

115671 CONNECTOR; 1/8 npt(m) x

are available at no cost.

Schematic, page 22

cal Schematic, page 22

intrinsically safe models only

non-intrinsically safe models only

1/4 in. (6 mm) OD tube; intrinsically safe models only

1/4 in. (6 mm) OD tube; non-intrinsically safe models only

5/32 in. (4 mm) OD tube

10-32 x 3/8 in. (10 mm)

1-1/2 in. (38 mm)

1/4 in. (6 mm) OD tube

1/4 in. (6 mm) tube

clear; see pages 44 and 47

black; see pages 44 and 47

red; see pages 44 and 47

green; see pages 44 and 47

OD; see pages 44 and 47

see pages 44 and 47

1/4 in. (6 mm) ID; 18 in. (457 mm); see also pages 44 and 47

1 2 2

1 2

2 4

7 2

2 ft

6.7 ft

4.2 ft

32 309909H

Page 33

Meter-based, Wall-mounted High Pressure Units

Part No. 234618 Series A, carbon steel Part No. 234619 Series A, stainless steel

Parts

21, 28

TI4917a

309909H 33

Page 34

Parts

Meter-based, Wall-mounted High Pressure Units, continued

67 63

65 (Ref)

1716

32 33

24 (Ref)

89 86

Wires to circuit board; see Electrical Schematic, page 22.

TI4918a

34 309909H

Page 35

Meter-based, Wall-mounted High Pressure Units, continued

See page 33 for model numbers and descriptions.

Ref. No. Part No. Description Qty.

1 15D771 FRAME, wall mount 2 234593 MANIFOLD, mix (234618); cst;

see 310654

234451 MANIFOLD, mix (234619); sst;

see 310654 3 287231 CONTROL, air; see page 53 4 109544 ELBOW, pipe; 3/8 npt (mbe) 5 116756 ELBOW, street, 45°; 3/8 npt (m x f) 6 155665 UNION, adapter; 3/8 npsm(f) x

3/8 npt(m) 7 117629 FILTER, air; 5 micron 8 114316 ELBOW; 3/8 npt(m) x

3/8 in. (10 mm) OD tube 9 15D795 FILTER, air; 40 micron 10 248270 PNEUMATIC CONTROL,

intrinsically safe; see page 54 11 234620 USER INTERFACE; see page 52 14 15D873 BRACKET, support, fluid manifold 16 C19038 WASHER, lock; 1/4 17 112925 SCREW, cap; 1/4-20 x

3/8 in. (10 mm) 20 103196 SCREW, machine, phillips;

8-32 x 7/16 in. (11 mm) 21 15D767 PLATE, side 22 119291 SCREW, self-tapping 24 220598 HOSE, air; nitrile; 1/2 in. (13 mm) ID;

1/2 npt (mbe); 18 in. (457 mm); see

also pages 46 and 47 25 C19024 ELBOW, swivel; 1/2 npt(m) x

1/2 npsm(f) 28▲ 290331 LABEL, warning 31 101765 GROMMET 32 100451 COUPLING; 1/8 npt (fbe) 33 115671 CONNECTOR; 1/8 npt(m) x

1/4 in. (6 mm) OD tube 37 244524 GROUND WIRE 38 113279 PLUG, tube fitting;

5/32 in. (4 mm) OD tube 39 113505 NUT, keps, hex hd; 10-24 40 551787 SCREW, cap, button hd;

10-32 x 3/8 in. (10 mm) 44 114104 SCREW, machine; 1/4-20 x

1-1/2 in. (38 mm) 45 115942 NUT, hex, flange hd; 1/4-20 46 113319 FITTING, air; 1/4 npt(m) x

3/8 in. (10 mm) OD tube 47 115841 ELBOW; 1/4 npt(m) x

3/8 in. (10 mm) OD tube 53 111763 ELBOW; 1/4 npt (mbe)

Ref. No. Part No. Description Qty.

56 598095 TUBE; nylon; 5/32 in. (4 mm) OD;

1 1

57 054753 TUBE; nylon; 5/32 in. (4 mm) OD;

58 054754 TUBE; nylon; 5/32 in. (4 mm) OD; red;

59 054757 TUBE; nylon; 5/32 in. (4 mm) OD;

1 1

60 590385 TUBE; polyethylene; 3/8 in. (10 mm)

63 162453 NIPPLE; 1/4 npsm x 1/4 npt

65 104641 FITTING, bulkhead

67 100840 ELBOW, street; 1/4 npt (m x f) 70 054123 TUBE; nylon; 1/4 in. (6 mm) OD; see

1 1

80 100206 BUSHING; 1/2 npt(m) x 1/4 npt(f) 83 501867 CHECK VALVE

86 114339 UNION, swivel; 1/4 npsm(f) x

1 5

87 15D957 HARNESS, wire

88 119159 SWITCH, air flow 89 166846 ADAPTER; 1/4 npsm x

90 239716 METER, G3000; see 308778

91 195283 SHIELD, ESD, G3000

▲ Replacement Danger and Warning labels, tags, and cards

are available at no cost.

1 2 2 2

1 2

2 4

7 1

clear; see pages 46 and 47

black; see pages 46 and 47

see pages 46 and 47

green; see pages 46 and 47

OD; see pages 46 and 47

pages 46 and 47

1/4 npt(m)

1/4 npt (mbe)

Parts

2 ft

3.5 ft 1 1 1

4 ft

1 2 2

1 1 2

2 2

309909H 35

Page 36

Parts

Pump-based, Wall-mounted High Pressure Units

Part No. 234606 Series A, HydraMix 500 carbon steel, intrinsically safe Part No. 234607 Series A, HydraMix 500 carbon steel, non-intrinsically safe Part No. 234609 Series A, HydraMix 600 carbon steel, intrinsically safe Part No. 234610 Series A, HydraMix 600 carbon steel, non-intrinsically safe Part No. 234612 Series A, HydraMix 700 carbon steel, intrinsically safe Part No. 234608 Series A, HydraMix 500 stainless steel, intrinsically safe Part No. 234826 Series A, HydraMix 500 stainless steel, non-intrinsically safe Part No. 234611 Series A, HydraMix 600 stainless steel, intrinsically safe Part No. 234827 Series A, HydraMix 600 stainless steel, non-intrinsically safe Part No. 234613 Series A, HydraMix 700 stainless steel, intrinsically safe

21, 28

TI4910b

36 309909H

Page 37

Pump-based, Wall-mounted High Pressure Units, continued

Parts

16 17

32 33

24 (Ref)

68 69

15 34

Detail of B Side Muffler

TI4911b

Pump Solenoid

Cable Connections

2 1

Downstroke solenoid connection.

Upstroke solenoid connection.

TI5294a

309909H 37

Page 38

Parts

Pump-based, Wall-mounted High Pressure Units, continued

See page 36 for model numbers and descriptions.

Ref. No. Part No. Description Qty.

1 15D771 FRAME, wall mount 2 234593 MIX MANIFOLD; cst; carbon steel

models only; see 310654

234451 MIX MANIFOLD; sst; stainless steel

models only; see 310654 3 287230 CONTROL, air; see page 53 4 109544 ELBOW, pipe; 3/8 npt (mbe); intrin-

sically safe models only

114316 ELBOW; 3/8 npt(m) x 3/8 in.

(10 mm) OD tube fitting; non-intrin-

sically safe models only 5 116756 ELBOW, street, 45°; 3/8 npt (mxf);

intrinsically safe models only 6 155665 UNION, adapter; 3/8 npsm(f) x

3/8 npt(m); intrinsically safe models

only 7 117629 FILTER, air; 5 micron; intrinsically

safe models only 8 114316 ELBOW; 3/8 npt(m) x

3/8 in. (10 mm) OD tube fitting;

intrinsically safe models only 9 15D795 FILTER, air; 40 micron 10 248270 PNEUMATIC CONTROL;

intrinsically safe models only;

see page 48

248316 PNEUMATIC CONTROL; non-intrin-

sically safe models only; see page

50 11 234620 USER INTERFACE; see page 52 12 248572 PUMP, HydraMix 500, cst; 234606

and 234607; see 310672

248573 PUMP, HydraMix 500, sst; 234608

and 234826; see 310672

248574 PUMP, HydraMix 600, cst; 234609

and 234610; see 310672

248575 PUMP, HydraMix 600, sst; 234611

and 234827; see 310672

248576 PUMP, HydraMix 700, cst; 234612;

see 310672

248577 PUMP, HydraMix 700, sst; 234613;

see 310672 13 100361 PLUG, pipe; 1/2 npt 14 15D873 BRACKET, support, fluid manifold 15 114110 ELBOW; 1/2 npt(m) x

1/2 in. (13 mm) OD tube fitting 16 C19038 WASHER, lock; 1/4 17 112925 SCREW, cap, button hd;

1/4-20 x 3/8 in. (10 mm) 20 103196 SCREW, machine, phillips;

8-32 x 7/16 in. (11 mm) 21 15D767 PLATE, side

Ref. No. Part No. Description Qty.

22 119291 SCREW, self-tapping

23 113802 SCREW, hex hd, flanged;

24 220598 HOSE, air; nitrile; 1/2 in. (13 mm)

25 C19024 ELBOW, swivel; 1/2 npt(m) x

26 15D607 CABLE, sensor; see Electrical

27 15D794 HARNESS, connector; see Electri-

28▲ 290331 LABEL, warning

31 101765 GROMMET 32 100451 COUPLING; 1/8 npt (fbe); intrinsi-

33 115671 CONNECTOR; 1/8 npt(m) x

1 1

34 15D966 BRACKET, muffler

35 15E020 FITTING, compression; cst;

1 2

36 15E018 ELBOW, compression; cst;

37 244524 GROUND WIRE

38 113279 PLUG, tube fitting;

39 113505 NUT, keps, hex hd; 10-24

40 551787 SCREW, cap, button hd;

42 15D998 TUBE, fluid, A component; see

43 15D999 TUBE, fluid, B component; see

5 5

44 114104 SCREW, machine; 1/4-20 x

45 115942 NUT, hex, flange hd; 1/4-20

100451 COUPLING; 1/8 npt (fbe);

115671 CONNECTOR; 1/8 npt(m) x

15E021 FITTING, compression; sst;

15E019 ELBOW, compression; sst;

3/8-16 x 5/8 in. (16 mm)

ID; 1/2 npt (mbe); 18 in. (457 mm); see also pages 45 and 47

1/2 npsm(f)

Schematic, page 22

cal Schematic, page 22

1 2 2

cally safe models only

non-intrinsically safe models only

1/4 in. (6 mm) OD tube; intrinsically safe models only

1/4 in. (6 mm) OD tube; non-intrinsically safe models only

2 2

carbon steel models only; 1/4 npt(m) x 1/2 in. (13 mm) tube

stainless steel models only; 1/4 npt(m) x 1/2 in. (13 mm) tube

carbon steel models only; 3/8 npt(m) x 1/2 in. (13 mm) tube

stainless steel models only; 3/8 npt(m) x 1/2 in. (13 mm) tube

1 2

5/32 in. (4 mm) OD tube

2 4

10-32 x 3/8 in. (10 mm)

pages 45 and 47

1-1/2 in. (38 mm)

38 309909H

Page 39

Parts

Ref. No. Part No. Description Qty.

50 102656 MUFFLER 56 598095 TUBE; nylon; 5/32 in. (4 mm) OD;

clear; see pages 45 and 47

57 054753 TUBE; nylon; 5/32 in. (4 mm) OD;

black; see pages 45 and 47

58 054754 TUBE; nylon; 5/32 in. (4 mm) OD;

red; see pages 45 and 47

59 054757 TUBE; nylon; 5/32 in. (4 mm) OD;

green; see pages 45 and 47

60 590385 TUBE; polyethylene; 3/8 in. (10 mm)

OD; see pages 45 and 47

61 061134 TUBE; nylon; 1/2 in. (13 mm) OD;

see pages 45 and 47

68 114129 FITTING; 3/8 npt(m) x

1/2 in. (13 mm) OD tube fitting

2 ft

0.7

5.2

Ref. No. Part No. Description Qty.

69 100081 BUSHING, pipe; 1/2 npt(m) x

3/8 npt(f)

70 054123 TUBE; nylon; 1/4 in. (6 mm) OD;

see pages 45 and 47 79 195889 BUSHING, strain relief 93 113796 SCREW, hex hd, flange; 1/4-20 x

3/4 in. (19 mm) 94 15A818 COVER, sensor; non-intrinsically

safe carbon steel models only 95 C20272 O-RING; non-intrinsically safe car-

96 15E383 BUSHING, strain relief;

ft 1

▲ Replacement Danger and Warning labels, tags, and cards

are available at no cost.

bon steel models only

non-intrinsically safe carbon steel

models only

4 ft

2 4

309909H 39

Page 40

Parts

Pump and Meter-based, Wall-mounted High Pressure Units

Part No. 234602 Series A, HydraMix 500 carbon steel pump and G3000 Meter Part No. 234603 Series A, HydraMix 500 stainless steel pump and G3000 Meter Part No. 234604 Series A, HydraMix 600 carbon steel pump and G3000 Meter Part No. 234605 Series A, HydraMix 600 stainless steel pump and G3000 Meter

21, 28

TI4907b

40 309909H

Page 41

Pump and Meter-based, Wall-mounted High Pressure Units, continued

Parts

65 (Ref)

17 16

32 33

24 (Ref)

16 17

89 86

TI4908a

Pump Solenoid

Cable Connections

2 1

Downstroke solenoid connection.

Upstroke solenoid connection.

TI5294a

309909H 41

Page 42

Parts

Pump and Meter-based, Wall-mounted High Pressure Units, continued

See page 40 for model numbers and descriptions.

Ref. No. Part No. Description Qty.

1 15D771 FRAME, wall mount 2 234593 MIX MANIFOLD; cst; carbon steel

models only; see 310654

234451 MIX MANIFOLD; sst; stainless steel

models only; see 310654 3 287230 CONTROL, air; see page 53 4 109544 ELBOW, pipe; 3/8 npt (mbe) 5 116756 ELBOW, street, 45°; 3/8 npt (mxf) 6 155665 UNION, adapter; 3/8 npsm(f) x

3/8 npt(m) 7 117629 FILTER, air; 5 micron 8 114316 ELBOW; 3/8 npt(m) x

3/8 in. (10 mm) OD tube fitting 9 15D795 FILTER, air; 40 micron 10 248270 PNEUMATIC CONTROL,

intrinsically safe; see page 48 11 234620 USER INTERFACE; see page 52 12 248572 PUMP, HydraMix 500, cst; 234602;

see 310672

248573 PUMP, HydraMix 500, sst; 234603;

see 310672

248574 PUMP, HydraMix 600, cst; 234604;

see 310672

248575 PUMP, HydraMix 600, sst; 234605;

see 310672 13 100361 PLUG, pipe; 1/2 npt 14 15D873 BRACKET, support, fluid manifold 15 114110 ELBOW; 1/2 npt(m) x

1/2 in. (13 mm) OD tube fitting 16 C19038 WASHER, lock; 1/4 17 112925 SCREW, cap, button hd;

1/4-20 x 3/8 in. (10 mm) 20 103196 SCREW, machine, phillips;

8-32 x 7/16 in. (11 mm) 21 15D767 PLATE, side 22 119291 SCREW, self-tapping 23 113802 SCREW, hex hd, flanged;

3/8-16 x 5/8 in. (16 mm) 24 220598 HOSE, air; nitrile; 1/2 in. (13 mm)

ID; 1/2 npt (mbe); 18 in. (457 mm);

see also pages 45, 46, and 47 25 C19024 ELBOW, swivel; 1/2 npt(m) x

1/2 npsm(f) 26 15D607 CABLE, sensor; see Electrical

Schematic, page 22 27 15D794 HARNESS, connector; see Electri-

cal Schematic, page 22 28▲ 290331 LABEL, warning 31 101765 GROMMET 32 100451 COUPLING; 1/8 npt (fbe)

Ref. No. Part No. Description Qty.

33 115671 CONNECTOR; 1/8 npt(m) x

1/4 in. (6 mm) OD tube

carbon steel models only; 1/4 npt(m) x 1/2 in. (13 mm) tube

stainless steel models only; 1/4 npt(m) x 1/2 in. (13 mm) tube

carbon steel models only; 3/8 npt(m) x 1/2 in. (13 mm) tube

stainless steel models only; 3/8 npt(m) x 1/2 in. (13 mm) tube

5/32 in. (4 mm) OD tube

10-32 x 3/8 in. (10 mm)

pages 45 and 47

1-1/2 in. (38 mm)

3/8 in. (10 mm) OD tube

clear; see pages 45, 46, and 47

black; see pages 45, 46, and 47

red; see pages 45, 46, and 47

green; see pages 45, 46, and 47

OD; see pages 45, 46, and 47

see pages 45, 46, and 47

1/2 in. (13 mm) OD tube fitting

3/8 npt(f)

34 15D966 BRACKET, muffler 35 15E020 FITTING, compression; cst;

1 1 1 1

36 15E018 ELBOW, compression; cst;

1 1

37 244524 GROUND WIRE 38 113279 PLUG, tube fitting;

1 1

39 113505 NUT, keps, hex hd; 10-24 40 551787 SCREW, cap, button hd;

42 15D998 TUBE, fluid, A component; see

44 114104 SCREW, machine; 1/4-20 x

45 115942 NUT, hex, flange hd; 1/4-20

46 113319 FITTING, air; 1/4 npt(m) x

1 1

47 115841 ELBOW; 1/4 npt(m) x

50 102656 MUFFLER

53 111763 ELBOW; 1/4 npt (mbe) 56 598095 TUBE; nylon; 5/32 in. (4 mm) OD;

57 054753 TUBE; nylon; 5/32 in. (4 mm) OD;

58 054754 TUBE; nylon; 5/32 in. (4 mm) OD;

59 054757 TUBE; nylon; 5/32 in. (4 mm) OD;

60 590385 TUBE; polyethylene; 3/8 in. (10 mm)

61 061134 TUBE; nylon; 1/2 in. (13 mm) OD;

63 162453 NIPPLE; 1/4 npsm x 1/4 npt 65 104641 FITTING, bulkhead

67 100840 ELBOW, street; 1/4 npt (m x f) 68 114129 FITTING; 3/8 npt(m) x

1 2

69 100081 BUSHING, pipe; 1/2 npt(m) x

15E021 FITTING, compression; sst;

15E019 ELBOW, compression; sst;

1 1

1 2

2 4

7 1

1 1

2 ft

4.6 ft

1 ft

1 1 1 1

42 309909H

Page 43

Ref. No. Part No. Description Qty.

70 054123 TUBE; nylon; 1/4 in. (6 mm) OD;

see pages 45, 46, and 47 79 195889 BUSHING, strain relief 80 100206 BUSHING; 1/2 npt(m) x 1/4 npt(f) 83 501867 CHECK VALVE 86 114339 UNION, swivel; 1/4 npsm(f) x

1/4 npt(m) 87 15D957 HARNESS, wire 88 119159 SWITCH, air flow 89 166846 ADAPTER; 1/4 npsm x

1/4 npt (mbe) 90 239716 METER, G3000; see 308778 91 195283 SHIELD, ESD, G3000

▲ Replacement Danger and Warning labels, tags, and cards

are available at no cost.

3.5

Parts

ft 1 1 1 1

1 1 1

1 1

309909H 43

Page 44

Parts

Tube Connections, Low Pressure Pumps

Find the keys on the drawing to ensure proper connections.

Ref.

Key Description

A1 Dispense Valve A OFF 56 24 (610) A2 Dispense Valve A ON 57 24 (610) B1 Dispense Valve B OFF 59 24 (610) B2 Dispense Valve B ON 58 24 (610) C1 Air to Pneumatic Control (10) 60 8 (203) D1 Air Filter (9) Drain Tube 70 24 (610) D2 Air Filter (7) Drain Tube 70 18 (457) G1 Gun Air Regulator (74) Input 60 31 (787)

No.

Length, in. (mm)

Ref.

Length,

Key Description

G2 Gun Air Regulator (74) Output 60 30 (762) L1 Fluid Line, Pump A to Dispense Valve A 78 18 (457) L2 Fluid Line, Pump B to Dispense Valve B 78 18 (457) M1 Air Filter (9) to Air Control (3) 24 18 (457) P1 Pump A Input Air 60 17 (432) P2 Pump B Input Air 60 21 (533) S1 Pump A Solenoid Inputs (2 tubes) 70 2 (51) S2 Pump B Solenoid Inputs (2 tubes) 70 2 (51)

No.

in. (mm)

D1 D2

A2B2

A SideB Side

S1S2

B1 A1

44 309909H

A2B2

TI5278a

Page 45

Tube Connections, High Pressure Pumps

Find the keys on the drawing to ensure proper connections.

Ref.

Key Description

No.

Length, in. (mm)

Ref.

Length,

Key Description

L1 Fluid Line, Pump A to Dispense Valve A 42 molded

L2 Fluid Line, Pump B to Dispense Valve B 43 molded

M1 Air Filter (9) to Air Control (3) 24 18 (457) P1 Pump A Input Air 61 18 (457) P2 Pump B Input Air 61 24 (610)

No.

in. (mm)

tube

P1P2

Parts

D1 D2

A2B2

P1P2

A SideB Side

E1E2

B1 A1

A2B2

309909H 45

TI5279a

Page 46

Parts

Tube Connections, Meters

Find the keys on the drawing to ensure proper connections. This page shows a unit with meters on both sides. If your model is a pump/meter combination unit, also refer to pages 44 and 45 for additional connections.

Ref.

Key Description

A1 Dispense Valve A OFF 56 24 (610) A2 Dispense Valve A ON 57 24 (610) B1 Dispense Valve B OFF 59 24 (610) B2 Dispense Valve B ON 58 24 (610) C1 Air to Pneumatic Control (10) 60 8 (203)

No.

Length, in. (mm)

Key Description

D1 Air Filter (9) Drain Tube 70 24 (610) D2 Air Filter (7) Drain Tube 70 18 (457) G1 Gun Air Flow Switch (88) to Gun Air Line 60 30 (762) M1 Air Filter (9) to Air Control (3) 24 18 (457)

No.

Length, in. (mm)

B Side

A2B2

A Side

B1 A1

A2B2

TI5280a

46 309909H

Page 47

Pneumatic Schematic

Parts

MOTOR UP

110 PSI RELIEF VALVE

3/4 AIR FILTER AUTO DRAIN 20 MICRON

GAUGE

AIR REGULATOR

GAUGE

MOTOR DOWN

3/8 AIR FILTER AUTO DRAIN 5 MICRON

3/4" BALL VALVE BLEED TYPE

PUMP UP, 12 VDC

PUMP DOWN, 12 VDC

AIR SUPPLY

TO MANIFOLD

3/8 TUBE

AIR REGULATOR SET @ 22 PSI

MOTOR

AIR EXHAUST,

SOLENOID

POSITION 3 (OPEN FOR OPT. CIRCULATION ACCESSORY SOLENOID)

POSITION 4 (OPEN WITH BLANK PLATE)

RELIEF VALVE 26 PSI FACTORY SET

1/2 TUBE X 24" LONG

12 VDC

POSITION 1

12 VDC

POSITION 2

MOTOR DOWN

PUMP UP, 12 VDC

PUMP DOWN, 12 VDC

TURBINE / POWER SUPPLY

MANIFOLD

METERING

VALVE

METERING

VALVE

309909H 47

Page 48

Parts

248270 Intrinsically Safe Pneumatic Control

Ref. No. Part No. Description Qty.

301* 248349 CIRCUIT BOARD, main 302 100035 SCREW, machine, phillips;

8-32 x 5/16 in. (8 mm)

304 245854 MODULE, alternator;

includes items 304a-304e 304a 193154 • GASKET; LDPE foam 1 304b 15A853 • WIRE HARNESS 1 304c 111225 • ELBOW; 1/8 npt(m) x

3/8 in. (10 mm) tube fitting 304d 114380 • SCREW; M5 x 25 4 304e 249254 • TURBINE ALTERNATOR 1

305 109466 NUT, lock, w/nylon insert; 8-32 306 248268 MODULE, solenoid, IS;

includes items 306a-306u 306a 15A822 • MANIFOLD 1 306b 117356 • VALVE, 12 VDC, IS 2 306c 114263 • FITTING; 1/8 npt x

5/32 in. (4 mm) tube 306d 156971 • NIPPLE; 1/4 npt 1 306e 115243 • AIR REGULATOR; 1/4 npt 1 306f 115841 • ELBOW; 1/4 npt x

3/8 in. (10 mm) tube fitting 306g 160701 • ELBOW, street; 1/8 npt(m x f) 1 306h 108190 • GAUGE 1 306j 15A798 • GASKET, neoprene 1 306k 15A799 • GASKET, neoprene 1 306m 110207 • ELBOW; 1/8 npt (mbe) 1 306n 104765 • PLUG, pipe; 1/8 ptf 6 306p 517449 • MUFFLER 1

Ref. No. Part No. Description Qty.

306q 112512 • WIRE FERRULE, orange

1 8

306r 117369 • CONNECTOR, 12 position 1 306s 150278 • ADAPTER, 1/4 x 1/8 npt 1

306t 117480 • SAFETY RELIEF VALVE,

306u 552183 • PLATE 2

307 15A800 GASKET; neoprene

308 195889 BUSHING, strain relief 309 106084 SCREW, machine;

310 C12508 TUBE, nylon, black; 3/8 in. (10

2 1

311 113505 NUT, keps; 10-24 312 104029 CLAMP, ground 313 15A849 HARNESS, wire, alarm

314 117442 CONNECTOR, plug, 18 position 315 15B090 WIRE, grounding, door 317 111307 WASHER, lock, external tooth; M5 318 065213 WIRE, copper

320 118132 TERMINAL, lug, lockwasher 321 118129 SPACER 322 114213 HARNESS, connector 323 246899 CIRCUIT BOARD 324 112512 FERRULE, wire 330 119163 CONNECTOR, plug, 8 position

(not shown)

26 psi (179 kPa, 1.8 bar)

M5 x 0.8; 10 mm

mm) OD

1 2 2

1 ft

1 1 1 1 1 1

1 ft

1 1 1 1 2 1

* When ordering 248349 as a replacement part, you must also order a data download kit to program the circuit

board to the specific machine configuration. Order Kit 248403 for hazardous locations or Kit 248404 for non-hazardous locations. See manual 309623 for further instructions.

48 309909H

Page 49

248270 Intrinsically Safe Pneumatic Control, continued

Parts

323

301 311

315 306

322

307

330

320

302, 321

314

Alternator Module (304) Detail

304a

304d

304

304e

304b

310

304c

313

Solenoid Module (306) Detail

306n

306p

306n

306f

306k

306a

306j

308

306g

306f 306d

306n

306b

306c

TI4561b

306u

306f

306h

306e

306m

306s

306t

TI4558a

309909H 49

Page 50

Parts

248316 Non-intrinsically Safe Pneumatic Control

Ref. No. Part No. Description Qty.

301* 248349 CIRCUIT BOARD 302 100035 SCREW, machine, phillips;

8-32 x 5/16 in. (8 mm) 305 109466 NUT, lock, w/nylon insert; 8-32 306 248297 MODULE, solenoid, non-IS

306a 15A822 • MANIFOLD 1 306b 117357 • VALVE, 12 VDC, non-IS 2 306c 114263 • FITTING; 1/8 npt x 5/32” (4 mm)

tube 306d 100721 • PLUG, pipe 2 306f 115841 • ELBOW, swivel; 1/4 npt x

3/8” (9.5 mm) tube 306j 15A798 • GASKET, neoprene 1 306k 15A799 • GASKET, neoprene 1 306n 104765 • PLUG, pipe; 1/8 ptf 6 306p 517449 • MUFFLER 1 306q 112512 • WIRE FERRULE, orange

(not shown) 306r 117369 • CONNECTOR, 12 position 1 306u 552183 • PLATE 2

307 15A800 GASKET; neoprene

Ref. No. Part No. Description Qty.

308 195889 BUSHING, strain relief

309 106084 SCREW, machine;

M5 x 0.8; 10 mm

311 113505 NUT, keps; 10-24

312 104029 CLAMP, ground

313 15A849 HARNESS, wire, alarm 314 117442 CONNECTOR, plug, 18 position

315 15B090 WIRE, grounding, door 317 111307 WASHER, lock, external tooth; M5 318 065213 WIRE, copper; 18 AWG;

green w/yellow stripe 320 118132 TERMINAL, lug, lockwasher 321 118129 SPACER 322 114213 HARNESS, connector 323 246899 CIRCUIT BOARD

324 112512 FERRULE, wire (not shown) 325 15D891 WIRE HARNESS 328 248325 POWER SUPPLY, 12 VDC

330 119163 CONNECTOR, plug, 8 position

1 2

1 1 1 1 1 1

1 ft

1 1 1 1 2 1 1 1

* When ordering 248349 as a replacement part, you must also order a data download kit to program the circuit

board to the specific machine configuration. Order Kit 248403 for hazardous locations or Kit 248404 for non-hazardous locations. See manual 309623 for further instructions.

50 309909H

Page 51

248316 Non-intrinsically Safe Pneumatic Control, continued

307

301

306r

321

323

Parts

330

317

312

318

306

320

314

302

322

Solenoid Module (306) Detail

306n

315

311

306a

313

308

306d 306n

305

309

328

TI4567b

306p

306n

306f

309909H 51

306k

306j

306c

306b

306u

TI4564a

Page 52

Parts

User Interface

234620, for pump-based and pump/meter units

234621, for meter-based units only

Ref. No. Part No. Description Qty.

401 15B062 DISPLAY 403 15A851 HARNESS, wire 404 15A801 GASKET; neoprene 405 15D853 KNOB, control 406 15A850 HARNESS, wire 407 15A852 HARNESS, wire, switch 408 15D796 LABEL, control, upper; 234620

only

15D797 LABEL, control, upper; 234621

only

409 15D798 LABEL, control, lower; 234620

only

15D799 LABEL, control, lower; 234621

only

404

Ref. No. Part No. Description Qty.

410 245706 CIRCUIT BOARD, display;

1 1

411 112546 SCREW, machine;

1 1

412 15A856 PANEL, display

413 C27076 NUT, lock, w/nylon insert; 4-40

414 111907 MOUNT, tie wrap

includes jam nut (N)

4-40 x 3/8 in. (10 mm)

416 15A854 HARNESS, wire, display 418 188438 WASHER; 0.120 in.

419 101366 SCREW, set; socket hd;

10-24 x 5/16 (8 mm)

1 4 3 1 4 1

413 418

407

408

410

411

406 405

407

419

403

52 309909H

409

401

TI4755a TI4756a

406

416

Page 53

287230 Pump Air Control

287231 Meter Air Control

Parts

Ref. No. Part No. Description Qty.

201 15D814 MANIFOLD, air; 287230 only

15D814 MANIFOLD, air; 287231 only

202 206197 REGULATOR, air; 1/2 npt(f) inlet

and outlet; 287230 only;

see manual 308168 203 119240 CAP, pipe, 1/2 in. (13 mm) 204 101689 GAUGE, air pressure; 287230

only

101689 GAUGE, air pressure; 287231

only 205 112678 PLUG; 1/4 npt; 287230 only 206 118762 VALVE, ball, bleed-type;

1/2 npt(fbe)

* These parts are included in 287230 Air Control only.

*204

Ref. No. Part No. Description Qty.

207 113498 VALVE, safety relief;

2 1

208 119246 STANDOFF

110 psi (0.8 MPa, 8 bar)

209 100081 BUSHING, pipe; 1/2 npt(m) x

3/8 npt(f)

210 C19024 ELBOW, swivel; 1/2 npt(m) x

1 2

1/2 npsm(f)

3 1

203

205*

201*

4 1

208

204

208

202*

205*

*205

207

201

209

210

TI4601a

206

309909H 53

Page 54

Technical Data

Mix ratio range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1:1-10:1 (in 0.1 increments), pump-based systems

0.1:1-30:1 (in 0.1 increments), meter-based systems

Ratio tolerance range . . . . . . . . . . . . . . . . . . . . . . . . . . . . up to +/- 1%

Flow rates

Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 qt/min (0.02 lpm)*, pump-based systems

0.1 qt/min (0.1 lpm)*, meter-based systems

Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 gpm (3.8 lpm)

Pump size

UltraMix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 cc/cycle

HydraMix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 cc/cycle

Pump cycle length (one cycle = one upstroke and one downstroke)

UltraMix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 in. (152 mm)/cycle

HydraMix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 in. (193 mm)/cycle

Fluid viscosity range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20,000 cps (heavier viscosities can be mixed with use

of optional heaters, heated hoses, and hardware)

Fluid filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mesh (238 micron) standard

Maximum fluid working pressure

2.5:1 UltraMix . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 psi (1.7 MPa, 17 bar)

24:1 HydraMix . . . . . . . . . . . . . . . . . . . . . . . . . . . 2400 psi (16 MPa, 166 bar)

34:1 HydraMix . . . . . . . . . . . . . . . . . . . . . . . . . . . 3400 psi (23 MPa, 234 bar)

47:1 HydraMix . . . . . . . . . . . . . . . . . . . . . . . . . . . 4700 psi (32 MPa, 324 bar)

Meter-based systems . . . . . . . . . . . . . . . . . . . . . 4000 psi (28 MPa, 280 bar)

Air supply pressure range. . . . . . . . . . . . . . . . . . . . . . . . . 60-110 psi (420-800 kPa, 4.2-8 bar)

Maximum air consumption at 100 psi (0.7 MPa, 7 bar)

2.5:1 UltraMix . . . . . . . . . . . . . . . . . . . . . . . . . . .

24:1 HydraMix . . . . . . . . . . . . . . . . . . . . . . . . . . .

34:1 HydraMix . . . . . . . . . . . . . . . . . . . . . . . . . . .

47:1 HydraMix . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ambient temperature range

Operating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-104° F (0-40° C)

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-160° F (–1-71° C)

10.8 scfm at 1 gpm (0.30 m

40.5 scfm at 1 gpm (1.13 m

54.7 scfm at 1 gpm (1.53 m

63.0 scfm at 1 gpm (1.76 m

/min at 3.8 lpm)

* Minimum flow rate is dependent on the material being sprayed and mixing capability. Test your material for spe-

cific flow rate.

54 309909H

Page 55

Technical Data

External Power Supply Requirements . . . . . . . . . . . . . . . 93-250 Vac, 50/60 Hz, 1.2 amps maximum draw

15 amp maximum circuit breaker required 14 AWG power supply wire gauge

Environmental Conditions Rating . . . . . . . . . . . . . . . . . . . Indoor/outdoor

Altitude up to 4000 meters Maximum relative humidity to 99% up to 40° C Pollution degree (1)

Installation category (2)

Sound pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 dBA at 100 psi (0.7 MPa, 7 bar)

Fluid inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UltraMix Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . See 310671

HydraMix Pumps . . . . . . . . . . . . . . . . . . . . . . . . . See 310672

Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See 308778

Fluid outlet size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UltraMix Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . See 310671

HydraMix Pumps . . . . . . . . . . . . . . . . . . . . . . . . . See 310672

Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See 308778

Air inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UltraMix Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . See 310671

HydraMix Pumps . . . . . . . . . . . . . . . . . . . . . . . . . See 310672

Wetted parts

Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See 310662

Dispense Valves . . . . . . . . . . . . . . . . . . . . . . . . . See 310655

Mix Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . See 310654

Meters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See 308778

PC Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RS-232

309909H 55

Page 56

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.

Original instructions. This manual contains English. MM 309909

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441

www.graco.com

Revised 02/2010