Graco 333282B User Manual

Instructions/Parts

Color Change an

d Remote Mix

333282B

Manifold Kits

To add optional color change function and at-the-gun mixing of two component materials when used with a ProMix™ PD2K Proportioner for Automatic Spray Applications. For professional use only.

Important Safety Instructions Read all warnings and instructions in this manual and in your system installation, operation, and repair/parts manuals. Save these instructions.

See page 3 approvals information.

for model part numbers and

EN

PROVEN QUALITY. LEADING TECHNOLOGY.

Table 1 . Low Pressure, Non-Circulating Remote Mix Manifold Kits Maximum Fluid Working Pressure: 300 psi (2.07 MPa, 20.7 bar)

Number of Color + Solvent Valves

1 24V157

2 24V158 24V331

4 24V159 24V332 24V343

6 24V160 24V333 24V344

8 24V161 24V334 24V345

12 24V162 24V335 24V346

Control Module Expansion Kits: Use to add a second control module (includes all needed solenoids, manifolds, valves and a CAN cable).

8

13–1

13–24 24V164

13–30 24V165

y Safe Modules

0359

II 2 G

Number of Catalyst + Solvent Valves

12

63

24V1

4

6 333282B

Table 2 . Low Pressure, Circulating Remote Mix Manifold Kits Maximum Fluid Working Pressure: 300 psi (2.07 MPa, 20.7 bar)

Models

Number of Color + Solvent Valves

1 24V166

2 24V167 24V336

4 24V308 24V337 24V347

6 24V309 24V338 24V348

8 24V326 24V339 24V349

12 24V327 24V340 24V350

Control Module Expansion Kits: Use to add a second control module (includes all needed solenoids, manifolds, valves and a CAN cable).

13–18 24V328

13–24 24V329

13–30 24V330

Table 3 . High-Pressure, Non-Circulating Remote Mix Manifold Kits Maximum Fluid Working Pressure: 1500 psi (10.34 MPa, 103.4 bar)

Number of Color + Solvent Valves

1 24V35

2 24V360 24V381

4 24V361 24V382 24V396

6 24V3

8 24V363 24V384 24V398

12 24V364 24V385 24V399

Control Module Expansion Kits: Use to add a second control module (includes all needed solenoids, manifolds, valves and a CAN cable).

18

13–

13–24 24V366

13–30 24V367

Number of Catalyst + Solvent Valves

12

Number of Catalyst + Solvent Valves

12

9

24V

62

365

24V3

83

Mo

97

24V3

dels continue on next page.

4

333282B

7

Models

Table 4 . High-Pressure, Circulating Remote Mix Manifold Kits Maximum Fluid Working Pressure: 1500 psi (10.34 MPa, 103.4 bar)

Number of Color + Solvent Valves

1 24V369

2 24V370 24V389

4 24V371 24V390 24V402

6 24V372 24V391 24V403

8 24V373 24V392 24V404

12 24V374 24V393 24V405

Control Module Expansion Kits: Use to add a second control module (includes all needed solenoids, manifolds, valves and a CAN cable).

13–18 24V375

13–24 24V376

13–30 24V377

NOTE: Systems can use 1 to 30 colors and up to 4 catalysts. To add colors/catalysts:

• If current control module is full: If all solenoid ports are in use in your IS control module, an additional IS control module is needed. Order a Control Module Expansion Kit, shown above.

• If current control module is not full: If empty solenoid ports remain in your control module, see

Expansion Kits, page 69.

Number of Catalyst + Solvent Valves

12

4

8 333282B

Warnings

The following exclamation p risks. When th Warnings. Pr the body of th

warnings are for the setup, use, grounding, maintenance and repair of this equipment. The oint symbol alerts you to a general warning and the hazard symbol refers to procedure-speciﬁc

ese symbols appear in the body of this manual or on warning labels, refer backtothese

oduct-speciﬁc hazard symbols and warnings not covered in this section may appear throughout

is manual where applicable.

WARNING

FIRE AND EX

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).

•Keepwork

• Do not plug or unplug power cords, or turn power or light switches on or off when ﬂammable fumes are present.

• Ground all equipment in the work area. See Grounding instructions.

•Useonly

• Hold gun ﬁrmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are antistatic or conductive.

• Stop operation immediately if static sparking occurs or you feel a shock, Do not use equipment until you identify and correct the problem.

• Keepaw

PLOSION HAZARD

area free of debris, including solvent, rags and gasoline.

grounded hoses.

orking ﬁre extinguisher in the work area.

ELECTRIC SHOCK HAZARD This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock.

•Turn

• Connect only to grounded power source.

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

333282B 9

off and disconnect power at main switch before disconnecting any cables and before

icing or installing equipment.

serv

and regulations.

Warnings

WARNING

INTRINSIC SAFETY

Intrinsical equipment wi Follow local

• Be sure your installation complies with national, state, and local codes for the installation of electrical apparatus in a Class I, Group D, Division 1 (North America) or Class I, Zones 1 and 2 (Europe) Hazardous Location, including all of the local safety ﬁre codes (for example, NFPA 33, NEC 500 and 516, OSHA 1910.107, etc.).

•Tohelpprev

• Equipment Safety. T unit from

SKIN INJECTION HAZARD

High-pr skin. Th immedia

• Do not point dispensing device at anyone or at any part of the body.

•Donotp

• Do not stop or deﬂect leaks with your hand, body, glove, or rag.

• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking, or servicing equipment.

•Tight

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

ly safe equipment that is installed improperly or connected to non-intrinsically safe

ll create a hazardous condition and can cause ﬁre, explosion, or electric shock.

regulations and the following safety requirements.

ent ﬁre and explosion:

• Do not install equipment approved only for a non-hazardous location in a hazardous location. See model ID label for the intrinsic safety rating of your model.

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

that comes in contact with the intrinsically safe terminals must be rated for Intrinsic his includes DC voltage meters, ohmmeters, cables, and connections. Remove the the hazardous area when troubleshooting.

essure ﬂuid from dispensing device, hose leaks, or ruptured components will pierce

is may look like just a cut, but it is a serious injury that can result in amputation. Get

te surgical treatment.

ut your hand over the ﬂuid outlet.

en all ﬂuid connections before operating the equipment.

MOVING PARTS HAZARD Moving parts can pinch, cut or amputate ﬁngers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

•Pres

TOX Tox inh

• Read MSDSs to know the speciﬁc hazards of the ﬂuids you are using.

•St

• Always wear chemically impermeable gloves when spraying, dispensing, or cleaning

surized equipment can start without warning. Before checking, moving, or servicing

pment, follow the Pressure Relief Procedure and disconnect all power sources.

equi

ICFLUIDORFUMES

ic ﬂuids or fumes can cause serious injury or death if splashed in the eyes or on skin,

aled, or swallowed.

ore hazardous ﬂuid in approved containers, and dispose of it according to applicable

idelines.

gu

equipment.

10 333282B

Warnings

WARNING

PERSONAL PROTECTIVE EQUIPMENT Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective equipment includes but is not limited to:

•Protectivee

• Respirators, protective clothing, and gloves as recommended by the ﬂuid and solvent manufacturer.

EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the inﬂuence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.

•Useﬂuids in all equ informat

• Do not leave the work area while equipment is energized or under pressure.

• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.

• Check eq manufac

• Do not alter or modify equipment. Alterations or modiﬁcations may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which youareusingit.

•Useequ

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

• Do not kink or over bend hoses or use hoses to pull equipment.

•Keepc

• Comply with all applicable safety regulations.

yewear, and hearing protection.

and solvents that are compatible with equipment wetted parts. See Technical Data

ipment manuals. Read ﬂuid and solvent manufacturer’s warnings. For complete

ion about your material, request MSDS from distributor or retailer.

uipment daily. Repair or replace worn or damaged parts immediately with genuine

turer’s replacement parts only.

ipment only for its intended purpose. Call your distributor for information.

hildren and animals away from work area.

333282B

11

Important Isocy

anate (ISO) Information

Important Iso

Isocyanates (ISO) are catalysts used in two component materials.

cyanate (ISO) Information

Isocyanate Conditions

Spraying or dispensing materials containing isocyanates creates potentially harmful mists, vapors, and atomized particulates.

Read and understand material manufacturer’s warnings and material MSDS to know speciﬁc hazards and precautions related to isocyanates.

Prevent inhalation of isocyanate mists, vapors, and atomized particulates by providing sufﬁcient ventilation in the work area. If sufﬁcient ventilation is not available, a supplied-air respirator is required foreveryoneintheworkarea.

To prevent contact with isocyanates, appropriate personal protective equipment, including chemically impermeable gloves, boots, aprons, and goggles, is also required for everyone in the work area.

Eventually a ﬁlm will form on the surface and the ISO will begin to gel, increasing in viscosity.

NOTICE

Partially c the life of a

• Always use a sealed container with a desiccant dryer in the vent, or a nitrogen atmosphere. Never store ISO in an open container.

• Keep the ISO pump wet cup or reservoir (if installed) ﬁlled with appropriate lubricant. The lubricant creates a barrier between the ISO and the atmosphere.

• Use only moisture-proof hoses compatible with ISO.

• Never use reclaimed solvents, which may contain moisture. Always keep solvent containers closed when not in use.

• Always lubricate threaded parts with an appropriate lubricant when reassembling.

NOTE: The amount of ﬁlm formation and rate of crystallization varies depending on the blend of ISO, the humidity, and the temperature.

ured ISO will reduce performance and

ll wetted parts.

Keep Components A and B Separate

Cross-contamination can result in cured material in ﬂuid lines which could cause serious injury or damage equipment. To prevent cross-contamination:

• Never interchange component A and component B wetted parts.

• Never use solvent on one side if it has been contaminated from the other side.

Moisture Sensitivity of Isocyanates

Exposure to moisture (such as humidity) will cause ISO to partially cure; forming small, hard, abrasive crystals, which become suspended in the ﬂuid.

Chang

Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime.

•When

•Alw

•Che

•Wh

ing Materials

NOTIC

changing materials, ﬂush the equipment

tiple times to ensure it is thoroughly clean.

mul

ays clean the ﬂuid inlet strainers after hing.

ﬂus

ck with your material manufacturer for

mical compatibility.

che

en changing between epoxies and urethanes

polyureas, disassemble and clean all ﬂuid

or

mponents and change hoses. Epoxies often

co

ve amines on the B (hardener) side. Polyureas

ha

ten have amines on the A (resin) side.

of

E

2

1

333282B

Setup the Module

s

Setup the Modu

Setup Non-IS C

NOTE: The PD2K System can use up to four pumps and six color change modules in the non-hazardous area. Use the following table to understand how many color change modules are needed for the number of pumps in your system, and which module should be associated to which pump.

Table 5 . Relationship of Non-IS Color Change Control Modules to Pumps

System Pum

Color

Pump(s)

1 0 1 Not Appli

112

213

p Conﬁguration

Catalyst

Pump(s)

ontrol Modules

Total

Pumps

les

Module 1

(Colors

1–8)

Color Chan

Module 2

(Colors

9–16)

All Non-IS modules ship from the factory as Module 1 (Colors 1–8). Labels for Modules 2 through 6 are provided with the module kit. Afﬁx the labels according to your system conﬁguration.

ge Control Modules, Colors, and Catalysts

Module

3(Colors

17–24)

Pump # 1 Pump # 1

Module 4

(Colors

25–30)

Catalyst

1–2

Module # 5

Pump # 2

Module # 5

Pump # 2

Catalyst

3–4

cable

2 0 2 Not Applicable

Pump#1

224

314

303

404

Pump#1

Pump #

Pump#2

3

Pump # 3

Pump # 4

e

Modul

#5

Pump #

2

Module # 5

Pump # 2

Not A

Not Applicable

Modul

#6

Pump #

pplicable

e

4

333282B 13

Setup the Module

s

Conﬁgure each module according to its designated number, as follows:

NOTICE

To avoid damaging the circuit boards, wear Part No. 112190 grounding strap on your wrist and ground appropriately.

To avoid elec system power

1. Remove elec

2. Open the col S4, S5, and S switches a

3. For each module, set the switches to ON or OFF, as shown in the following table.

trical component damage, remove all

before plugging any connectors.

trical power from the system.

or change module. Locate switches

6onthecontrolmoduleboard. The

re shipped in the OFF position.

Non-IS Control Module Switch Settings

Control

S6 S5 S4

Module

Module 1

Module 2

Module 3

Module 4

Module 5

Module 6

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

4. Use the following ﬁgure and tables to determine the solenoid valve assigned to each valve in the valve manifold.

NOTE: There can be only one solvent valve and one dump valve per pump.

Inlet Manifold Outlet Manifold

Figure 1 Non-IS Control Module

4

1

333282B

Setup the Module

s

Non-IS Control Module 1

Inlet Manifol

Solenoid

1

2

3

4

5

6

7

8

9

Inlet Manifold Outlet Manifold

Solenoid

1

2

3

4

5

6

7

8

d

Valve

Solvent

Color 1

Color 2

Color 3

Color 4

Color 5

Color 6

Color 7

Color 8

Non-IS Control Module 2

Valve

(Solvent)*

Color 9

Color 10

Color 11

Color 12

Color 13

Color 14

Color 15

Outlet Manifo

Solenoid

1Dump

2

3

4

5

6

7

8

9

Solenoid

1

2

3

4

5

6

7

8

ld

Valve

Color 1

Color 2

Color 3

Color 4

Color 5

Color 6

Color 7

Color 8

Valve

(Dump)*

Color 9

Color 10

Color 11

Color 12

Color 13

Color 14

Color 15

Non-IS Control Module 4

Inlet Manifol

Solenoid

1

2

3

4

5

6

7

8 Not Used 8 Not Used

9NotUse

Inlet Manifold Outlet Manifold

Solenoid

1

2

3

4

5

6 Not Used 6 Not Used

7

8 Not Used 8 Not Used

d

Valve

(Solvent)*

Color 25

Color 26

Color 27

Color 28

Color 29

Color 30

d

Non-IS Control Module 5

Valve

(Solvent)*

Catalyst 1

Catalyst 2

Catalyst 3

Catalyst 4

Not Used

Outlet Manifo

Solenoid

1

2

3

4

5

6

7

9NotUse

Solenoid

1

2

3

4

5

7

ld

Valve

(Dump)*

Color 25

Color 26

Color 27

Color 28

Color 29

Color 30

Valve

(Dump)*

Catalyst 1

Catalyst 2

Catalyst 3

Catalyst 4

Not Used

d

9

Inlet Manifold Outlet Manifold

Solenoid

1

2

3

4

5

6

7

8

9

* There should be only one solvent valve and one dump valve per pump.

Color 16

Non-IS Control Module 3

Valve

(Solvent)*

Color 17

Color 18

Color 19

Color 20

Color 21

Color 22

Color 23

Color 24

9

Solenoid

1

2

3

4

5

6

7

8

9

Color 16

Valve

(Dump)*

Color 17

Color 18

Color 19

Color 20

Color 21

Color 22

Color 23

Color 24

9 Not Used 9 Not Used

Non-IS Control Module 6

Inlet Manifold Outlet Manifold

Solenoid

1

2

3

4 Not Used 4 Not Used

5

6 Not Used 6 Not Used

7

8 Not Used 8 Not Used

9 Not Used 9 Not Used

Valve

(Solvent)*

Catalyst 3

Catalyst 4

Not Used

Solenoid

1

2

3

5

7

Valve

(Dump)*

Catalyst 3

Catalyst 4

Not Used

333282B 15

Setup the Module

s

Setup IS Contr

ol Modules

NOTE: Two IS color change control modules may be installed in the hazardous area. The module for colors 1–12 is labeled board 7. The module for colors 13–30 is labeled board 8. An alternate label for Module 8 (Colors 13–30) is provided with the module kit. Afﬁx the label according to your system conﬁguration.

Conﬁgure ea number, as f

ch module according to its designated

ollows:

NOTICE

To avoid da No. 112190 ground app

To avoid electrical component damage, remove all system power before plugging any connectors.

1. Remove electrical power from the system.

2. Open the color change module. Locate switches S4, S5, and S6 on the control module board. The switches may be shipped in the OFF position.

maging the circuit boards, wear Part

grounding strap on your wrist and

ropriately.

3. For each module, set the switches to ON or OFF, as shown in the following table.

IS Control Mod

Control

ule Switch Settings

S6 S5 S4

Module

Module 7

Module 8

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

4. Use the following ﬁgure and tables to determine the solenoid valve assigned to each valve in the valve manifold.

Figure 2 IS Control Module

16 333282B

Setup the Module

s

Solenoid

1

2

3

4

5

6

7

8

9

IS Control Module 7

Valve

Color Solvent

Color 1

Color 2

Color 3

Color 4

Color 5

Color 6

Color 7

Color 8

Solenoid

1

2

3

4

5

6

7

8

9

Valve

Catalyst Solvent

Catalyst 1

Catalyst 2

Catalyst 3

Catalyst 4

Color 9

Color 10

Color 11

Color 1

2

Solenoid

1

2

3

4

5

6

7

8

9

IS Control Module 8

Valve

Color 13

Color 14

Color 15

Color 16

Color 17

Color 18

Color 19

Color 20

Color 2

1

Solenoid

1

2

3

4

5

6

7

8

9

Valve

Color 22

Color 23

Color 24

Color 25

Color 26

Color 27

Color 28

Color 29

Color 3

0

333282B

17

Installation

• To avoid electric shock, turn off power at the main circuit breaker before opening the enclosure.

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

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

• Do not install equipment approved only for non-hazardous location in a hazardous location. See the identiﬁcation label for the intrinsic safety rating for your model.

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

NOTE: The smaller color change control modules must be mounted in the Non-IS area. The larger remote color change module may be mounted in the IS area.

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

5. Bolt the equipment securely.

Air Supply

Connect a clean and dry air supply to the air inlet ﬁtting (317) of each color change control module in the non-hazardous area and each remote module in the hazardous area. The ﬁtting is for 1/4 in. (6 mm) ODtubing. Usea5micronﬁlter. Regulatetheair pressure to 85–100 psi (0.6–0.7 MPa, 6.0–7.0 bar).

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized ﬂuid, such as skin injection, splashing ﬂuid and moving parts, follow the Pressure Relief Procedure in the PD2K Operation Manual before installing the kit.

Mounting the Control Modules

1. See Dimensions, page 71.

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

Grounding

This equipment must be grounded to reduce the risk of static sparking and electric shock. Electric or static sparking can cause fumes to ignite or explode. Improper grounding can cause electric shock. Grounding provides an escape wire for the electric current.

Connect a ground wire from each color change module in the non-hazardous area to a true earth ground.

Intrinsically safe remote color change modules located in the hazardous area must be connected to a true earth ground in the hazardous area.

18 333282B

Non-Hazardous Location

Connect the Color Change Control Modules

NOTE: Non-IS color change control modules provide control for the pump’s inlet and outlet color/catalyst change valves. Depending on the number of valves in the system, as many as six control modules may be installed in the non-hazardous location.

1. Mount the ﬁrst non-IS color

control module as described in

Mounting the Control Modules, page 18.

2. Connect the 5–pin CAN cable (109) to J7 on the

color control module (108).

Installation

7. To install additional color control modules (six maximum), mount the module(s) as described in

Mounting the Control Modules, page 18. Connect

a 5–pin CAN cable from J11 of the previous color control module to J7 of the next control module.

8. Replace the cover of the PD2K electrical control box before turning on power to the system.

Figure 3 Cable Connector J7 at Non-IS Color Control Module

NOTICE

To avoid damaging the circuit boards, wear Part No. 112190 grounding strap on your wrist and ground appropriately.

To avoid electrical component damage, remove all system power before plugging any connectors.

3. Remove electrical power from the system.

4. Remove the cover from the PD2K electrical control box.

5. Install the supplied 2–cable grommet (110) on the cable (109) and secure the grommet to the side of the electrical control box.

6. Connect the cable (109) to J2 on the non-IS side of the isolation board inside the electrical control box. See Electrical Schematics, page 36 for a list of M12 CAN cables for use in a non-hazardous area.

Figure 4 Cable Connection at PD2K Electrical Control Box

Figure 5 Detail of Isolation Board Cable Connections

333282B 19

Installation

Install the Valve Manifolds

NOTE: Always label the color connections to prevent cross-connections. Label the inlet manifold, outlet manifold, and each color valve with its assigned color. The solvent and dump valves should be furthest from the manifold stack primary inlet or outlet.

1. Install a mou with four scr For stabilit (103) to the

nting bracket (101) on the PD2K

ews (103). High pressure systems:

y, be sure to fasten the bottom screws

pump bracket.

with 16 valve positions (14 colors). On high pressure systems, the supplied bracket (101) will accommodate a manifold with 14 valve positions (12 colors). A larger valve stack will require a customer supplied/sourced bracket.

3. Repeat for the opposite side of the PD2K.

4. Connect the air lines from the solenoids to the valves. See Connect the Valve Air Lines, page 24.

NOTE: On high pressure systems, see

Install the Back Pressure Regulator (High Pressure Systems Only), page 21.

5. Connect the ﬂuid supply lines to the valves. See

Connect the Fluid Lines, page 26.

2. Install the inlet and outlet valve manifolds (102) on the mounting bracket (101) with four screws (104), washers (105), and nuts (106).

NOTE: On low pressure systems, the supplied bracket (101) will accommodate a manifold

Figure 6 Install the Valve Manifolds

20 333282B

Install the Back Pressure Regulator (High Pressure Systems Only)

Installation

NOTE: The back pressure regulator is required on high pressure systems to prevent the system’s feed pumps from overdriving the dosing pumps during color change pump ﬂush and color ﬁll operations. Adjust the back pressure during the dump process to be approximately 75% of the supply pressure from the feed pumps, but never more than 300 psi (2.1 MPa, 21 bar) less than the supply pressure.

Install the attaching h manifold st

1. Install the gauge (123) in the open port of the

2. Screw the tee (122) onto the dump valve ﬁtting of

3. Assemble the two nipples (121) to the back

4. Connect a 1/4 npt(f) dump line to the downward

back pressure regulator (120) and

ardware at the dump valve of the outlet ack.

tee (122).

the outlet manifold stack.

pressure regulator (120). Screw the regulator assembly into the tee (122) as shown.

facing nipple (121).

5. Connect the ﬂuid supply lines to the valves. See

Connect the Fluid Lines, page 26.

Figure 7 I Valve of O

nstall Back Pressure Regulator at Dump

utlet Stack

333282B

21

Installation

Hazardous Location

Connect Remot

e Color Change Control

Module

NOTE: IS color change control modules provide control for remote color/catalyst change valves located in the hazardous location for use with automatic spray systems. A maximum of two IS control modules may be installed in the hazardous location. See

IS Color Change Control Modules, page 66 for a list

of modules approved for installation in a hazardous location.

NOTICE

To avoid damaging the circuit boards, wear Part No. 112190 grounding strap on your wrist and ground appropriately.

To avoid electrical component damage, remove all system power before plugging any connectors.

Figure 8 Intrinsically Safe Cable Connections

3. Connect the hazardous location cable (C1) to J7 on the remote color control module (108).

Only approved cables may be used in the hazardous location. Hazardous location cables are marked with a light blue ﬂag next to each connector. See Optional Cables and Modules, page 42 for a list of M12 CAN cables for use in a hazardous area.

1. Remove electrical power from the system.

2. Mount the ﬁrst remote color change control module as described in

Mounting the Control Modules, page 18.

Figur Color

4. Remo rol box. Install the grommet (G) on the

cont supp to th J4 on

ctrical control box. Connect the cable (C1) to

ele

See Electrical Schematics, page 36.

J4.

e 9 Cable Connectors J7 and J11 at IS

Control Module

ve the cover from the PD2K electrical

lied cable (C1) and secure the grommet

e side of the electrical control box. Locate

theISsideoftheisolationboardinthe

2

333282B

Installation

J11ontheﬁrst color control module to J7 on the second module.

6. Replace the cover of the PD2K electrical control box before turning on power to the system.

Install the Remote Valve Manifolds

1. Using the equipment as a template, mark the mounting holes on the wall at a convenient height for the operator and so the equipment is easily accessible for maintenance. Mount the remote valve manifolds near the remote color module and the automatic dispensing device.

2. Install the mounting brackets for the color valve manifolds and the catalyst valve manifolds. See

Dimensions, page 71. Use bolts to attach the

equipment securely.

Figure 10 Detail of Isolation Board Cable Connections

5. If your system includes a second remote color control module mount it as described in

Mounting the Control Modules, page 18. Connect

the supplied hazardous location cable (C2) from

3. Install the color and catalyst valve manifolds to the brackets with four screws, washers, and nuts.

4. Connect the air lines from the solenoids to the valves. See Connect the Valve Air Lines, page 24.

5. Connect the ﬂuid supply lines to the valves. See

Connect the Fluid Lines, page 26.

333282B 23

Installation

Install the Remote Mix Manifold

1. Using the equipment as a template, mark the mounting holes on the wall or robot arm, near the automatic dispensing device.

2. Install the remote mix manifold. See

Dimensions, page 71. Use two bolts to attach

the equipment securely.

3. Install the remote mix manifold to the bracket with four screws.

4. Connect the ﬂuid supply lines to the remote mix valve. See Connect the Fluid Lines, page 26.

Connect the Va

Non-Hazardous Area

1. Connect 5/32 i inlet soleno using the lab as a guide. Se

2. Repeat for th

Hazardous Area

Connect 5/32 in (4 mm) OD air tubes from the solenoids to the air inlet of each valve, using the labels inside of the remote color control module as a guide. See Setup the Modules, page 13.

lve Air Lines

n. (4 mm) OD air tubes from the

ids to the air inlets of each inlet valve,

el inside of the color control module

e Setup the Modules, page 13.

e outlet valves.

4

2

333282B

Notes

Installation

333282B 25

Installation

Connect the Fl

uid Lines

Connect Non-Circulating Fluid Lines

NOTE: There can be only one solvent valve (S) and one dump valve (D) per pump.

NOTE: On high

Install the Systems Onl

1. Use the top valve of the inlet valve stack as the solvent valve (S). Connect a solvent supply line to the 1/4 npt(m) solvent valve inlet on the color and catalyst valve stacks.

Hazardo

us

Area

pressure systems, see

Back Pressure Regulator (High Pressure

y), page 21.

2. Usethetopvalveoftheoutlet valve stack as the dump valve (D). Connect a waste dump line to the 1/4 npt(m) dump valve outlet on the color and catalyst valve stacks.

3. Connect the supply line for each color to the corresponding color valve ﬁtting (C1, C2, etc.) on the inlet color valve stack.

4. Connect a supply line from the bottom ﬁtting of the inlet color valve stack to the inlet manifold of the material A dosing pump.

5. Connect a supply line from the outlet manifold of the material A dosing pump to the bottom ﬁtting of the outlet color valve stack.

Remote

Color an

Catalys

Manifol

d

t

Valve

ds

Non-

Hazardous

Area

Valve Manifold Stack Schematic

Non-IS

inlet and

outlet

color and

catalyst

valve

manifolds

26 333282B

Installation

6. Connect a dedicated supply line for each color to the corresponding color valve ﬁtting (C1, C2, etc.) on the outlet color valve stack. Connect the other end of each line to the corresponding color valveﬁttingontheremotecolorstack.

7. Connect a supply line from the outlet valve on the bottom of the remote color valve stack to inlet A on the remote mix manifold.

8. Connect the supply line for each catalyst to the corresponding catalyst valve ﬁtting on the inlet catalyst valve stack.

9. Connect a supply line from the bottom ﬁtting of the inlet catalyst valve stack to the inlet manifold of the material B dosing pump.

10. Connect a supply line from the outlet manifold of the material B dosing pump to the bottom ﬁtting of the outlet catalyst valve stack.

11. Connect a dedicated supply line for each catalyst to the corresponding catalyst valve ﬁtting on the outlet catalyst valve stack. Connect the other end of each line to the corresponding catalyst valve ﬁtting on the remote catalyst valve stack.

NOTE: If your system uses more colors than catalysts, branch the catalyst line to connect it to each mix manifold. Install a check valve on each branch of the catalyst line.

NOTE: For ease of maintenance, install a ball valve at all ﬂuid line tees.

13. Connect the static mixer to the outlet valve of the remote mix manifold.

14. Connect a ﬂuid line from the static mixer to the automatic dispense device.

Figure 11 (Non-Cir

KEY

A Air inlet

W

S Solvent ﬁtting

C1 Color 1 ﬁtting

C2 Color

Color Change Connections

culating System)

Seal wee lubrica

pand

tion port

2ﬁtting

12. Connect a supply line from the outlet valve of the remote catalyst valve stack to inlet B on the remote mix manifold.

333282B

27

Installation

Connect Circulating Fluid Lines

Circulation valves enable constant circulation of a color when that color is not being sprayed:

•Whenacolorva the dosing pum inlet color v remote color back to the co

• When a color v shut off. Th A dosing pum stack and mi

NOTE: On circulating systems, install a cap (T) on any unused valve ﬁttings.

NOTE: There can be only one solvent valve (S) and one dump valve (D) per pump.

NOTE: On h

Install t Systems O

1. Connect all ﬂuid lines as described in

2. Connect the circulation lines as follows:

he Back Pressure Regulator (High Pressure

nly), page 21.

Connect Non-Circulating Fluid Lines, page 26.

These lines are used during normal mixing and spraying.

a. Connect a 1/4 npt(f) circulation line for each

color from the color valve’s circulation ﬁtting (R1, R2, etc.) on the inlet color valve stack (B) to the corresponding circulation ﬁtting (R1, R2, etc.) on the outlet color valve stack (C). This circulation line bypasses the material A dosing pump when the color valve is closed, allowing continuous circulation of that color.

lve is closed, the system bypasses

p by directing that color from the

alve to the outlet color valve to the

valve, through a circulation line, then

lor supply.

alve is open, the circulation line is

e color is directed through the material

p and out to the remote color valve

x manifold, as in normal operation.

igh pressure systems, see

b. Connect a dedicated ﬂuid supply line for

each color to the corresponding color valve (C1, C2, etc.) on the outlet color valve stack. Connect the other end of each line to the corresponding color valve on the remote color stack.

c. Connect a 1/4 n

circulation theﬂuidsupp

Figure 12 Valve Manifold Connections (Circulating System)

KEY

D

Dump valve ﬁtting

S Solvent ﬁtting

C1 Color 1

C2 Color 2 ﬁtting

R1

Color 1 circulation ﬁtting

R2

Colo

ﬁtting

r 2 circulation ﬁtting

pt(f) circulation line from the

port on each remote valve back to

ly container.

28 333282B

KEY

A

Color supply

Installation

Fluid Flow Schematic Diagram in Circulating Mode (Pump Not Shown for Clarity)

BInletcolo

C Outlet color stack

DRemoteco

E

Remote mix manifold

F Automa

G Return line to ﬂuid supply

rstack

lor stack

tic spray gun

333282B 29

Installation

Install an Expansion Kit

Expansion Kits are available to add valves or manifolds to your system. For each additional color/catalyst desired, order a Non-IS Expansion Kit and a corresponding IS Expansion Kit. See

Expansion Kits, page 69 for available kits.

NOTE: Remember that you may need up to 6 Non-IS control modules and up to 2 IS control modules.

Follow Steps 1–7 to install solenoids, manifolds, and valves, ﬁrst in the Non-IS area, and then in the IS area.

1. Remove electrical power from the system.

2. Relieve pressure as described in your PD2K

Operation Manual.

3. Open the control module cover. Install the

solenoid(s) and air ﬁtting(s) at the appropriate position(s) in the solenoid manifold. See

Setup the Modules, page 13. Connect one end

of the tubing to the solenoid’s air ﬁtting.

6. Install the valves as follows:

a. For a one valve kit, remove the plug

(4) and o-ring (2). Install a new o-ring (2), the valve (3), and retainer (5), using the valve installation tool. See

Replace a Color Valve, page 43.

b. For a manifold kit with one valve, install

the o-ring (2), valve (3), and retainer (5), using the valve installation tool. See

Replace a Color Valve, page 43.Installthe

plug (4) in the unused manifold port.

c. For a manifold kit with two valves, install

the o-rings (2), valves (3), and retainers (5), using the valve installation tool. See

Replace a Color Valve, page 43.

7. Install the o-ring(s) (12) and ﬂuid ﬁtting(s) (13).

8. For each color/catalyst, connect ﬂuid lines from the source to the input color/catalyst stack. Then, connect ﬂuid lines from each output valve to the corresponding remote color change valve.Install the air ﬁtting(s) (14).

9. Connect the tubing from the solenoid valve(s) (see step 3) to the ﬁtting(s) in both the IS and and Non-IS areas.

10. Install the control module covers.

11. Return the unit to service.

4. Connect the solenoid wires to the appropriate pins on the control module board. See

Electrical Schematics, page 36.

NOTE: If installing a one valve kit, it is not necessary to disassemble the manifold stack as shown in the ﬁgure. Skip step 5 and go on to step 6.

5. If your kit is adding a manifold block (1), remove the screws (10). Slide the existing manifolds off the rods (15, 16), keeping the manifolds in the correct order. Install the new manifold block (1). The new block must be in the bottom position to maintain correct location of the solvent and dump valves. Screw the rods (16) included in the kit into the existing rods. Slide the existing manifold blocks onto the rods, being sure that they are in the same positions as before. Ensure all o-rings (6,17)areinplace,theninstallthescrews(10).

30 333282B

Installation

Figure 13 Install an Expansion Kit (Low Pressure Valve Manifold Shown)

333282B 31

Troubleshootin

g

Troubleshooting

NOTE: Check all possible remedies before disassembling the system.

Color Change Solenoid Valves

NOTE: Refer to Electrical Schematics, page 36. 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 are loose.

3. Solenoid failure. Check the applicable solenoid’s LED; see Color Change Board, page 34. If lit,

Check that air pressure is at least 85 psi (0.6 MPa, 6.0 bar). Do not go above 100 psi (0.7 MPa, 7.0 bar).

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

proceed 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:

• In a non-hazardous location, replace the solenoid if voltage is 24 Vdc.

• In a hazardous location, replace the solenoid if voltage is between 9–15 Vdc.

Test the valves as explained under Maintenance Screen 4 in your PD2K Operation manual. Valves should open and close 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 the air supply has a 5 micron ﬁlter installed.

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

32 333282B

Cause Solution

Troubleshootin

g

4. Control boa failure.

rd or cable

Ifthereisnov LEDs D8, D9, an in the module a

If D9 is not lit:

• Verify the condition of the fuse (F1) and replace if necessary. See

Replace the Color Change Board Fuse, page 44.

• Check if the cable is disconnected or damaged.

• Check the isolation board. See the PD2K Repair-Parts manual.

If D8 is not b

• Cycle the system power.

• Check if the cable is disconnected or damaged.

• Check the isolation board. See the PD2K Repair-Parts manual.

If D10 is not occasionally blinking:

• Check if t

• Check the

oltage across the pins on the board or it is less than 9 Vdc, check

d D10. If they are lit and functioning properly, or other solenoids

re working properly, replace the color change board.

linking:

he cable is disconnected or damaged.

isolation board. See the PD2K Repair-Parts manual.

333282B 33

Troubleshootin

g

Color Change B

oard

NOTICE

To avoid damaging the circuit boards, wear Part No. 112190 grounding strap on your wrist and ground appropriately.

To avoid electrical component damage, remove all system power before plugging any connectors.

Figure 14 Color Change Board

34 333282B

Color Change Board Diagnostics

Troubleshootin

g

ID

D8

D9

D10

D27–D39, D41, D43–D46

F1 Fuse, 0.125

Component or In

LED (green) Blinks (heartbeat) during normal operation.

LED (green)

LED (yellow)

LED (green)

dicator

A, 125 V

Function

Turns on when board.

Turns on when board is communicating with electronic control.

Turn on when a signal is sent to actuate the related solenoid valve.

power is supplied to the

333282B 35

Electrical Sche

matics

Electrical Sc

hematics

NOTE: The electrical schematic illustrates all possible wiring expansions in a ProMix PD2K system. Some components shown are not included with all systems. NOTE: See Optional Cables and Modules, page 42, for a list of cable options.

RELAY

(16U820)

16W159

BREAKOUT MODULE PUMP 2

BREAKOUT MODULE PUMP 4

POWER MODULE

(24R257)

16W159

(24N527)

SPLITTER

(16P243)

4

CABLE (16T659) CABLE (16T659) CABLE (16T659) CABLE (16T659)

(24P658)

ENCODER AND MOTOR

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

PUMP V/P FOR

FLUID REG.

UP

DOWN

(16P812)

SOLENOID

MAC SERIES 46

FLOW SENSOR

(120278) OR G3000 METER (239716, 258718

16M510, 16M519)

(24P658)

ENCODER AND MOTOR

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

PUMP V/P FOR

FLUID REG.

UP

DOWN

(16P812)

SOLENOID

MAC SERIES 46

FLOW SENSOR

(120278) OR G3000 METER (239716, 258718

16M510, 16M519)

POWER IN

FAN

2 POSITION

SWITCH

(16U725)

CABLE 16T658

LINE FILTER

(16V446)

CABLE

16H078

TERMINAL BLOCK

(114095)

(24N527)

BREAKOUT MODULE PUMP 1

(24N527)

BREAKOUT MODULE PUMP 3

24V

POWER SUPPLY (16T660)

48V-10A POWER SUPPLY

TERMINAL BLOCKS WITH FUSES

16W159

FAN

(24P658)

ENCODER AND MOTOR

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

PUMP V/P FOR

FLUID REG.

UP

DOWN

(16P812)

SOLENOID

MAC SERIES 46

FLOW SENSOR

(120278)

OR G3000 METER

(239716, 258718

16M510, 16M519)

FAN

(24P658)

ENCODER AND MOTOR

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

PUMP V/P FOR

FLUID REG.

UP

DOWN

(16P812)

SOLENOID

MAC SERIES 46

FLOW SENSOR

(120278)

OR G3000 METER

(239716, 258718

16M510, 16M519)

Figure 15 Electrical Schematic, Sheet 1

INTEGRATION

GATEWAY

3

GATEWAY

(24R910)

CABLE (15V206)

2

CABLE

3

16T072

CAN

IS BOARD

(24M485)

CABLE

(16T280)

BARRIER

BOARD

(248192)

065161, 065159

5

CABLE

(121227)

AWI

5

(121227)

CABLE

3

(121001)

6

(24N935)

MODULE 1

COLOR CHANGE

CABLE

2

(15V206)

GCA

MODULE

EFCM

(24N913)

FLOW RATE ANALOG IN

1

CABLE (16V429)

2

CABLE

(15V206)

6

(24N935)

MODULE 2

COLOR CHANGE

FLOW RATE ANALOG IN

2

CABLE

(15V206)

6

(24N935)

MODULE 3

COLOR CHANGE

CABLE

2

(15V206)

GUN TRIGGER INPUTS

119159 119159 119159 119159

SOLENOID (121324)

PRESSURE SW (121323)

SOLVENT CUTOFF (121324) SWITCH (120278) SWITCH (120278)

SOLVENT METER (258718)

SAFETY INTERLOCK SWITCH

3

ADVANCED

CABLE

DISPLAY MODULE

(121003)

CABLE

1

(24N935)

MODULE 4

MODULE 5

CATALYST CHANGE

CABLE

2

(15V206)

(24E451)

COLOR CHANGE MODULE 7

(24R219)

COLOR CHANGE MODULE 8

(24R219)

(16V426)

BOOTH CONTROL (24M731)

HAZARDOUS LOCATION

NON-HAZARDOUS LOCATION

INTERFACES

MODULE 6

CATALYST CHANGE

GFB

SOLVENT

FLOW

INPUTS

LIGHT TOWER (15X472)

7

6

(24N935)

CABLE

1

(16V426)

36 333282B

Electrical Sche

matics

SPLITTER

(16P243)

UNUSED

POWER SUPPLY

(16T660)

L (BROWN)

N03 N03

2 POSITION

SWITCH

(16U725)

N04 N04

CABLE

(16T658)

L N

LINE

FILTER

(16V446)

L GRND N

CABLE

(16H078)

L N GRND

TERMINAL

BLOCK

(114095)

L N GRND

345

24V

2

1

UNUSED

GRND (GRN/YEL)

N (BLUE)

CABLE (16V429)

1

CONTINUED ON PAGE 3

2

3

CABLE

(15V206)

1 2 3 4 5

CAN IS BOARD

2

(NON IS)

(IS)

4

(24M485)

1 2 3 4 5

UNUSED

1 2 3 4 5

CABLE

(16T280)

1 2 3 1 2 3

BARRIER

BOARD

(248192)

13 A1(+) A2(-)

RELAY

14

N L GRND

48V-10A

POWER SUPPLY

(16U820)

+ -

+ - + - + - + -

F4

F3

F2

F1

+ - + - + - + -

DETAIL A, LOW PRESSURE PUMPS (24M706, 24M714)

BREAKOUT MODULE

(24N527)

2

1 2 3 4 5 1 2 3 4

WIRE HARNESS

(24P684)

CABLE (121227)

16T072

1 2 3 4 5

1

3

UNUSED

RED WIRE (065161)

BLACK WIRE (065159)

1 2 3 4 5 1 2 3 4

(24R257)

POWER MODULE

3

DRAIN/FOIL

CABLE

1 2 3 4 5

P3

AWI

GATEWAY

(24R910)

1 2 3

P4

4 5

(121227)

3

1 2 3

P3

4 5

INTEGRATION

5

GFB INTERFACE

(121324)

SOLVENT CUTOFF (121324)

SOLVENT

METER

(258718)

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

GROUND BAR

BREAKOUT MODULE PUMP 1 (24N527)

2

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 1

SEE DETAIL A OR B

3

1 2 3 4 5 1 2 3 4 5 1 2

TWISTED PAIR CABLE (16W159)

5

4

PUMP 1

(16P289 OR 16P290)

INLET TRANSDUCER

(16P289 OR 16P290)

OUTLET TRANSDUCER

DETAIL B, HIGH PRESSURE PUMPS (24M707, 24M715)

BREAKOUT MODULE

2

1 2 3 4 5 1 2 3 4

GATEWAY

5

6

1 2 3 4

(24N527)

WIRE HARNESS

(24P685)

1 2 3

P4

4 5

+12VDC COM UNUSED UNUSED +12VDC COM +12VDC COM

UNUSED

PUMP 1

+24VDC

V/P FOR FLUID REG.

PUMP 1

MANIFOLD

UNUSED UNUSED

UNUSED

CABLE

(121001)

3

1

7

3 4

5 6 7 8

COM

+24VDC

UP

DOWN

PUMP 1

METER

PUMP 1

(EITHER, 239716,

258718,16M510,

(16P812 QTY 2)

MAC SERIES 46

3

5 4 3

10

2 1

1 2 3

8

4 5

1 2 3 4 5 6

5

7 8 9 10 11 12

25 PIN D-SUB CABLE

(16T659)

1 2 3 4

+48V

COM

PWR (RED)

SIG (WHITE)

COM (BLACK)

SHIELD/GRN

G3000

OR 16M519)

GRND SCREW

DRAIN/FOIL

CONTINUED ON PAGE 3

GCA MODULE

(24N913)

12

4

252423222120191817161413121110 15987654321

BREAKOUT MODULE PUMP 2 (24N527)

3

2

FAN PUMP 1

+48V

COM

(24P658)

1 2 3 4 5 1 2 3 4

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 2

SEE DETAIL A OR B

1 2 3 4 5 1 2 3 4 5 1 2

TWISTED PAIR CABLE (16W159)

EFCM

252423222120191817161413121110 15987654321 252423222120191817161413121110 15987654321

5

4

PUMP 2

(16P289 OR 16P290)

INLET TRANSDUCER

(16P289 OR 16P290)

OUTLET TRANSDUCER

6

1 2 3 4

PUMP 2

V/P FOR FLUID REG.

25 PIN

(16T659)

D-SUB CABLE

4

1

3 4

COM

+24VDC

UP

DOWN

PUMP 2

MANIFOLD

(16P812 QTY 2)

MAC SERIES 46

7

5 6 7 8

G3000 METER PUMP 2

(EITHER, 239716, 258718,16M510,

OR 16M519)

PWR (RED)

SIG (WHITE)

COM (BLACK)

SCREW

88

1 2 3 4

+48V

COM

SHIELD/GRN

GRND

+48V

FAN PUMP 2

252423222120191817161413121110 15987654321

COM

(24P658)

DRAIN/FOIL

UNUSED UNUSED

UNUSED

UNUSED UNUSED

UNUSED

UNUSED UNUSED

POWER IN

UNUSED

DRAIN/FOIL

1 2 3 4 5 6 7 8 9

PUMP ENCODER AND MOTOR

MOTOR MOUNTING SCREW

UNUSED

UNUSED UNUSED

UNUSED

12

11

10

(16P037)

UNUSED

1 2 3 4 5 6 7 8 9

UNUSED

UNUSED UNUSED UNUSED

UNUSED

12

11

1 2

MOTOR MOUNTING SCREW

1 2 3 4 5 6 7 8 9

PUMP ENCODER AND MOTOR

10

(16P036)

1 2 3 4 5 6 7 8 9

UNUSED

10

Figure 16 Electrical Schematic, Sheet 2, Part 1

CONTINUED ON THE NEXT PAGE

333282B 37

Electrical Sche

matics

GUN TRIGGER INPUTS

SIG

1

COM

2

SIG

3

COM

4

SIG

5

COM

6

7

SIG

8

COM

9

SIG

10

COM

11

SIG

12

1 2 3 4 5 6

7

7 8 9

10

11

12

1 2 3

9

4 5

COM

FLOW RATE ANALOG IN 1 FLOW RATE ANALOG COMMON 1 FLOW RATE ANALOG IN 2 FLOW RATE ANALOG COMMON 2 FLOW RATE ANALOG IN 3 FLOW RATE ANALOG COMMON 3 FLOW RATE ANALOG IN 4 FLOW RATE ANALOG COMMON 4 SIG COM SIG COM

CABLE

(121003)

3

GCA MODULE

EFCM

(24N913)

34

252423222120191817161413121110 15987654321 252423222120191817161413121110 15987654321

119159

GFB PRESSURE SWITCH (121323) SOLVENT FLOW SWITCH 1 (120278)

SOLVENT FLOW SWITCH 2 (120278) SAFETY INTERLOCK SWITCH

1

ADVANCED

2

DISPLAY MODULE

3 4

(24E451)

5

1 2 3 4 5

LIGHT

TOWER

(15X472)

25 PIN

(16T659)

D-SUB CABLE

4

5

PUMP 3

(16P289 OR 16P290)

OUTLET TRANSDUCER

252423222120191817161413121110 15987654321

6

1 2 3 4

PUMP 3

V/P FOR FLUID REG.

3 4

COM

+24VDC

UP

PUMP 3

MANIFOLD

(16P812 QTY 2)

MAC SERIES 46

COM

DOWN

7

5 6 7 8

G3000

METER

PUMP 3

(EITHER, 239716, 258718,16M510,

OR 16M519)

1

BREAKOUT MODULE PUMP 3 (24N527)

3

2

1 2 3 4 5 1 2 3 4 1 2 3 4 5 1 2 3 4

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 3

SEE DETAIL A OR B

4

1 2 3 4 5 1 2 3 4 5 1 2

PUMP 3

(16P289 OR 16P290)

INLET TRANSDUCER

TWISTED PAIR CABLE (16W159)

Figure 17 Electrical Schematic, Sheet 2, Part 2

CONTI

NUED ON THE NEXT PAGE

PWR (RED)

SIG (WHITE)

COM (BLACK)

SCREW

25 PIN D-SUB CABLE

8

1 2 3 4

+48V

COM

SHIELD/GRN

FAN PUMP 3

GRND

(16T659)

COM

(24P658)

4

2

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 4

SEE DETAIL A OR B

5

PUMP 4

(16P289 OR 16P290)

OUTLET TRANSDUCER

252423222120191817161413121110 15987654321

6

1 2 3 4

PUMP 4

V/P FOR FLUID REG.

3 4

COM

+24VDC

UP

PUMP 4

MANIFOLD

(16P812 QTY 2)

MAC SERIES 46

7

COM

DOWN

1

BREAKOUT MODULE PUMP 4 (24N527)

3

4

1 2 3 4 5 1 2 3 4 5 1 2 1 2 3 4

PUMP 4

(16P289 OR 16P290)

INLET TRANSDUCER

TWISTED PAIR CABLE (16W159)

5 6 7 8

PWR (RED)

SIG (WHITE)

G3000 METER PUMP 4

(EITHER, 239716, 258718,16M510,

OR 16M519)

+48V

COM (BLACK)

SHIELD/GRN

GRND

SCREW

8

COM

+48V

FAN PUMP 4

COM

(24P658)

38 333282B

Electrical Sche

matics

FLUSH COLOR 1 COLOR 2

COLOR 3 COLOR 4 COLOR 5

COLOR 6 COLOR 7 COLOR 8

*FLUSH

COLOR 9

COLOR 10

COLOR 11 COLOR 12 COLOR 13

COLOR 14 COLOR 15 COLOR 16

CABLE (15V206)

2

MANIFOLD

+12VDC +12VDC +12VDC

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC +12VDC +12VDC

COM COM COM

1 2 3 4 5 6

2

1 2 3 4 5 6

FROM CAN IS BOARD (24M485) ON PAGE 2

2

345

1

COLOR

CHANGE

MODULE 1

(COLORS

6

1 THRU 8)

J8

J15

J14

1

2

6

J16

J10

345

COM

5

+12VDC

4

COM

J9

3

+12VDC

2

COM

1

+12VDC

6

COM

5

+12VDC

4

COM

3

+12VDC

2

COM

1

+12VDC

6

COM

5

+12VDC

4

COM

3

+12VDC

2

COM

1

+12VDC

CABLE

J8

J15

J14

2

345

1

COLOR

CHANGE

MODULE 2

(COLORS

9 THRU 16)

6

2

345

1

J16

J10

J9

(15V206)

6 5 4 3 2 1

COM +12VDC COM +12VDC COM +12VDC

MANIFOLD

DUMP COLOR 1 COLOR 2

COLOR 3 COLOR 4 COLOR 5

COLOR 6 COLOR 7 COLOR 8

DUMP* COLOR 9 COLOR 10

COLOR 11 COLOR 12 COLOR 13

COLOR 14 COLOR 15 COLOR 16

FLUSH CATALYST 1 CATALYST 2

CATALYST 3 CATALYST 4

FROM CAN IS BOARD (24M485) ON PAGE 2

MANIFOLD

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM UNUSED UNUSED

UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED

1 2 3 4 5 6

CATALYST

CHANGE MODULE 5 (CATALYST

1 THRU 4)

J8

J15

J14

2

1

6

345

J16

J10

COM +12VDC COM +12VDC COM +12VDC

COM +12VDC COM +12VDC UNUSED UNUSED

UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED

MANIFOLD

DUMP CATALYST 1 CATALYST 2

CATALYST 3 CATALYST 4

6 5 4

J9

3 2 1

6 5 4 3 2 1

2

*FLUSH COLOR 17 COLOR 18

COLOR 19 COLOR 20 COLOR 21

COLOR 22 COLOR 23 COLOR 24

MANIFOLD

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

1 2 3 4 5 6

CABLE

J8

J15

J14

2

345

1

COLOR

CHANGE

MODULE 3

(COLORS

17 THRU 24)

6

2

4

5

3

J9

J16

J10

1

(15V206)

6 5 4 3 2 1

COM +12VDC COM +12VDC COM +12VDC

Figure 18 Electrical Schematic, Sheet 3

* May be unused in some conﬁgurations.

CONTINUED ON THE NEXT PAGE

MANIFOLD

DUMP* COLOR 17 COLOR 18

COLOR 19 COLOR 20 COLOR 21

COLOR 22 COLOR 23 COLOR 24

2

COLOR 25 COLOR 26

COLOR 27 COLOR 28 COLOR 29

COLOR 30

CABLE (15V206)

*FLUSH

MANIFOLD

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM UNUSED UNUSED UNUSED UNUSED

22

1 2 3 4 5 6

CABLE

2

1

COLOR

CHANGE

MODULE 4

(COLORS

25 THRU 32)

J8

J15

J14

2

1

345

6

345

J16

J10

J9

(15V206)

6 5 4 3 2 1

COM +12VDC COM +12VDC COM +12VDC

COM +12VDC UNUSED UNUSED UNUSED UNUSED

MANIFOLD

DUMP* COLOR 25 COLOR 26

COLOR 27 COLOR 28 COLOR 29

COLOR 30

333282B 39

Electrical Sche

matics

CATALYST 3 CATALYST 4

CATALYST 1 CATALYST 2

FLUSH

MANIFOLD

+12VDC

COM

+12VDC

COM

+12VDC

COM

UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED

+12VDC

COM

+12VDC

COM

+12VDC

COM

UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED

1 2 3 4 5 6

22

1 2 3 4 5 6

CATALYST

CHANGE

MODULE 6

(CATALYST

3 THRU 4)

J8

J15

J14

2

1

CABLE

5

4

CATALYST

CHANGE

MODULE 5

(CATALYST

1 THRU 2)

J8

J15

J14

2

1

6

345

2

3

6

345

J9

J16

J10

1

J9

J16

J10

6 5 4 3 2 1

(15V206)

6 5 4 3 2 1

COM +12VDC COM +12VDC COM +12VDC

UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED

COM +12VDC COM +12VDC COM +12VDC

UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED

MANIFOLD

DUMP CATALYST 3 CATALYST 4

MANIFOLD

DUMP CATALYST 1 CATALYST 2

Figure 19 Electrical Schematic, Sheet 3, Alternate Conﬁguration for Catalyst Change Control

INUED ON THE NEXT PAGE

CONT

2

CABLE

2

345

1

COLOR

CHANGE

MODULE 4

(COLORS

25 THRU 32)

(15V206)

40 333282B

FROM CAN IS BOARD (24M485) ON PAGE 2

Electrical Sche

matics

COLOR FLUSH

COLOR 1 COLOR 2

COLOR 3 COLOR 4 COLOR 5

COLOR 6 COLOR 7 COLOR 8

COLOR 13 COLOR 14 COLOR 15

COLOR 16 COLOR 17 COLOR 18

COLOR 19 COLOR 20 COLOR 21

MANIFOLD

+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

COM

1 2 3 4

J8

5 6

1 2 3

J15

4 5 6

1 2 3 4

J14

5 6

1

1 2 3

J8

4 5 6

1 2 3

J15

4 5 6

1 2 3

J14

4 5 6

2

345

1

COLOR

CHANGE

MODULE 7

(COLORS

33 THRU 40)

7

2

345

1

CABLE

2

345

1

COLOR

CHANGE

MODULE 8

(COLORS

41 THRU 48)

7

5

2

3

4

J16

J10

J9

J16

J10

J9

(16V426)

1

NON-HAZARDOUS LOCATION

HAZARDOUS LOCATION

COM +12VDC COM +12VDC COM +12VDC

MANIFOLD

6 5 4 3 2 1

6

COM

5

+12VDC

4

COM

3

+12VDC

2

COM

1

+12VDC

6 5 4 3 2 1

CATALYST FLUSH CATALYST 1 CATALYST 2

CATALYST 3 CATALYST 4 COLOR 9

COLOR 10 COLOR 11 COLOR 12

COLOR 22 COLOR 23 COLOR 24

COLOR 25 COLOR 26 COLOR 27

COLOR 28 COLOR 29 COLOR 30

1

BOOTH CONTROL

Figure 20 Electrical Schematic, Sheet 3, Hazardous Location

333282B

CABLE

5

4

(24M731)

(16V426)

2

3

1

41

Electrical Sche

matics

Optional Cabl

NOTE: Thetotallengthofallcableusedinthesystemmustnotexceed150ft(45m). See the

Electrical Schematics, page 36.

M12 CAN Cables, for Hazardous Locations

NOTE: The total length of cable used in the

hazardous location must not exceed 120 ft (36 m).

Cable Part N

16V423

16V424

16V425

16V426

16V427

16V428

16V429

16V430

M12 CAN Ca

15U531

15U532

15V205

15V206

15V207

15V208

15U533

15V213

CAN Cables, for Non-Hazardous

Part No.

Cable

125306

123422

121000

121227

121001

121002

121003

120952

121201

121004

121228

es and Modules

o.

Location

Locations Only

Length ft (m

2.0 (0.6)

3.0 (1.0)

6.0 (2.0)

10.0 (3.0)

15.0 (5.0)

25.0 (8.0)

50.0 (16.

100.0 (32

bles, for Non-Hazardous

sOnly

2.0 (0.6)

3.0 (1.0)

6.0 (2.0)

10.0 (3.0)

15.0 (5.0)

25.0 (8.0)

50.0 (16.0)

100.0 (32.0)

Lengt

1.0 (0

1.3 (0

1.6 (

2.0 (

3.0 (

5.0 (

10.0

13.

20.

25.

50.

0)

.0)

hft(m)

.3)

.4)

0.5)

0.6)

1.0)

1.5)

(3.0)

0 (4.0)

0 (6.0)

0 (8.0)

0(15.0)

25 Pin D-SUB Cables, for Non-Hazardous

Locations Only

16T659

)

16V659

Alternates f

for Non-Haza

Module Part

CGMDN0*, DeviceNet CGMPB0*, Proﬁbus

CGMEP0*, Ethernet IP CGMPN0*, Proﬁnet

* You must purchase Map Token Kit 17C087 for usewiththesekits.

Alternate

by Part Num

Non-Hazar

Module Par

24T557 2 color/2

24T558 4 color/4

24T559 6 color/6

24T560 8 color/

Alternates for Color Change Modules by Part

Number (Factory Conﬁguration), for Hazardous

24T571 2 color/2 catalyst

24T572 4 color/2 catalyst

24T573 6 color/2 catalyst

24T574 8 color/2 catalyst, 13–24

24T774 12 color/2 catalyst

24T775 4 color/4 catalyst

24T776 6 color/4 catalyst

24T777 8 color/4 catalyst

24T778 12 color/4 catalyst, 13–30

24T779 13–18 color

or Communication Module 24R910,

No.

s for Color Change Modules

ber (Factory Conﬁguration), for

dous Locations Only, see page 61

tNo.

Locations Only, see page 62

2.5 (0.8)

6.0 (1.8)

rdous Locations Only

Module Part

Descripti

color

on

catalyst

8 catalyst

No.

2

4

333282B

Repair

• To avoid electric shock, turn off power at the main circuit breaker before opening the control module.

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

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

NOTICE

To avoid damaging the circuit boards, wear Part No. 112190 grounding strap on your wrist and ground appropriately.

Repair

Figure 21 Remove Retainer

3. Using the other end of the tool (114), screw it all the way onto the valve (3). Pull the valve from the manifold.

To avoid electrical component damage, remove all system power before plugging any connectors.

Replace a Color Valve

Use the following procedure to replace a valve, whether the valve is part of the color stacks near the pump or part of the remote color stacks.

1. Flush and relieve pressure as described in your PD2K operation manual.

2. Engage the pins of the tool (114) with the notches in the retainer (5) and unscrew the retainer.

Figure 22 Remove the Valve

NOTE: See manual 332454 to repair the valve.

4. Install the valve in the reverse order of disassembly. Be sure all o-rings are in place and lubricated, and that the valve is seated completely in the manifold.

5. Return the system to service.

333282B 43

Repair

Replace a Sole

1. Remove electrical power from the system.

2. Remove air supply pressure from the system.

3. Remove the color change module cover (304).

4. Disconnect the two solenoid wires from the color change board (302). See the color change board wiring diagrams in the

Electrical Schematics, page 36.

5. Remove the solenoid (310) from the manifold (309).

6. Install the new solenoid.

7. Connect the two solenoid wires to the color change board (302). See the color change board wiring diagrams in the

Electrical Schematics, page 36.

8. Reinstall the cover.

noid

Replace the Co

lor 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.

2. Remove the color change module cover (304).

3. Locate fuse F1 (302a) on the color change board. Pull the fuse away from the board.

4. Install the new fuse.

5. Reinstall the cover. Restore electrical power to the system.

4

333282B

Repair

Replace the Co

lor Change Board

NOTICE

To avoid damaging the circuit boards, wear Part No. 112190 grounding strap on your wrist and ground appropriately.

To avoid electrical component damage, remove all system power before plugging any connectors.

1. Remove electrical power from the system.

2. Remove the col

3. Note where each cable is connected, then

disconnect all cables from the color change board connectors.

4. Remove the seven mounting screws (303) and

the board (302).

5. Install the new board. Reinstall the screws.

6. Reconnect the cables to the proper

connectors, as noted in step 3. See

Electrical Schematics, page 36.

7. Reinstall the cover (304). Restore electrical

power to the system.

or change module cover (304).

re 23 Control Module Repair (Non-IS Module

Figu

n)

Show

333282B 45

Parts

Non-IS Color Change Kits

Detail of Back Pressure Regulator (High Pressure Outlet Stack only)

46 333282B

Parts

Ref. No.

101 24U237

102

103 100157

104 103195

105 100016

106 100015 NUT, hex; 1/

107 24N346

108

109 15V206

110 16V819

111 24U236

114

Part No.

◆

Description

BRACKET, mounting

KIT, manifold, valve

SCREW, cap, h 1/4–20 x 0.37

SCREW, cap, hex head; 1/4–20 x 4.0 in. (101 mm)

WASHER, lock; 1/4

HOSE, ﬂuid; 1/4 npsm (fbe);

2.5 ft (0.76 m); ptfe

KIT, module, control 1

CABLE, CA 10 ft (3.0

GROMMET, cable

TOOL, repair, valve (not shown)

TOOL, installation, valve (not shown)

5m)

ex head;

5in.(10mm)

4–20

N; 5–pin female;

Qty

1

2

4

2

1

Ref. No.

115 598095

120 222200

121 113070 NIPPLE; 3/8 npt x 1/4 npt; sst;

122 110290

123 112564

Part No.

Description

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

REGULATOR, back pressure; used on high pressure kits only (see detail drawing); see manual 307892

used on high pressure kits only (see detail drawing)

TEE; 1/4 npt(f); sst; used on high pressure kits only (see detail drawing)

GAUGE, pressure, ﬂuid; used on high pressure kits only (see detail drawing)

Qty

◆

1

2

1

◆ See the following tables for the part number used in your color change kit.

Low Pressure Non-IS Kits

Kit No. Kit Description

Standard Valve Manifold Kits (102) [see

Low Pressure Valve Manifold Kits, page 53 for

Control Module Kit (108) [see

Non-IS Color Change Control Modules, page

64 for parts]

all available kits]

Low Pressure Non-Circulating Color Change Kits

24R915 2 color or 2

24T458 24T557 24U239

catalyst

24R916 4 color or 4

24T460 24T558 24U239

catalyst

24R917 6 color 24T462 24T559 24U239

24R918 8 color 24T464 24T560 24U239

Low Pressure Circulating Color Change Kits

24R919 2 color 24T488 24T557 24U239

24R920 4 color 24T490 24T558 24U239

24R921 6 color 24T492 24T559 24U239

Tool (114)

Tube Length (115)

60 ft (18.3 m)

120 ft (36.6 m)

210 ft (64.05 m)

360 ft (109.8 m)

60 ft (18.3 m)

120 ft (36.6 m)

210 ft (64.05 m)

24R922 8 color 24T494 24T560 24U239

333282B

360 ft (109.8 m)

47

Parts

High Pressure Non-IS Kits

Kit No. Kit Description

High Pressure Non-Circulating Color Change Kits

24R959 2 color or 2

catalyst

24R960 4 color or 4

catalyst

24R961 6 color 24T652 24T559 24U240

24R962 8 color 24T654 24T560 24U240

High Pre

24T579 2 catalyst 24U182 24T557 24U240

24T580 4 catal

24R963 2 color 24T678 24T557 24U240

ssure Acid Compatible Non-Circulating Catalyst Change Kits

yst

Standard Valve Manifold Kits (102) [see

High Pressure Valve Manifold Kits, page 58 for

all available kits]

24T648 24T557 24U240

24T650 24T558 24U240

24U183 24T558 24U240

High P

ressure Circulating Color Change Kits

Control Module Kit (108) [see

Non-IS Color Change Control Modules, page 64 for parts]

Tool (114)

Tube Length (115)

60 ft (18.3 m

120 ft (36.6 m)

210 ft (64.05 m)

360 ft (109.8 m)

60 ft (18.3 m)

120 ft (36.6 m)

60 ft (18.3 m)

)

64

24R9

24R965 6 color 24T682 24T559 24U240

24R966 8 color 24T684 24T560 24U240

4col

or

24T6

80

24T5

58

24U2

40

120 ft (36.6 m)

ft (64.05 m)

210

360 ft (109.8 m)

48 333282B

Notes

Parts

333282B 49

Parts

IS Color Chang

eKits

Ref. No.

101

103 24V351

104 24N346

105

10

107 16Y954

108 100015 NUT, hex 4

109

Part No. Description

◆

16W564 Low Pressure

16W563 High Pressure

◆

6

104429 Low Pressure

113469 High Pressure

KIT, manifold, valve; . See

Valve Manifold Kits, page 53 for available kits.

MANIFOLD, mix, remote

HOSE, coupled, 2.5 ft.

HOSE

T, module, control

KI

BRACKET, manifold

CREW, cap, hex

S

, static mixer

Qty

2

1

2

1

2

4

Ref. No.

110

111

112 223

113 100016

114 16V429

Part No. Description

TOOL, repair, color change valve, not shown

24U236 Low Pressure

24R124 High Pressure

, installation, color

TOOL

ge valve, not shown

chan

24U239 Low Pressure

24U240 High Pressure

547

WIRE,assembly,25ft.

WASHER, lock

CABLE, CAN, 50 ft (15.2 m); not shown

Qty

1

2

4

1

◆ See the following tables for the part number used in your color change kit.

50 333282B

Low Pressure IS Kits

Parts

Kit No. Kit Description

Low Pressure Non-Circulating Color Change Kits

24V157 1 color and 1 catalyst

24V158 2 colors and 1 catalyst 24T458, 24T457 24T571

24V159 4 colors and 1 catalyst 24T460, 24T457 24T572

24V160 6 colors an

24V161 8 colors and 1 catalyst 24T464, 24T457 24T574

24V162 12 colors and 1 catalyst 24T468, 24T369 24T774

24V331 2 colors a

24V332 4 colors and 2 catalysts 24T460, 24T458 24T572

24V333 6 colors

24V334 8 colors and 2 catalysts 24T464, 24T458 24T574

24V335 12 colors and 2 catalysts 24T468, 24T458 24T774

3

24V34

24V344 6 colors and 4 catalysts 24T462, 24T460 24T776

4colo

d 1 catalyst

nd 2 catalysts

and 2 catalysts

rs and 4 catalysts

Standard Valve Man-

ifold Kits (101) [see

Low Pressure Valve

Manifold Kits, page 53 for

all available kits]

24T457 (2)

24T462, 24

24T458 (2)

24T462,

24T460 (2)

T457

24T458

Control Module Kit (106) [see

IS Color Change Control Modules, page 66 for

parts]

24T571

24T573

24T571

24T573

24T77

5

45

24V3

24V346 12 colors and 4 catalysts 24T468, 24T460 24T778

24V166 1 color and 1 catalyst

24V167 2 colors and 1 catalyst 24T488, 24T487 24T571

24V308 4 colors and 1 catalyst 24T490, 24T487 24T572

V309

24

24V326 8 colors and 1 catalyst 24T494, 24T487 24T574

24V327 12 colors and 1 catalyst 24T498, 24T487 24T774

4V336

2

24V337 4 colors and 2 catalysts 24T490, 24T488 24T572

24V338 6 colors and 2 catalysts 24T492, 24T488 24T573

24V339 8 colors and 2 catalysts 24T494, 24T488 24T574

24V340 12 colors and 2 catalysts 24T498, 24T488 24T774

24V347 4 colors and 4 catalysts

24V348 6 colors and 4 catalysts 24T492, 24T490 24T776

24V349 8 colors and 4 catalysts 24T494, 24T490 24T777

ors and 4 catalysts

8col

Low Pressure Circulating Color Change Kits

olors and 1 catalyst

6c

colors and 2 catalysts

2

64, 24T460

24T4

487 (2)

24T

T492, 24T487

24

24T488 (2)

24T490 (2)

77

24T7

24T571

T573

24

4T571

2

24T775

24V350 12 colors and 4 catalysts 24T498, 24T490 24T778

333282B 51

Parts

High Pressure IS Kits

Kit No. Kit Description

High Pressure Non-Circulating Color Change Kits

24V359 1 color and 1 catalyst

24V360 2 colors and 1 catalyst 24T648, 24T647 24T571

24V361 4 colors and 1 catalyst 24T650, 24T647 24T572

24V362 6 colors an

24V363 8 colors and 1 catalyst 24T654, 24T647 24T574

24V364 12 colors and 1 catalyst 24T658, 24T647 24T774

24V381 2 colors a

24V382 4 colors and 2 catalysts 24T650, 24T648 24T572

24V383 6 colors

24V384 8 colors and 2 catalysts 24T654, 24T648 24T574

24V385 12 colors and 2 catalysts 24T658, 24T648 24T774

6

24V39

24V397 6 colors and 4 catalysts 24T652, 24T650 24T776

4colo

d 1 catalyst

nd 2 catalysts

and 2 catalysts

rs and 4 catalysts

Standard Valve Manifold Kits (101) [see

Low Pressure Valve Manifold Kits, page 53 for

all available kits]

24T647 (2)

24T652, 24

24T648 (2)

24T652,

24T650 (2)

T647

24T648

Control Module Kit (106) [see

IS Color Change Control Modules, page 66 for

parts]

24T571

24T573

24T571

24T573

24T77

5

98

24V3

24V399 12 colors and 4 catalysts 24T658, 24T650 24T778

24V369 1 color and 1 catalyst

24V370 2 colors and 1 catalyst 24T678, 24T677 24T571

24V371 4 colors and 1 catalyst 24T680, 24T677 24T572

V372

24

24V373 8 colors and 1 catalyst 24T684, 24T677 24T574

24V374 12 colors and 1 catalyst 24T688, 24T677 24T774

4V389

2

24V390 4 colors and 2 catalysts 24T680, 24T678 24T572

24V391 6 colors and 2 catalysts 24T682, 24T678 24T573

24V392 8 colors and 2 catalysts 24T684, 24T678 24T574

24V393 12 colors and 2 catalysts 24T688, 24T678 24T774

24V402 4 colors and 4 catalysts

24V403 6 colors and 4 catalysts 24T682, 24T680 24T776

24V404 8 colors and 4 catalysts 24T684, 24T680 24T777

ors and 4 catalysts

8col

High Pressure Circulating Color Change Kits

olors and 1 catalyst

6c

colors and 2 catalysts

2

54, 24T650

24T6

677(2)

24T

T682, 24T677

24

24T678 (2)

24T680 (2)

77

24T7

24T571

T573

24

4T571

2

24T775

24V405 12 colors and 4 catalysts 24T688, 24T680 24T778

52 333282B

Parts

Valve Manifol

The low pressure and high pressure valve manifold kits listed in this section are used in both the Non-IS and IS color valve stacks.

dKits

Low Pressure Valve Manifold Kits

Non-Circulating Valve Manifold Kits

Kit No.

24T457 A 2 valves

24T458 A 3 valves

24T459 A 4 valves

24T460 A 5 valves

24T461 A 6 valves

24T462 A 7 valves

24T463 A 8 valves

24T464 A 9 valves

24T465 A 10 valve

24T466 A 11 valves

Series

Kit Description

s

Circulating Valve Manifold Kits

Kit No.

24T487 A 2 valves

24T488 A 3 valves

24T489 A 4 valves

24T490 A 5 valves

24T491 A 6 valves

24T492 A 7 valves

24T493 A 8 valves

24T494 A 9 valves

24T495 A 10 valve

24T496 A 11 valves

Series

Kit Description

s

24T467 A 12 valves

8

24T46

24T469 A 14 valves

24T470 A 15 valves

71

24T4

24T472 A 17 valves

24T473 A 18 valves

474

24T

24T475 A 20 valves

24T476 A 21 valves

T477

24

24T478 A 23 valves

24T479 A 24 valves

4T480

2

24T481 A 26 valves

24T482 A 27 valves

24T483 A 28 valves

A13val

A16va

A19v

A22

A2

ves

lves

alves

valves

5valves

24T497 A 12 valves

8

24T49

24T499 A 14 valves

24T500 A 15 valves

01

24T5

24T502 A 17 valves

24T503 A 18 valves

504

24T

24T505 A 20 valves

24T506 A 21 valves

T507

24

24T508 A 23 valves

24T509 A 24 valves

4T510

2

24T511 A 26 valves

24T512 A 27 valves

24T513 A 28 valves

A13val

A16va

A19v

A22

A2

ves

lves

alves

valves

5valves

24T484 A 29 valves

24T485 A 30 valves

24T486 A 31 valves

24T514 A 29 valves

24T515 A 30 valves

24T516 A 31 valves

333282B 53

Parts

Valve Manifold Kit Parts

54 333282B

Parts

Ref. No.

1 16P259

2

3

4 24R051

5

6 111457

7

8 24T522

9 157974

10 104092

11 100179 NUT, he

Low Pre

Kit No.

24T457

24T45

Part No. Description

MANIFOLD

111450

24T441

24T442

16N256 RETAINER, nut

24T521

O-RING; chemically resistant

VALVE, for non-circulating kits; includes item 2

VALVE, for circulating kits; includes item 2

PLUG, cc valve

O-RING; ptfe

PLATE, outlet, manifold

PLATE, en

WASHER, plain

SCREW, cap, socket head; 10–24 x 0.625 in. (16 mm)

d, manifold

x; 10–24

Qty

★

Ref. No.

12 104893

13 24T523

14 111328

15 24T525

16 24T524

17 111504

18 557716

19 104644

★ See the following tables to determine the quantity of each part in your valve manifold kit.

ssure Non-Circulating Valve Manifold Kit Part Quantities

Reference Numbers

123

1

2

8

5

4

2202211333203120

43143113443301

7

6

8 101213141516171819

24T459 244043113

Part No. Description

O-RING; ptfe

FITTING, ﬂuid; 7/16–20 x 1/4 npt(m)

CONNECTOR, t 10–32(m) x 5/ mm) OD tube

ROD, connecting; 3 in. (76 mm)

ROD, connecting; 1.5 in. (38 mm)

O-RING; chemically resistant

PLUG; 7/16–20

PLUG, screw; 10–32 x 0.156 in. (4 mm)

55

3

4

Qty

ube;

32 in. (4

★

5

2

0140

24T460 3 6

61

24T4

24T462

24T463

464

24T

24T465

24T466

4T467

2

24T468

24T469

24T470

24T471

24T472

24T473

24T474

24T475

3

4

5

6

7

8

9

10

5

16411366

66064113

7

8

18

8808

5

11388

5

11399860180

77

5

331

7

2

633160

7

60192

10 9 1 10 6 1 1 3 10 10 9 6 3 1 11 2

10100106113111110631100

12 11 1 12

212

1

01

7

113121211901132

7

2

11313131

2

901120

14131148113141413931152

14140148113151514931140

16 15 1 16 9 1 1 3 16 16 15 12 0 1 17 2

16 16 0 16 9 1 1 3 17 17 16 12 0 1 16 0

18 17 1 18 10 1 1 3 18 18 17 12 3 1 19 2

18 18 0 18 10 1 1 3 19 19 18 12 3 1 18 0

20 19 1 20 11 1 1 3 20 20 19 15 0 1 21 2

20 20 0 20 11 1 1 3 21 21 20 15 0 1 20 0

333282B 55

Parts

Kit No.

24T476

24T477

24T478

24T479

24T480

24T481

24T482

24T483

24T484

24T485

24T486

Reference Numbers

5

123

11

22 21 1 22 12 1 1 3 22 22 21 15 3 1 23 2

11

22 22 0 22 12 1 1 3 23 23 22 15 3 1 22 0

12

24 23 1 24 13 1 1 3 24 24 23 18 0 1 25 2

12

24 24 0 24 13 1 1 3 25 25 24 18 0 1 24 0

13

26 25 1 26 14 1 1 3 26 26 25 18 3 1 27 2

13

26 26 0 26 14 1 1 3 27 27 26 18 3 1 26 0

14

28 27 1 28 15 1 1 3 28 28 27 21 0 1 29 2

14

28 28 0 28 15 1 1 3 29 29 28 21 0 1 28 0

15

30 29 1 30 16 1 1 3 30 30 29 21 3 1 31 2

15

30 30 0 30 16 1 1 3 31 31 30 21 3 1 30 0

16

32 31 1 32 17 1 1 3 32 32 31 24 0 1 33 2

4

7

6

8 101213141516171819

56 333282B

Low Pressure Circulating Valve Manifold Kit Part Quantities

Parts

Kit No.

24T487

24T488

5

123

1

22022113

2

43143113

4

6

Reference Numbers

7

8 101213141516171819

55

77

203100

330122

24T489 244043113994

24T490 3 6

24T491

24T492

24T493

24T494

24T495

24T496

24T497

24T498

24T499

24T500

24T501

24T502

24T503

24T50

24T505

24T506

07

24T5

24T508

24T509

T510

24

24T511

24T512

4T513

2

24T514

24T515

24T516

4

3

4

5

6

7

8

9

10

11

12

13

14

1

15

16

4

5

1641131111533122

660641131313633100

7

8

18

8808

5

1131515760122

5

1131717860100

10911061131919963122

1010010611321211063100

12 11 1 12

12 12 0 12

7

11323231190122

7

11325251290100

1413114811327271393122

1414014811329291493100

16151 169 1 1 3 313115120 1 2 2

16160 169 1 1 3 333316120 1 0 0

18171 18101 1 3 353517123 1 2 2

18180 18101 1 3 373718123 1 0 0

20191 20111 1 3 393919150 1 2 2

20200 20111 1 3 414120150 1 0 0

22211 22121 1 3 434321153 1 2 2

22220 22121 1 3 454522153 1 0 0

24231 24131 1 3 474723180 1 2 2

24240 24131 1 3 494924180 1 0 0

26251 26141 1 3 515125183 1 2 2

26260 26141 1 3 535326183 1 0 0

28 27 1 28 15 1 1 3

282802815113

55 55

57 57

27210122

28210100

30291 30161 1 3 595929213 1 2 2

30300 30161 1 3 616130213 1 0 0

32311 32171 1 3 636331240 1 2 2

3

0100

333282B 57

Parts

High Pressure Valve Manifold Kits

Non-Circulating Valve Manifold Kits

Kit No.

24T647 A 2 valves

24T648 A 3 valves

24T649 A 4 valves

24T650 A 5 valves

24T651 A 6 valves

24T652 A 7 valves

24T653 A 8 valves

24T654 A 9 valves

24T655 A 10 valves

24T656 A 11 valves

24T657 A 12 valves

24T658 A 13 valve

24T659 A 14 valves

24T660 A 15 valves

24T661 A 16 valv

Series

Kit Description

es

Circulating Valve Manifold Kits

Kit No.

24T677 A 2 valves

24T678 A 3 valves

24T679 A 4 valves

24T680 A 5 valves

24T681 A 6 valves

24T682 A 7 valves

24T683 A 8 valves

24T684 A 9 valves

24T685 A 10 valves

24T686 A 11 valves

24T687 A 12 valves

s

24T688 A 13 valve

24T689 A 14 valves

24T690 A 15 valves

24T691 A 16 valv

Series

Kit Description

s

es

24T662 A 17 valves

24T663 A 18 valves

4

24T66

24T665 A 20 valves

24T666 A 21 valves

67

24T6

24T668 A 23 valves

24T669 A 24 valves

T670

24

24T671 A 26 valves

24T672 A 27 valves

4T673

2

24T674 A 29 valves

24T675 A 30 valves

24T676 A 31 valves

24T845 (acidcatalyzed)

24T846 (acidcatalyzed)

A19val

A22va

A25

A2

A3valves

A5valves

ves

lves

valves

8valves

24T692 A 17 valves

24T693 A 18 valves

4

24T69

24T695 A 20 valves

24T696 A 21 valves

97

24T6

24T698 A 23 valves

24T699 A 24 valves

T700

24

24T701 A 26 valves

24T702 A 27 valves

4T703

2

24T704 A 29 valves

24T705 A 30 valves

24T706 A 31 valves

A19val

A22va

A25

A2

ves

lves

valves

8valves

58 333282B

Valve Manifold Kit Parts

Parts

333282B 59

Parts

Ref. No.

1

2

3

4 24R052

5

6 111457

7

8 24T726

10 111820

12 104893

Part No. Description

16N271

111450

24T581

24T582

24T583

16N269 RETAINER, nut

24T725

MANIFOLD, for circulating kits

O-RING; chemically resistant

VALVE, for no kits; includ

VALVE, for circulating kits; includes item 2

VALVE, for non-circulating, acid compatible kits; includes item 2

PLUG, cc valve

O-RING; ptfe

PLATE, outlet, manifold

PLATE, end, manifold

SCREW, cap, socket head; 10–24 x 0.75 in. (19 mm)

O-RING

n-circulating

es item 2

;ptfe

Qty

★

Ref. No.

13 24T523

14 111328

15 24T729

16 24T728

18 557716

19 104644

Part No. Description

FITTING, ﬂuid; 7/16–20 x 1/4 npt(m)

CONNECTOR, tube; 10–32(m) x 5/32 in. (4 mm) OD tube

ROD, connect (84 mm)

ROD, connecting; 1.645 in. (42 mm)

PLUG; 7/16–20

PLUG, screw; 10–32 x 0.156 in. (4 mm)

Qty

ing; 3.290 in.

★

★ See the following tables to determine the quantity of each part in your valve manifold kit.

High P

ressure Non-Circulating Valve Manifold Kit Part Quantities

.

Kit No

24T647

48

24T6

5

123

1

220221133320100

2

431431134431012

4

7

6

Reference Numbers

8 1012131415161819

24T649 244043113

24T650 3 6

651

24T

24T652

24T653

T654

24

24T655

24T656

4T657

2

24T658

24T659

24T660

24T661

24T662

3

4

5

6

7

8

9

5

16411366

66064113

7

8

18

8808

5

11388

5

1139982000

1091106113101092112

10100 106 1 1 3 1111102 1 0 0

12 11 1 12

2

1

2

1

01

7

1131212113012

7

2

113131

14131 148 1 1 3 1414133 1 1 2

14140 148 1 1 3 1515143 1 0 0

16151 169 1 1 3 1616154 0 1 2

16160 169 1 1 3 1717164 0 0 0

18171 18101 1 3 1818174 1 1 2

55

77

3

1

4

5

000

1112

61100

7

2012

2

1

3000

60 333282B

Parts

Kit No.

24T663

24T664

24T665

24T666

24T667

24T668

24T669

24T670

24T671

24T672

24T673

24T674

24T675

24T676

24T845

24T846

Reference Numbers

5

123

9

18 18 0 18 10 1 1 3 19 19 18 4 1 0 0

10

20 19 1 20 11 1 1 3 20 20 19

10

20 20 0 20 11 1 1 3 21 21 20

11

22 21 1 22 12 1 1 3 22 22 21

11

22 22 0 22 12 1 1 3 23 23 22

12

24 23 1 24 13 1 1 3 24 24 23 6 0 1 2

12

24 24 0 24 13 1 1 3 25 25 24 6 0 0 0

13

26 25 1 26 14 1 1 3 26 26 25 6 1 1 2

13

26 26 0 26 14 1 1 3 27 27 26 6 1 0 0

14

28 27 1 28 15 1 1 3 28 28 27

14

28 28 0 28 15 1 1 3 29 29 28

15

30 29 1 30 16 1 1 3 30 30 29

15

30 30 0 30 16 1 1 3 31 31 30

16

32 31 1 32 17 1 1 3 32 32 31 8 0 1 2

2

431431134431012

3

6

4

5

16411366

7

6

8 1012131415161819

5

012

5

000

5

112

5

100

7

012

7

000

7

112

7

100

5

1112

333282B 61

Parts

High Pressure Circulating Valve Manifold Kit Part Quantities

Kit No.

24T677

24T678

5

123

1

22022113

2

43143113

4

6

Reference Numbers

7

8 1012131415161819

55

77

20100

31022

24T679 244043113994

24T680 3 6

24T681

24T682

24T683

24T684

24T685

24T686

24T687

24T688

24T689

24T690

24T691

24T692

24T693

24T69

24T695

24T696

97

24T6

24T698

24T699

T700

24

24T701

24T702

4T703

2

24T704

24T705

24T706

4

3

4

5

6

7

8

9

10

11

12

13

14

1

15

16

4

5

1641131111

66064113131361100

7

8

18

8808

5

1131515

5

113171782000

10 9 1 10 6 1 1 3 19 19 9 2 1 2 2

10 10 0 10 6 1 1 3 21 21 10 2 1 0 0

12 11 1 12

12 12 0 12

7

1132323113022

7

1132525123000

14 13 1 14 8 1 1 3 27 27 13 3 1 2 2

14 14 0 14 8 1 1 3 29 29 14 3 1 0 0

16 15 1 16 9 1 1 3 31 31 15 4 0 2 2

16 16 0 16 9 1 1 3 33 33 16 4 0 0 0

18 17 1 18 10 1 1 3 35 35 17 4 1 2 2

18 18 0 18 10 1 1 3 37 37 18 4 1 0 0

20 19 1 20 11 1 1 3 39 39 19

20 20 0 20 11 1 1 3 41 41 20

22 21 1 22 12 1 1 3 43 43 21

22 22 0 22 12 1 1 3 45 45 22

24 23 1 24 13 1 1 3 47 47 23 6 0 2 2

24 24 0 24 13 1 1 3 49 49 24 6 0 0 0

26 25 1 26 14 1 1 3 51 51 25 6 1 2 2

26 26 0 26 14 1 1 3 53 53 26 6 1 0 0

28 27 1 28 15 1 1 3

8

2

8

2

0281

5

113

55 55

57 57

30 29 1 30 16 1 1 3 59 59 29

30 30 0 30 16 1 1 3 61 61 30

32 31 1 32 17 1 1 3 63 63 31 8 0 2 2

5

7

27

2

8

1

000

1122

2022

5

022

5

000

5

122

5

100

7

022

7

000

7

122

7

100

62 333282B

Notes

Parts

333282B 63

Parts

Color Change C

Non-IS Color Change Control Modules

ontrol Module Kits

64 333282B

Parts

Ref. No.

301

302 24T566

302a 123690

303 112324

304 24T562

305 119162

307 116343

308 123691

309 24T563

310 16P316

311 117831

312 103833

313 24T565

314 113418

315 10013

Part No.

———

Description

PANEL 1

BOARD, circuit

FUSE; 125 mA

SCREW, machine, pan head; 4–40 x 0.25 in. (6 mm)

COVER

CONNECTOR,

SCREW, ground; M5 x 0.8

HOLDER, fuse

MANIFOLD

SOLENOID

SCREW, machine, pan head; 6–32 x 0.5 in. (13 mm)

SCREW, 10–32 x

PLUG; 5/8–32; includes item 314

O-RING; buna-N

9

PLUG, pipe; 1/8 npt

6–position

machine, pan head;

0.375 in. (10 mm)

Qty

1

6

1

★

1

2

★

4

8

★

14

3

Ref. No.

316

317 115671

318 112698

319 590332

320 598095

321

322

324 114263

332 151395

Part No.

C06061

———

Description

MUFFLER 2

FITTING, connector; 1/8 npt(m) x 1/4 in. (6 mm) OD tube

ELBOW; 1/8 np (6 mm) OD tube

TUBE; polyethylene; 1/4 in. (6 mm) OD

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

STRAP, tie

FERRULE ★

FITTING, connector; 1/8 npt(m) x 5/32 in. (4 mm) OD tube

WASHER

t(m) x 1/4 in.

Qty

1

2

1

★

4

★ See the following table to determine the quantity of each part in your control module kit.

Parts labeled — — — are not available separately.

Non-IS Control Module Part Quantities

Find your module kit no. in the left column and the desired reference number inthetoprowtoﬁndthepart quantity used in your control module kit.

Kit No. Kit

Description

6–Position Connector (305)

Solenoid (310)

Plug (313) Tie Strap

(321)

Ferrule (322)

Connector Fitting (324)

24T557 2 color 2 6 12 4 12 6

24T558 4 color 4 10 8 4 20 10

24T559 6 color 6 14 4 4 28 14

24T560 8 color 6 18 0 4 36 18

333282B 65

Parts

IS Color Change Control Modules

66 333282B

Parts

Ref. No.

301

302 24T566

302a 123690

303 112324

304 24U567

305 119162

307 116343

308 123691

309 15T636

310 121324

311

Part No.

———

16M00 7

312 103833

313 121628

315 100139

316

317 115671

C0606

Description

PANEL 1

BOARD, circuit

FUSE; 125 mA

SCREW, machine, pan head; 4–40 x 0.25 in. (6 mm)

COVER

CONNECTOR,

SCREW, ground; M5 x 0.8

HOLDER, fuse

MANIFOLD

SOLENOID

SCREW, machine, serrated head; 10–32 x 0.5 in. (13 mm)

SCREW, machine, pan head; 10–32 x 0.375 in. (10 mm)

SCREW, self-sealing; 4–40 x

0.25 in. (6 mm)

PLUG, pipe; 1/8 npt

MUFFLER 2

1

FITTING, connector; 1/8 npt(m) x 1/4 in. (6 mm) OD tube

6–position

Qty

1

6

1

6

1

2

★

4

★

3

1

Ref. No.

318 112698

319 590332

320 598095

321

322

324 109193

331 16U743

332 16U744 PLATE, non-conductive 1

333 16U745 PLATE, ground 1

334 16U746

335 16W501LABEL, instructions 1

339 102794 NUT, he

340 101764

341 188773

Part No.

———

Description

ELBOW; 1/8 npt(m) x 1/4 in. (6 mm) OD tube

TUBE; polyethylene; 1/4 in. (6 mm) OD

TUBE; nylon; OD

STRAP, tie

FERRULE ★

ELBOW, con (m) x 5/32 i

SPACER

SCREW, pan-head; 4–40

WASHER, lock

WASHER, ﬂat

5/32 in. (4 mm)

nector; 10–32

n. (4 mm) OD tube

x

Qty

2

1

2

★

6

3

7

★ See the following table to determine the quantity of each part in your control module kit.

labeled — — — are not available separately.

Parts

IS Control Module Part Quantities

Find your module kit no. in the left column and the desired reference number inthetoprowtoﬁndthepart quantity used in your control module kit.

Kit No. Kit

Description

24T571 2 color and 2

noid

Sole

0)

(31

624

Plug

(313)

(320)

Tube

30 ft (9.1 m)

ule (322)

Ferr

12 6

Conn

ting (324)

Fit

ector

catalyst

24T572 4 color and 2

820

ft (12.2 m)

40

16 8

catalyst

T573

24

24T574 8 color and 2

olor and 2

6c

talyst

ca

10 16

12 12

50 ft (15.2 m)

60 ft (18.3 m)

20 10

24 12

catalyst

24T774 12 color and

16 4

0ft(24.4m)

8

32 16 2 catalyst; 13–24 color

24T775 4 color and 4

10 16

50 ft (15.2 m)

20 10 catalyst

333282B 67

Parts

Kit No. Kit

Description

24T776 6 color and 4

catalyst

24T777 8 color and 4

catalyst

24T778 12 color and

4 catalyst; 13–30 color

24T779 13–18 color 6 24

Solenoid (310)

12 12

14 8

18 0

Plug (313) Tube (320) Ferrule (322) Connector

60 ft (18.3 m)

70 ft (21.3 m)

90 ft (27.4 m)

30 ft. (9.1 m

24 12

28 14

36 18

12 6

)

Fitting (324)

68 333282B

Expansion Kits

Parts

To add colors/ Kit. See IS Exp

Non-IS Expans

The followin room for a val valves alrea

catalysts, order the correct Non-IS Expansion Kit. Also order the corresponding IS Expansion

ansion Kits, page 70.

ion Kits

g kits are available to add color valves in a non-IS area. Order a kit without a manifold if you have

ve on an existing manifold. Order a kit with a manifold if all ports on your existing manifolds have

dy. See Install an Expansion Kit, page 30 for instructions.

Low Pressure Expansion Kits

Kit No. Kit Description

Without Manifold

24T443 One non-ci

(replaces solenoid,

24T444 One circulating valve (replaces a

plug). Includes valve, solenoid, ﬁttings, and tubing.

With Manifold

24T445 Manifold with one non-circulating

valve. Includes valve, plug, solenoid, ﬁttings, and tubing.

24T446 Manifold with one circulating valve.

Includes valve, plug, solenoid, ﬁttings, and tubing.

24T447 Manifold with two non-circulating

valves. Includes valves, solenoids, ﬁttings, and tubing.

8

24T44

Manif valve ﬁttin

rculating valve

a plug). Includes valve,

ﬁttings, and tubing.

old with two circulating

s. Includes valves, solenoids,

gs, and tubing.

High Pressure Expansion Kits

Kit No. Kit Description

Without Manifold

24T584 One non-ci

(replaces solenoid,

24T585 One circulating valve (replaces a

plug). Includes valve, solenoid, ﬁttings, and tubing.

With Manifold

24T586 Manifold with one non-circulating

valve. Includes valve, plug, solenoid, ﬁttings, and tubing.

24T587 Manifold with one circulating valve.

Includes valve, plug, solenoid, ﬁttings, and tubing.

24T588 Manifold with two non-circulating

valves. Includes valves, solenoids, ﬁttings, and tubing.

9

24T58

Manif valve ﬁttin

rculating valve

a plug). Includes valve,

ﬁttings, and tubing.

old with two circulating

s. Includes valves, solenoids,

gs, and tubing.

High P

ressure Acid-Compatible Expansion Kits

.

Kit No

Without Manifold

24T590 One non-circulating acid-

With Manifold

24T591 Manifold with one non-circulating

24T592 Manifold with two non-circulating

scription

Kit De

compatible valve (replaces a plug). Includes valve, solenoid, ﬁttings, and tubing.

acid-compatible valve. Includes valve, plug, solenoid, ﬁttings, and tubing.

acid-compatible valves. Includes valves, solenoids, ﬁttings, and tubing.

333282B 69

Parts

IS Expansion Kits

The following kits are available to add color valves in an IS area. Order a kit without a manifold if you have roomforavalveonanexistingmanifold. Orderakitwithamanifoldifallports on your existing manifolds have valves already. See Install an Expansion Kit, page 30 for instructions.

Low Pressure E

Kit No. Kit Descript

Without Manifold

24T449 One non-circulating valve

24T450 One circulating valve (replaces a

With Manifold

24T451 Manifold with one non-circulating

24T452 Manifold

24T453 Manifold with two non-circulating

24T454 Manifold with two circulating

xpansion Kits

ion

(replaces a plug). Includes valve, IS solenoid, ﬁttings, and tubing.

plug). Includes valve, IS solenoid, ﬁttings, and tubing.

valve. Includes valve, plug, IS solenoid, ﬁttings, and tubing.

with one circulating valve.

s valve, plug, IS solenoid,

Include

, and tubing.

ﬁttings

valves. Includes valves, IS solenoids, ﬁttings, and tubing.

High Pressure

Kit No. Kit Descript

Without Manifold

24T712 One non-circulating valve

24T713 One circulating valve (replaces a

With Manifold

24T714 Manifold with one non-circulating

24T715 Manifold

24T716 Manifold with two non-circulating

24T717 Manifold with two circulating

Expansion Kits

ion

(replaces a plug). Includes valve, IS solenoid, ﬁttings, and tubing.

plug). Includes valve, IS solenoid, ﬁttings, and tubing.

valve. Includes valve, plug, IS solenoid, ﬁttings, and tubing.

with one circulating valve.

s valve, plug, IS solenoid,

Include

, and tubing.

ﬁttings

valves. Includes valves, IS solenoids, ﬁttings, and tubing.

High Pressure Acid-Compatible Expansion Kits

Kit No. Kit Description

Without Manifold

24T718 One non-circulating acid-

compatible valve (replaces a plug). Includes valve, IS solenoid, ﬁttings, and tubing.

With Manifold

719

24T

24T720 Manifold with two non-circulating

ifold with one non-circulating

Man

d-compatible valve. Includes

aci

ve, plug, IS solenoid, ﬁttings,

val

tubing.

and

acid-compatible valves. Includes valves, IS solenoids, ﬁttings, and tubing.

70 333282B

Dimensions

Figure 24 Non-IS Control Module

Dimensions

AB

11.30 in. (1478 mm)

Figure 25 IS Control Module

7.67 in. (195 mm)

C

9.8 in. (249 mm) 5.70 in. (145

DEF

mm)

0.31 in. (8 mm) 5.80 in. (147 mm)

AB

16.57 in. (421 mm)

333282B

8.22 in. (209 mm)

C

15.07 in. (383 mm)

DEF

6.70 in. (170 mm)

0.31 in. (8 mm) 4.52 in. (115 mm)

71

Dimensions

Figure 26 Manifold Mounting Bracket, Non-IS

TUV

3.84 in. (98 mm)

11.44 in. (291 mm)

0.312 in. (8

mm) diameter

2

7

333282B

Dimensions

Figure 2

7 IS Valve Manifold Bracket

AB

5.63 in (168 mm)

G

0.24 in (6 mm) 1.00 in (25 mm) 0.88 in (22 mm) 0.40 in (10 mm) 0.40 in (10 mm) 0.11 in (3 mm)

NP

4 x 0.28 in (7

mm)

1.92 in (49 mm) 3.35 in (85 mm) 1.80 in (46 mm) 1.32 in (34 mm) 0.65 in. (17

HJKLM

2 x 0.41 in (10

mm)

C

DEF

mm)

333282B 73

Dimensions

Figure 28 Remote Mix Manifold Bracket

AB

3.00 in (76 mm) 1.45 in (37 mm) 2.00 in (51 mm) 1.05 in (27 mm) 2.50 in (64 mm) 0.50 in (13 mm)

G

.25 in (32 mm)

1

4

7

HJK

.11(3mm)

0

C

x0.22in(6

4

m)

m

DEF

x0.41(10

2

m)

m

333282B

Technical Data

Color Change Kits U.S.

Maximum ﬂuid working pressure:

Low pressure kits 300 psi 2.1 MPa, 21 bar

High pressu

Maximum working air pressure:

Air supply: 85–100 psi 0.6–0.7 MPa, 6.0–7.0 bar

Viscosity range of ﬂuid:

Fluid inl

Fluid out

Air inle

Wetted p

et size:

let size:

tsize:

arts:

Valve m

re kits

anifold

Valve

1500 psi 10.5 MPa, 10

100 psi 0.7 MPa, 7.0 bar

20–5000 ce

1/4 npt(f)

5/32 in. OD tube 4 mm OD tube

ﬁlled polyphenylene sulﬁde, 316 SST, PTFE, chemically resistant o-rings

Glass-

See va

lve manual 332454.

ntipoise

Metric

5bar

333282B 75

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 Grac

This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage o 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.

o’s written recommendations.

r wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper

Graco Information

For the latest information about Graco products, visit www.graco.com.

For patent information, see www.graco.com/patents.

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 333282

Graco Headquarters: Minneapolis

International Ofﬁces: Belgium, China, Japan, Korea

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

www.graco.com

Revision B, September 2014

Graco 333282B User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Related Manuals

Models

Non-Intrinsically Safe Modules

Table 1 . Low Pressure, Non-Circulating Remote Mix Manifold Kits Maximum Fluid Working Pressure: 300 psi (2.07 MPa, 20.7 bar)

Table 2 . Low Pressure, Circulating Remote Mix Manifold Kits Maximum Fluid Working Pressure: 300 psi (2.07 MPa, 20.7 bar)

Table 3 . High-Pressure, Non-Circulating Remote Mix Manifold Kits Maximum Fluid Working Pressure: 1500 psi (10.34 MPa, 103.4 bar)

Table 4 . High-Pressure, Circulating Remote Mix Manifold Kits Maximum Fluid Working Pressure: 1500 psi (10.34 MPa, 103.4 bar)

Warnings

Isocyanate Conditions

Keep Components A and B Separate

Moisture Sensitivity of Isocyanates

Table 5 . Relationship of Non-IS Color Change Control Modules to Pumps

Installation

Air Supply

Mounting the Control Modules

Grounding

Non-Hazardous Location

Connect the Color Change Control Modules

Install the Valve Manifolds

Install the Back Pressure Regulator (High Pressure Systems Only)

Hazardous Location

Install the Remote Valve Manifolds

Install the Remote Mix Manifold

Notes

Connect Non-Circulating Fluid Lines

Connect Circulating Fluid Lines

Install an Expansion Kit

Troubleshooting

Color Change Solenoid Valves

Repair

Replace a Color Valve

Parts

Non-IS Color Change Kits

Low Pressure Non-IS Kits

High Pressure Non-IS Kits

Notes

Low Pressure IS Kits

High Pressure IS Kits

Low Pressure Valve Manifold Kits

High Pressure Valve Manifold Kits

Notes

Non-IS Color Change Control Modules

IS Color Change Control Modules

Expansion Kits

IS Expansion Kits

Dimensions

Technical Data

Graco Standard Warranty

Graco Information