Graco 312787G User Manual

Instructions-Parts

Color Change

312787G

Module Kits

Includes color change valve stack and control module to add or expand color change
function on ProMix® 2KS and ProMix 3KS Electronic Proportioners.

For professional use only.
Approved for use in explosive atmospheres only when used in conjunction with ProMix

2KS or ProMix 3KS Electronic Proportioners.

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

Important Safety Instructions

Read all warnings and instructions in this manual. For complete
warnings and instructions see your proportioning system manual.
Hazard symbols refer to specific procedure risks. Save all instruc­tions.

EN

Color Change Kit shown installed in a
ProMix 2KS Proportioning System

TI12828b

Related Manuals

Contents

Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Low Pressure Kits . . . . . . . . . . . . . . . . . . . . . . . . 3

High Pressure Kits . . . . . . . . . . . . . . . . . . . . . . . 3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Install Color Change Control Module . . . . . . . . . 4

Install Color Valve Stacks . . . . . . . . . . . . . . . . . . 7

Connect Valve Air Lines . . . . . . . . . . . . . . . . . . . 7

Connect Valve Fluid Lines . . . . . . . . . . . . . . . . . . 7

Color Change Board Switch Settings . . . . . . . . . 7

Accessory Dump Valve Kit . . . . . . . . . . . . . . . . . 7

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

Color Change Solenoid Valves . . . . . . . . . . . . . 10

Color Change Board Fuse . . . . . . . . . . . . . . . . 10

Replace a Solenoid . . . . . . . . . . . . . . . . . . . . . . 11

Replace the Color Change Board Fuse . . . . . . 11

Color Change Board Diagnostics . . . . . . . . . . . 12

Replace the Color Change Board . . . . . . . . . . . 13

Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . 14

System Pneumatic Diagram . . . . . . . . . . . . . . . 14

Color Change Module Electrical Schematic . . . 15

System Electrical Schematic . . . . . . . . . . . . . . . 16

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Low Pressure Color Change Kits . . . . . . . . . . . 18

High Pressure Color Change Kits . . . . . . . . . . . 18

Color Change Control Modules . . . . . . . . . . . . . 20

277752 2-Color Control Module . . . . . . . . . . . . 22

278095 1 Catalyst/1 Flush Control Module

(0 Color) . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 26

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . 26

Related Manuals

See the following manuals for additional information on
the color change module and kits.

Manual Description

312775 ProMix 2KS Manual System Installation
312776 ProMix 2KS Manual System Operation
312777 ProMix 2KS Manual System

Repair-Parts

312778 ProMix 2KS Automatic System Installa-

tion

312779 ProMix 2KS Automatic System Opera-

tion

312780 ProMix 2KS Automatic System

Repair-Parts
313881 ProMix 3KS Installation
313882 ProMix 3KS Manual System Operation
313883 ProMix 3KS Repair-Parts
313885 ProMix 3KS Automatic System Opera-

tion
312782 Dispense Valve
312783 Color and Catalyst Change Valve Stacks
312786 Dump Valve and Third Purge Valve Kits

2 312787G

Models

Models

Low Pressure Kits

100 psi (0.7 MPa, 7.0 bar) Maximum Air Inlet Pressure

300 psi (2.1 MPa, 21 bar) Maximum Fluid Working
Pressure

Kit Part No. Series Description

256581
256582
256583
256584
256585
256586
256587
256588
256589
256590
256591
256592
256593
256594
256595

A

2 color
4 color
7 color
12 color
2 color/2 catalyst
4 color/2 catalyst
4 color/4 catalyst
7 color/2 catalyst
7 color/4 catalyst
12 color/2 catalyst
12 color/4 catalyst
13-18 color
13-24 color
13-30 color
1 catalyst/1 flush (0 color)

High Pressure Kits

100 psi (0.7 MPa, 7.0 bar) Maximum Air Inlet Pressure

3000 psi (21 MPa, 210 bar) Maximum Fluid Working
Pressure

Kit Part No. Series Description

256596
256597
256598
256599
256600
256601
256602
256603
256604
256605
256606
256607
256608
256609
256610

A

2 color
4 color
7 color
12 color
2 color/2 catalyst
4 color/2 catalyst
4 color/4 catalyst
7 color/2 catalyst
7 color/4 catalyst
12 color/2 catalyst
12 color/4 catalyst
13-18 color
13-24 color
13-30 color
1 catalyst/1 flush (0 color)

312787G 3

Installation

Installation

Install Color Change Control Module

• To avoid electric shock, turn off equipment power
and shut off power at main circuit breaker before
installing.

• All electrical wiring must be done by a qualified
electrician and comply with all local codes and
regulations.

• Do not substitute system components as this
may impair intrinsic safety.

To reduce the risk of serious injury, including fluid
injection, relieve pressure before installing the kit.
Follow the Pressure Relief Procedure in the
ProMix 2KS Operation or Service manual.

Location

Install the color change control module (101) near the
fluid station. The module is approved for use in a haz­ardous location. Also see your system installation man­ual. See F

IG. 1.

Mounting

1. See Dimensions, page 24.

2. Ensure that the wall and mounting hardware are
strong enough to support the weight of the equip­ment, fluid, hoses, and stress caused during opera­tion.

3. Using the equipment as a template, mark the
mounting holes on the wall at a convenient height
for the operator and so equipment is easily accessi­ble for maintenance.

4. Drill mounting holes in the wall. Install anchors as
needed.

5. Bolt equipment securely.

FSL

13

11

SV

FIG. 1: Control Module Installation

4 312787G

101

FSL

EC

11

SV

TI12828b

Connect Module to Fluid Station Board

NOTICE

To avoid damaging circuit board when servicing, wear
grounding strap on wrist and ground appropriately.

1. Remove the Fluid Station cover.

Installation

2. See F

IG. 1. Connect a 5-pin electrical cable (EC)

from the labeled connection port

(J11) on the

fluid station control board to the color change board.
Also see F

IG. 2 and FIG. 5.

NOTE: See Table 1 for a list of available cables to con­nect the color change control module and fluid station.
Recommended length is 3 ft (1.0 m) or 6 ft (2.0 m).

Table 1: Intrinsically Safe CAN Cables

Part No. Length in ft (m)

15U531 2 (0.6)
15U532 3 (1.0)
15V205 6 (2.0)
15V206 10 (3.0)
15V207 15 (5.0)
15V208 25 (8.0)
15U533 50 (16.0)
15V213 100 (32.0)

To Install a Second Control Module

J11
(Color
Change
Module)

FIG. 2: Fluid Station Control Board Connection

Connect Air Supply to Control Module

Connect a 1/4 in. (6 mm) OD tube (13) between the sys­tem’s air manifold (at the bottom rear of the fluid station)
and the module air inlet fitting (29). See F

The air supply must be clean and dry. Use a 5 micron fil­ter. Regulate the air pressure to 75-100 psi (0.52-0.70

MPa, 5.25-7.0 bar).

IG. 3.

If you are using two color change modules to add colors,
connect a 5-pin electrical cable from the first color
change board to the second color change board. See
F

IG. 5.

29

F

IG. 3: Solenoid Air Connection

312787G 5

TI12824a

Installation

6 312787G

Installation

Install Color Valve Stacks

1. Install the bracket (17) on the fluid station (FS) with
two screws (20). See F

2. Install the color or catalyst valve stack (VS) to the
bracket (17) with two screws (20).

F

IG. 4: Install Valve Stacks

20

IG. 4.

FS

17

20

VS

TI12829a

FM

Connect Valve Air Lines

See FIG. 1. Connect 5/32 in. (4 mm) OD air tubes (11)
from the valve solenoids to the air inlets of each valve.
Refer to the System Pneumatic Diagram, page 14,
and the label inside the color control module.

NOTE: The high pressure color change valves use a
spring-operated exhaust which does not require a sec­ond air line.

Connect Valve Fluid Lines

1. See FIG. 1. Connect fluid supply lines (FSL) to the
1/4 npt(f) inlet of each valve adapter. Supply solvent
to one valve (SV) at the top of the stack,

NOTICE

Verify that all unused fluid ports on the color change
valve stack are plugged before operation. An open
port will leak fluid.

2. Connect the hose (19) from the manifold stack fluid
outlet (F) to the flow meter inlet (M). F

NOTICE

A check valve is recommended on all dead head
valves to prevent color crossover if two valves are
open at the same time.

IG. 4.

Color Change Board Switch Settings

Set switches S3-S6 on the color change board(s) as
shown in Table 2 and F
of color change boards and color change modules being
used in your system.

IG. 5, depending on the number

Accessory Dump Valve Kit

15V821 Dump Valve Kit, for Wall Panel Systems

15V822 Dump Valve Kit, for RoboMix Systems

Accessory Dump Valve Kits are available. The kits
include one dump valve, one solenoid, all necessary
parts for installation, and instruction manual 312786.
Order one kit for each dump valve desired.

312787G 7

Installation

Table 2: Color Change Board Switch Settings for ProMix 2KS Systems

Two Color Change Boards

Color Change Board 1 Color Change Board 2

S3 S6 S5 S4 S3 S6 S5 S4

Termination

Resistor Board ID

OFFONONONONOFF

OFF ON OFF ON ON OFF

Catalyst

On/Off

Color

On/Off

Termination

Resistor Board ID

Catalyst

On/Off

NOT USED

Color

On/Off

One Color Change Board

ON ON ON ON

ON ON ON OFF

ON ON OFF ON

NOT PRESENT

Table 3: Color Change Board Switch Settings for ProMix 3KS Systems

Two Color Change Boards

Color Change Board 1 Color Change Board 2

S3 S6 S5 S4 S3 S6 S5 S4

Termination

Resistor Board ID

OFFONONONONOFFOFFON

OFF ON OFF ON ON OFF OFF ON

OFFONONONONOFFONON

OFF ON OFF ON ON OFF ON ON

Catalyst

On/Off

Color

On/Off

Termination

Resistor Board ID

Component

C On/Off

Color

On/Off

Effect on System

4 catalyst/30 color valves

0 catalyst/30 color valves

4 catalyst/12 color valves

4 catalyst/0 color valves

0 catalyst/12 color valves

Effect on System

4 catalyst valves, 25
color valves

0 catalyst valves, 25
color valves

4 catalyst valves, 4 com­ponent C valves, 25 color
valves

4 component C valves,
25 color valves

One Color Change Board

ON ON ON ON

ON ON ON OFF

ON ON OFF ON

NOT PRESENT

8 312787G

4 catalyst valves, 12
color valves

4 catalyst valves, 0 color
valves

0 catalyst valves, 12
color valves

Switch S3-S6

Positions

Installation

S6

S5

J7 J11

FIG. 5. 256172 Color Change Board Switch Settings

S3

S4

ON

OFF

ON

OFF

TI13661a

312787G 9

Troubleshooting

Troubleshooting

Color Change Solenoid Valves

NOTE: Refer to the Schematic Diagrams, page 14. If the color change valves are not turning on or off correctly, it

could be caused by one of the following.

Cause Solution

1. Air regulator pressure set too
high or too low.

2. Air or electrical lines dam­aged or connections loose.

3. Solenoid failure.

4. Fluid station control board or
cable failure.

Check air pressure. 80-90 psi (550-630 kPa, 5.5-6.3 bar) is commonly used.
Do not go below 75 psi (0.52 MPa, 5.2 bar) or above 100 psi (0.7 MPa, 7 bar).

Visually inspect air and electrical lines for kinks, damage, or loose connec­tions. Service or replace as needed.

Check the applicable solenoid’s LED (see F
with the following checks. If not lit, go to Cause 4.

Remove the connector for the applicable solenoid and measure voltage across
the pins on the board. If voltage is between 9-15 Vdc, replace the solenoid.

Manually operate the valves by removing the color change module cover and
pressing and releasing solenoid valve override buttons. F

Valves should snap open and shut quickly. If the valves actuate slowly, it could
be caused by:

• Air pressure to the valve actuators is too low. See Cause 1.

• Solenoid is clogged. Make sure air supply has 10 micron filter installed.

• Something is restricting the solenoid or tubing. Check for air output from air
line for corresponding solenoid when valve is actuated. Clear restriction.

If there is no voltage across the pins on the board or it is less than 9 Vdc,
check LEDs D9 and D10 (see F
ing properly, or other solenoids in the module are working properly, replace the
color change board.

IG. 7 and Table 4). If both are lit and function-

IG. 7 and Table 4). If lit, proceed

IG. 6.

If D9 and D10 are not lit:

• Check if the cable is disconnected or damaged.

• Check the fluid station control board (see the ProMix 2KS Repair-Parts
Manual).

Color Change Board Fuse

Problem Cause Solution

No power to board. Communication
between color change module and
fluid station is interrupted.

10 312787G

Color change board fuse (F1) is
blown.

Verify condition of fuse. Replace if
necessary. See page 11.

Troubleshooting

Replace a Solenoid

1. Remove air supply pressure from the system.
Remove the color change module cover (30).

2. Disconnect the 2 solenoid wires from the color
change board (15). See F

Module Electrical Schematic on page 15, and the
System Electrical Schematic on page 17.

3. Unscrew 2 screws (P) and remove the solenoid (4).
See F

IG. 6.

4. Install the new solenoid (4).

5. Connect the 2 solenoid wires to the color change
board (15). Solenoid wires are polarized (red
+12Vdc, black –). Refer to the Color Change Mod-

ule Electrical Schematic on page 15 and the Sys-
tem Electrical Schematic on page 17.

6. Reinstall the cover (30).

IG. 7, the Color Change

Replace the Color Change Board Fuse

NOTE: Replacing the fuse with a non-Graco fuse voids

the IS system safety approval.

Fuse Part No. Description

F1 123690 Fuse; 125 mA, intrinsically safe

1. Remove electrical power from the system. Remove
the color change module cover (30).

2. Locate fuse (F1) on the color change board. See
F

IG. 7. Remove the screw and metal strap.

3. Pull the fuse away from the board.

4. Install new fuse (F1). Reinstall the strap over the
fuse.

Solenoid

Identification

Label

5. Reinstall the cover (30). Restore electrical power to
the system.

Color Catalyst

Solenoid
Identification
Label

Color

TI12826a

P

Manual Solenoid Overrides

FIG. 6: Color Change Solenoids

312787G 11

Troubleshooting

Color Change Board Diagnostics

See FIG. 7 and Table 4 to troubleshoot the color change board. Also see the System Electrical Schematic on pages
16 and 17.

16

J8, Pin 1

D33

D31

D29

J15, Pin 1

D41

D35

D27

J14, Pin 1

D30

D28

16

D34

D43

D44
J9, Pin 1

D39

D32

D38
J16, Pin 1

D37

D45

D46

J10, Pin 1

D36

16

D8

16

J7 J11

IG. 7: 256172 Color Change Board

F

16

D9

16

D10

F1

12 312787G

Table 4: Color Change Board Diagnostics

Troubleshooting

Connector

LED

and Pin Nos.

D8 n/a Board OK Board OK Blinks (heartbeat) during nor-

D9 n/a Communication (yellow) Communication (yellow) Turns on when board is com-

D10 J7 Power Power Turns on when power is sup-

D27 J15, 5 & 6 Color 3 Color 16
D28 J14, 3 & 4 Color 1 Color 14
D29 J8, 5 & 6 Color 6 Color 19
D30 J14, 1 & 2 Color 2 Color 15
D31 J8, 3 & 4 Color 7 Color 20
D32 J16, 3 & 4 Catalyst 4 Color 26
D33 J8, 1 & 2 Color 8 Color 21
D34 J9, 5 & 6 Color 9 Color 22
D35 J15, 3 & 4 Color 4 Color 17
D36 J14, 5 & 6 Solvent (Color) Color 13
D37 J10, 5 & 6 Catalyst 2 Color 28

Board 1 Signal
Description

Board 2 Signal
Description Diagnosis

mal operation.

municating with ProMix 2KS.

plied to the board.

D27 through D46 turn on when
ProMix 2KS sends a signal to
actuate the related solenoid
valve.

D38 J16, 1 & 2 Catalyst 3 Color 27
D39 J16, 5 & 6 Color 12 Color 25
D41 J15, 1 & 2 Color 5 Color 18
D43 J9, 3 & 4 Color 10 Color 23
D44 J9, 1 & 2 Color 11 Color 24
D45 J10, 3 & 4 Catalyst 1 Color 29
D46 J10, 1 & 2 Solvent (Catalyst) Color 30

Replace the Color Change Board

1. Remove electrical power from the system. Remove
the color change module cover (30).

2. See F

IG. 7 on page 12. Note where each cable is

connected, then disconnect all cables from the color
change board connectors (J7, J8, J9, J10, J11, J14,
J15, J16).

3. Remove the six mounting screws (16) and the board
(15).

4. Install the new board (15). Reinstall the screws (16).

5. Reconnect the cables to the proper connectors, as
noted in step 2.

6. Reinstall the cover (30). Restore electrical power to
the system.

312787G 13

Schematic Diagrams

Schematic Diagrams

System Pneumatic Diagram

PURGE AIR

AIR INPUT

3/8 AIR FILTER
MANUAL DRAIN
5 MICRON
WALL MOUNT ONLY

AIR INPUT

MANIFOLD

COLOR
CHANGE

AIR EXHAUST MUFFLER

12 VDC

4-WAY SOLENOID

12 VDC

TO MANIFOLD 1/4 TUBE

05

CONTROL AIR

4-WAY SOLENOID

12 VDC

4-WAY SOLENOID

12 VDC

4-WAY SOLENOID

12 VDC

4-WAY SOLENOID

AIR EXHAUST MUFFLER

12 VDC

3-WAY SOLENOID

12 VDC

3-WAY SOLENOID

12 VDC

3-WAY SOLENOID

12 VDC

3-WAY SOLENOID

A

B

A

B

A

B

A

B

A

B

A

A

A

A

MANIFOLD

CLOSE

5/32 TUBE

OPEN

CLOSE

5/32 TUBE

OPEN

CLOSE

5/32 TUBE

OPEN

CLOSE

5/32 TUBE

OPEN

CLOSE

5/32 TUBE

OPEN

5/32 TUBE

OPEN

5/32 TUBE

OPEN

5/32 TUBE

OPEN

5/32 TUBE

OPEN

DOSE A
VALVE

DOSE B
VALVE

PURGE A
VALVE

PURGE B
VALVE

PURGE C
VALVE
(OPTIONAL)

DUMP A
VALVE
(OPTIONAL)

DUMP B
VALVE
(OPTIONAL)

GFB 1
VALVE
(OPTIONAL)

GFB 2
VALVE
(OPTIONAL)

FLUSH AIR TO FLUID INLET 1/4 TUBE

CONTROL

36 SERIES SOLENOID VALVES

COLOR
VALVE
STACKS

COLOR 1
COLOR 2
COLOR 3
COLOR 4
COLOR 5
COLOR 6
COLOR 7
COLOR 8
COLOR SOLVENT
COLOR 9
COLOR 10
COLOR 11
COLOR 12
CATALYST 1
CATALYST 2
CATALYST 3
CATALYST 4
CATALYST SOLVENT

COLOR 13
COLOR 14
COLOR 15
COLOR 16
COLOR 17
COLOR 18
COLOR 19
COLOR 20
COLOR 21
COLOR 22
COLOR 23
COLOR 24
COLOR 25
COLOR 26
COLOR 27
COLOR 28
COLOR 29
COLOR 30

MAC

14 312787G

Color Change Module Electrical Schematic

WIRING DIAGRAM

Schematic Diagrams

COLOR 8 (21)

COLOR 7 (20)

COLOR 6 (19)

COLOR 5 (18)

COLOR 4 (17)

COLOR 3 (16)

COLOR 2 (15)

COLOR 1 (14)

COLOR FLUSH (13)

+12VDC
COM

+12VDC
COM

+12VDC
COM

+12VDC
COM

+12VDC
COM

+12VDC
COM

+12VDC
COM

+12VDC
COM

+12VDC
COM

J8

J15

J14

J9

J16

J10

COM
+12VDC

COM
+12VDC

COM
+12VDC

COM
+12VDC

COM
+12VDC

COM
+12VDC

COM
+12VDC

COM
+12VDC

COM
+12VDC

COLOR 9 (22)

COLOR 10 (23)

COLOR 11 (24)

COLOR 12 (25)

CATALYST 4 (26)

CATALYST 3 (27)

CATALYST 2 (28)

CATALYST 1 (29)

CATALYST FLUSH (30)

312787G 15

Schematic Diagrams

System Electrical Schematic

Non-Hazardous Area

OPERATOR INTERFACE

+

POWER

+

SUPPLY

-

-

BARRIER
BOARD

POWER DIST.
TERMINAL
BLOCKS

-

-

-

-

I/O HARNESSES

+

+

+

+

MEMBRANE
SWITCH
WITH
RIBBON
CABLE

DISPLAY

J4

1
2
3
4
5
6
7
8
9
10
11

J2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

POWER HARNESS

DISPLAY
BOARD

J9

RJ45

J6

J5

J10

DC OK
+24 VDC

COMMON
COMMON

1

+

2

-

3
4

RJ45

FLOW CONTROL CAL. (BLK)

1

GUN TRIGGER (WHT )

2

DIGITAL IN COMMON (RED)

3

REMOTE STOP (GRN)

4

ALARM RESET (BRN)

5

ALARM OUTPUT (BLU)

6

DIGITAL OUTPUT COMMON (ORG)

7

POT LIFE (YEL)

8

FLOW RATE ANALOG IN (PUR)

9

FLOW RATE ANALOG COMMON (GRAY )

10

RS485 INTEGRATION A (WHT/BLU)

1

RS485 INTEGRATION B (BLU/WHT)

2

RS485 INTEGRATION GROUND (SHIELD)

3

RS485 NETWORK A (WHT/ORG)

4

RS485 NETWORK B (ORG/WHT)

5

RS485 NETWORK GROUND (SHIELD)

6

J1

J5

J4

12L1

1

UNUSED

2

UNUSED

3

UNUSED

4

UNUSED

5

UNUSED

1
2
3

1

+24VDC

2

OPEN

3

COMMON

N

85-250 VAC

+12VDC I/S (RED)
COM (BLACK)
SHIELD

+

-

SHIELD

HARNESS

3'

1
2
3
4
5
6
7
8
9
10

1
2
3
4
5
6

ALARM

RJ45

RJ45

REMOTE
I/O
INTEGRATION
BOARD

TERMINAL
BLOCKS

NON-HAZARDOUS AREA

LINE
FILTER

OPEN

OPEN

J2

J3

J4

J5

L1
N
GND

1

GND LUG

2
3

1

POWER

2

ROCKER

1A

SWITCH

1B
2A
2B

CABLE

(50' STD.)/

(100' OPTION)

1

MIX INPUT

2

PURGE INPUT

3

JOB COMPLETE INPUT

4

EXTERNAL CLR CHG READY

5

RESET ALARM INPUT

6

DIGITAL INPUT COMMON

1

DIGITAL INPUT COMMON

2

RECIPE BIT 0 INPUT

3

RECIPE BIT 1 INPUT

4

RECIPE BIT 2 INPUT

5

RECIPE BIT 3 INPUT

6

RECIPE BIT 4 INPUT

7

RECIPE BIT 5 INPUT

8

RECIPE CHANGE INPUT

1

DIGITAL OUTPUT COMMON/POWER

2

PURGE/RECIPE CHG ACTIVE OUTPUT

3

MIX ACTIVE OUTPUT

4

MIX READY OUTPUT

5

FILL ACTIVE

6

FLOW CAL. ACTIVE

7

FLOW RATE ALARM OUTPUT

8

DIGITAL OUTPUT COMMON/POWER

1

DIGITAL OUTPUT COMMON/POWER

2

SPECIAL OUTPUT #1

3

SPECIAL OUTPUT #2

4

SPECIAL OUTPUT #3

5

SPECIAL OUTPUT #4

6

DIGITAL OUTPUT COMMON/POWER

L1
N
GND

(+24) YEL

(COM) GRAY

ORG
BRN

RED

TERMINAL
BLOCK

L1
N
GND

BEACON

GND N L1

85-250
VAC

L1
N

CABLE

J7

FO IN (BLK)

J8

FO OUT (BLU)

RJ45

RJ45

P1

3'

RJ45
BULKHEAD

3'
(25'-200' OPTIONS)

RJ45

WEB SERVER

RJ45

MODULE

16 312787G

System Electrical Schematic

Hazardous Area

Schematic Diagrams

FO OUT
(BLU)

FO IN
(BLK)

FLUID PANEL CONTROL BOX

FLUID
PANEL
CONTROL
BOARD

J10

+12VDC I/S

1

COM

2

SHIELD

3

J4

J6

J13

MH2

J15

J14

HAZARDOUS AREA

1
2
3

J3

4
5
6

1
2
3

J12

4
5
6

UNUSED

1

UNUSED

2

UNUSED

3

UNUSED

4

UNUSED

5

UNUSED

6

1
2
3

J5

4
5
6

3
2

J11

5
4
1

3
2

J7

5
4
1

6
5
4

J8

3
2
1

6
5
4
3
2
1

6
5
4
3
2
1

6
5
4

J9

3
2
1

1
2
3
4
5
6

J1

7
8
9
10

6' STD.
(3'-100' OPTIONS)

50' STD.

GRD (BLK)
+12VDC (RED)
SHIELD (BARE)

CAN H (WHT)

CAN L (BLU)

BLACK
RED
BLACK
RED
BLACK
RED

BLACK
RED
BLACK
RED
BLACK
RED

BLACK
RED
BLACK
RED
BLACK
RED

BLACK
RED
BLACK
RED
BLACK
RED

SIG
COM
SIG
COM
SIG
COM
SIG
COM
SIG
COM

PWR (RED)
COM (BLACK)
SIG (WHITE)
SHIELD/GRN
PWR (RED)
COM (BLACK)
SIG (WHITE)
SHIELD/GRN
PWR (RED)
COM (BLACK)
SIG (WHITE)
SHIELD/GRN

GROUND
TERMINAL

MANIFOLD

MANIFOLD

3X CABLE

(10')/
(40')

GRD (BLK)
+12VDC (RED)
SHIELD (BARE)
CAN H (WHT)
CAN L (BLU)

BOOTH

3

CONTROL

2

BOARD

5
4
1

DUMP B

GFB #1

GFB #2

DUMP A

NOT USED

PURGE C

PURGE B

PURGE A

NOT USED

NOT USED

DOSE B

DOSE A

AIR FLOW SWITCH 1

AIR FLOW SWITCH 2

SOLVENT FLOW SWITCH

GFB 1 PRESSURE SWITCH

GFB 2 PRESSURE SWITCH

FLOW METER A

FLOW METER B

FLOW METER SOLVENT

12 VDC

3-WAY SOLENOID

12 VDC

4-WAY SOLENOID

V/P ANALOG OUT (WHT)
PRESS. (GRN)
+12 V (RED)
GND (BLK)
CHASSIS (BARE)

MANIFOLD

CLR 8

CLR 7

CLR 6

CLR 5

CLR 4

CLR 3

CLR 2

CLR 1

SOL CLR

MANIFOLD

CLR 21

CLR 20

CLR 19

CLR 18

CLR 17

CLR 16

CLR 15

CLR 14

CLR 13

I.S. METERS

+12VDC

+12VDC

+12VDC

+12VDC

+12VDC

+12VDC

+12VDC

+12VDC

+12VDC

+12VDC

+12VDC

+12VDC

+12VDC

+12VDC

+12VDC

+12VDC

+12VDC

+12VDC

COM

COM

COM

COM

COM

COM

COM

COM

COM

COM

COM

COM

COM

COM

COM

COM

COM

COM

J1

1
2
3
4
5

J7/J11

FLOW
CONTROL
BOARD

1
2
3
4
5
6

1
2
3
4
5
6

1
2
3
4
5
6

J7/J11

J7/J11

1
2
3
4
5
6

1
2
3
4
5
6

1
2
3
4
5
6

1
2

1
2
3
4
5

1 4 5 2 3

COLOR
BOARD 1
(COLORS
1 THRU 12,
CATALYST
1 THRU 4)

J8

J16

J15

J14

1 4 5 2 3

1 4 5 2 3

COLOR
BOARD 2
(COLORS
13 THRU 30)

J8

J15

J16

J14

J10

J2

SIG (RED)
COM (BLK)

J4

+ PRESSURE (GRN)
COM (RED)
EX+ (WHT)

- PRESSURE (BLK)
SHIELD (BARE)

6
5
4
3

J9

2
1

6
5
4
3
2
1

6
5
4

J10

3
2
1

6' STD.

6
5
4

J9

3
2
1

6
5
4
3
2
1

6
5
4
3
2
1

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

MANIFOLD

MANIFOLD

TECNO
V/P

FLUID
PRESS.
SENS.

CLR 9

CLR 10

CLR 11

CLR 12

CAT 4

CAT 3

CAT 2

CAT 1

SOL CAT

CLR 22

CLR 23

CLR 24

CLR 25

CLR 26

CLR 27

CLR 28

CLR 29

CLR 30

312787G 17

Parts

Parts

Low Pressure Color Change Kits

Kit Part

No. Series Kit Description

256581
256582 4 color
256583 7 color
256584 12 color
256585 2 color/2 catalyst
256586 4 color/2 catalyst
256587 4 color/4 catalyst
256588 7 color/2 catalyst
256589 7 color/4 catalyst
256590 12 color/2 catalyst
256591 12 color/4 catalyst
256592 13-18 color
256593 13-24 color
256594 13-30 color
256595 1 catalyst/1 flush

A

2 color

Control Module

(101; see page 20)

277752 15V812 none
277753 15V813 none
277754 15V814 none
277755 15V815 none
277879 15V812 15V812
277880 15V813 15V812
277881 15V813 15V813
277882 15V814 15V812
277883 15V814 15V813
277884 15V815 15V812
277885 15V815 15V813
278113 256293 none
278114 15V815 none
277885 256305 none
278095 none 256994

Color Valve Stack
(102; see 312783)

Catalyst Valve Stack

(103; see 312783)

High Pressure Color Change Kits

Kit Part

No. Series Description

256596
256597 4 color
256598 7 color
256599 12 color
256600 2 color/2 catalyst
256601 4 color/2 catalyst
256602 4 color/4 catalyst
256603 7 color/2 catalyst
256604 7 color/4 catalyst
256605 12 color/2 catalyst
256606 12 color/4 catalyst
256607 13-18 color
256608 13-24 color
256609 13-30 color
256610 1 catalyst/1 flush

A

2 color

Control Module

(101; see page 20)

277752 15V816 none
277753 15V817 none
277754 256343 none
277755 256348 none
277879 15V816 15V816
277880 15V817 15V816
277881 15V817 15V817
277882 256343 15V816
277883 256343 15V817
277884 256348 15V816
277885 256348 15V817
278113 256342 none
278114 256348 none
277885 256354 none
278095 none 256995

Color Valve Stack

(102; see 312783)

Catalyst Valve Stack

(103; see 312783)

18 312787G

Color Change Kits Parts

Parts

13

102

11

30

101

Screw Location
(item 32)

11

103

19

20

17

TI12828b

20

TI12829a

312787G 19

Parts

Color Change Control Modules

(Ref. No. 101; see page 18)

Ref.
No. Part No. Description Qty

1 277752 MODULE, control, color change; see page 22

278095 MODULE, control, 1 catalyst/1 flush change; see page 23
2 15T636 MANIFOLD, color change control
3 114669 SCREW, machine, phillips pan hd; M5 x 10 mm (behind panel 12 and manifold 2)
4 121324 VALVE, solenoid
5 121628 SCREW, self-sealing; 4-40 x 1/4 in. (6 mm)
6 112698 ELBOW, tube; 1/8 npt(m) x 1/4 in. (6 mm) OD tube
7 121487 GROMMET
8 109193 ELBOW, tube; 10-32 x 5/32 in. (4 mm) OD tube
9 100139 PLUG, pipe; 1/8 -27 npt
10 15V821 KIT, dump valve; see 312786
11 598095 TUBE; 5/32 in. (4 mm) OD; nylon; see page 19
13 590332 TUBE; 1/4 in. (6 mm) OD
14 119162 CONNECTOR, plug, 6 position
17 15U927 BRACKET, color change; see page 19
18 C06061 MUFFLER
19 24N345 HOSE; ptfe; 1/4 npsm(fbe); 1/4 in. (6 mm) ID; 1.5 ft (0.46 m); see page 19
20 C19798 SCREW, cap, socket-hd; 1/4-20 x 3/8 in. (10 mm); see page 19

See

Ta bl e

Below

Control Module Part Quantities

Module
No.

277753 1 0 0 2 0 0 0 2 0 0 10 (3) 0 1 0 0 0
277754100500050025 (7.6)0 2000
277755 1 1 2 10 0 1 1 10 2 0 50 (15.2) 0.7 (0.2) 3 0 1 0
277879

277756‡
277880

277757‡
277882

277758‡
277884

277759‡
277881

277771‡
277883

277772‡
277885

277773‡
278113 1 0 0 3 0 0 0 3 0 0 15 (4.6) 0 1 0 0 0
278114112901192045 (13.7)0.7 (0.2)3110

1234567891011* 13* 14171819

11231211320215 (4.6) 0.7 (0.2) 1 1 1 1

1 1 2 5 8 1 1 5 2 0

11281011820240 (12.2) 0.7 (0.2) 3 1 1 1

1 1 2 13 0 1 1 13 2 0

1127411720235 (10.7) 0.7 (0.2) 2 1 1 1

1 1 2 10 0 1 1 10 2 0

112150111520275 (22.9) 0.7 (0.2) 4 1 1 1

Ref. Nos.

25 (7.6) 0.7 (0.2) 2 1 1 1

2

65 (19.8) 0.7 (0.2) 4 1 1 1

2

50 (15.2) 0.7 (0.2) 3 1 1 1

2

* Quantities for ref. nos. 11 and 13 are in feet (meters). ‡ These modules include two dump valve kits (10).

20 312787G

Parts

14

613 9

2

5

4

18

789

TI12826a

312787G 21

Parts

277752 2-Color Control Module

Ref.
No. Part No. Description Qty

2 15T636 MANIFOLD, color change control
3 103833 SCREW, machine, pan hd; 10-32 x 3/8 in. (10 mm) (behind panel 12 and manifold 2)
4 121324 VALVE, solenoid
5 121628 SCREW, self-sealing; 4-40 x 1/4 in. (6 mm)
7 121487 GROMMET
8 109193 ELBOW, tube; 10-32 x 5/32 in. (4 mm) OD tube
9 100139 PLUG, pipe; 1/8 -27 npt
11 598095 TUBE; 5/32 in. (4 mm) OD; 15 ft (4.6 m); nylon; see page 19
12 15T635 PANEL
13 590332 TUBE; 1/4 in. (6 mm) OD; 5 ft (1.5 m); see page 19
14 119162 CONNECTOR, plug, 6 position
15 256172 BOARD, circuit
16 112324 SCREW, machine, pan-hd, 4-40 x 1/4 in. (6 mm)
17 15U927 BRACKET, color change; see page 19
18 C06061 MUFFLER
19 24N345 HOSE; ptfe; 1/4 npsm(fbe); 1/4 in. (6 mm) ID; 1.5 ft (0.46 m); see page 19
20 C19798 SCREW, cap, socket-hd; 1/4-20 x 3/8 in. (10 mm); see page 19
26 116343 SCREW, ground
29 115671 FITTING, connector; 1/8 npt(m) x 1/4 in. (6 mm) OD tube
30 15T752 COVER, color change control; see page 19
31 123690 FUSE; 125 mA
32 n/a SCREW, machine, serrated hex-head (see page 19)

1
2
3

12

1
3
2
1
1
1
1
1
6
1
1
1
4
1
1
1
1
4

Parts labeled n/a are not available separately.

912

2

5

14

78

18 29

15

16

31

1

1

Replacing the fuse with a non-Graco fuse
voids the IS system safety approval.

4

26

TI12824a

22 312787G

Parts

278095 1 Catalyst/1 Flush Control Module (0 Color)

Ref.
No. Part No. Description Qty

2 15T636 MANIFOLD, color change control
3 103833 SCREW, machine, pan hd; 10-32 x 3/8 in. (10 mm) (behind panel 12 and manifold 2)
4 121324 VALVE, solenoid
5 121628 SCREW, self-sealing; 4-40 x 1/4 in. (6 mm)
7 121487 GROMMET
8 109193 ELBOW, tube; 10-32 x 5/32 in. (4 mm) OD tube
9 100139 PLUG, pipe; 1/8 -27 npt
11 598095 TUBE; 5/32 in. (4 mm) OD; 15 ft (4.6 m); nylon; see page 19
12 15T635 PANEL
13 590332 TUBE; 1/4 in. (6 mm) OD; 5 ft (1.5 m); see page 19
14 119162 CONNECTOR, plug, 6 position
15 256172 BOARD, circuit
16 112324 SCREW, machine, pan-hd, 4-40 x 1/4 in. (6 mm)
17 15U927 BRACKET, color change; see page 19
18 C06061 MUFFLER
19 24N345 HOSE; ptfe; 1/4 npsm(fbe); 1/4 in. (6 mm) ID; 1.5 ft (0.46 m); see page 19
20 C19798 SCREW, cap, socket-hd; 1/4-20 x 3/8 in. (10 mm); see page 19
26 116343 SCREW, ground
29 115671 FITTING, connector; 1/8 npt(m) x 1/4 in. (6 mm) OD tube
30 15T752 COVER, color change control; see page 19
31 123690 FUSE; 125 mA
32 n/a SCREW, machine, serrated hex-head (see page 19)

1
2
2

14

1
2
2
1
1
1
1
1
6
1
1
1
4
1
1
1
1
4

Parts labeled n/a are not available separately.

31

1

1

Replacing the fuse with a non-Graco fuse
voids the IS system safety approval.

26

15

912

2

5

14

16

TI13546a

4

1829

78

312787G 23

Dimensions

Dimensions

16.57 in. (420.9 mm)

4.52 in.

(114.8 mm)

15.07 in. (382.8 mm)

5.31 in.

(134.9 mm)

TI12824a

8.71 in.

(221.2 mm)

TI12825b

24 312787G

Technical Data

Air Specifications

Maximum Air Input Pressure . . . . . . . . . . . . . . . . . . . 100 psi (0.7 MPa, 7.0 bar)

Minimum Air Input Pressure. . . . . . . . . . . . . . . . . . . . 75 psi (0.52 MPa, 5.2 bar)

Fluid Specifications

Maximum Fluid Working Pressure . . . . . . . . . . . . . . . Low Pressure Valve Stacks: 300 psi (2.1 MPa, 21 bar)

High Pressure Valve Stacks: 3000 psi (21 MPa, 210 bar)

Fluid Wetted Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 303 SST, Tungsten Carbide, ptfe

Hose: ptfe
Color Change Valves: see manual 312782

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see table below

Technical Data

Control Module Weight, lb (kg)

2 color
4 color
7 color
12 color
2 color/2 catalyst
4 color/2 catalyst
4 color/4 catalyst

6.10 (2.77)

6.50 (2.95)

7.10 (3.22)

7.95 (3.61)

6.55 (2.97)

6.95 (3.15)

7.35 (3.33)

Control Module Weight, lb (kg)

7 color/2 catalyst
7 color/4 catalyst
12 color/2 catalyst
12 color/4 catalyst

7.55 (3.42)

7.95 (3.61)

8.30 (3.76)

8.70 (3.95)

312787G 25

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: [phone] or Toll Free: 1-800-328-0211 Fax: [phone]

All written and visual data contained in this document reflects the latest product information available at the time of publication.

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS, MN 55440-1441 • USA

Copyright 2008, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

Graco reserves the right to make changes at any time without notice.

Original instructions. This manual contains English. MM 312787

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revised September 2012