Graco 333282B Color Change And Remote Mix Manifold Kits Users Manual 333282B, Kits, Instructions/Parts, English
333282B to the manual 61de6f35-adf9-4708-a0bf-17068e34f083
2015-04-02
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Instructions/Parts Color Change and Remote Mix 333282B Manifold Kits EN 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 for model part numbers and approvals information. PROVEN QUALITY. LEADING TECHNOLOGY. Contents Related Manuals ................................................ 3 Models............................................................... 4 Non-Intrinsically Safe Modules ...................... 4 Warnings ........................................................... 9 Important Isocyanate (ISO) Information ................ 12 Setup the Modules.............................................. 13 Setup Non-IS Control Modules...................... 13 Setup IS Control Modules ............................. 16 Color Change Solenoid Valves ..................... 32 Color Change Board .................................... 34 Electrical Schematics .......................................... 36 Optional Cables and Modules ....................... 42 Repair................................................................ 43 Replace a Color Valve.................................. 43 Replace a Solenoid ...................................... 44 Replace the Color Change Board Fuse ........... 44 Replace the Color Change Board.................. 45 Installation.......................................................... 18 Mounting the Control Modules ...................... 18 Air Supply.................................................... 18 Grounding ................................................... 18 Non-Hazardous Location .............................. 19 Hazardous Location ..................................... 22 Connect the Valve Air Lines.......................... 24 Connect the Fluid Lines ................................ 26 Install an Expansion Kit ................................ 30 Parts.................................................................. 46 Non-IS Color Change Kits ............................ 46 IS Color Change Kits.................................... 50 Valve Manifold Kits ...................................... 53 Color Change Control Module Kits ................ 64 Expansion Kits............................................. 69 Troubleshooting.................................................. 32 Graco Standard Warranty.................................... 76 2 Dimensions ........................................................ 71 Technical Data ................................................... 75 333282B Related Manuals Related Manuals Current manuals are available at www.graco.com. Manual No. Description Manual No. Description 332458 PD2K Proportioner, Installation Manual, Systems for Automatic Spray Applications 332709 Pump Repair-Parts Manual 332454 Color Change Valve Repair-Parts Manual 332456 3rd and 4th Pump Kits Instructions-Parts Manual 332564 PD2K Proportioner Operation Manual, Systems for Automatic Spray Applications 332565 PD2K Proportioner Repair-Parts Manual, Systems for Automatic Spray Applications 333282B 3 Models Models Non-Intrinsically Safe Modules These kits are installed in the non-hazardous location, near the pumps. See the Kit label for the product part number. See the module identification label for maximum air working pressure, approval information and certification. Non-Intrinsically Safe Color Change Control Module Label Kit No. Series Kit Description Kit Identification Label Maximum Air Working Pressure (Control Module) Maximum Fluid Working Pressure (Valves) Low Pressure Non-Circulating Color Change Kits 24R915 A 2 color or 2 catalyst 100 psi (0.7 MPa, 7.0 bar) 300 psi (2.068 MPa, 20.68 bar) 24R916 A 4 color or 4 catalyst 100 psi (0.7 MPa, 7.0 bar) 300 psi (2.068 MPa, 20.68 bar) 24R917 A 6 color 100 psi (0.7 MPa, 7.0 bar) 300 psi (2.068 MPa, 20.68 bar) 24R918 A 8 color 100 psi (0.7 MPa, 7.0 bar) 300 psi (2.068 MPa, 20.68 bar) Low Pressure Circulating Color Change Kits 24R919 A 2 color 100 psi (0.7 MPa, 7.0 bar) 300 psi (2.068 MPa, 20.68 bar) 24R920 A 4 color 100 psi (0.7 MPa, 7.0 bar) 300 psi (2.068 MPa, 20.68 bar) 24R921 A 6 color 100 psi (0.7 MPa, 7.0 bar) 300 psi (2.068 MPa, 20.68 bar) 24R922 A 8 color 100 psi (0.7 MPa, 7.0 bar) 300 psi (2.068 MPa, 20.68 bar) 4 333282B Models Kit No. Series Kit Description Maximum Air Working Pressure (Control Module) Maximum Fluid Working Pressure (Valves) High Pressure Non-Circulating Color Change Kits 24R959 A 2 color or 2 catalyst 100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar) 24R960 A 4 color or 4 catalyst 100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar) 24R961 A 6 color 100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar) 24R962 A 8 color 100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar) High Pressure Acid Compatible Non-Circulating Catalyst Change Kits 24T579 A 2 catalyst (acid compatible) 100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar) 24T580 A 4 catalyst (acid compatible) 100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar) High Pressure Circulating Color Change Kits 24R963 A 2 color 100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar) 24R964 A 4 color 100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar) 24R965 A 6 color 100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar) 24R966 A 8 color 100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar) 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 control module(s), an additional control module is needed. Order another complete color change change kit, shown above. • If current control module is not full: If empty solenoid ports remain in your control module, see Expansion Kits, page 69. 333282B 5 Models Intrinsically Safe Modules These kits utilize intrinsically safe control modules that are installed in the hazardous area, near the dispense valve. See the kit identification label for the product part number. See the module identification label for maximum air working pressure, approval information and certification. Intrinsically Safe Color Change Module Identification Label 0359 Kit Identification Label II 2 G 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 Number of Catalyst + Solvent Valves 1 4 2 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). 13–18 24V163 13–24 24V164 13–30 24V165 6 333282B Models Table 2 . Low Pressure, Circulating Remote Mix Manifold Kits Maximum Fluid Working Pressure: 300 psi (2.07 MPa, 20.7 bar) Number of Color + Solvent Valves Number of Catalyst + Solvent Valves 1 4 2 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 Number of Catalyst + Solvent Valves 1 24V359 2 24V360 24V381 4 24V361 24V382 24V396 6 24V362 24V383 24V397 1 4 2 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). 13–18 24V365 13–24 24V366 13–30 24V367 Models continue on next page. 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 Number of Catalyst + Solvent Valves 1 4 2 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. 8 333282B Warnings Warnings The following warnings are for the setup, use, grounding, maintenance and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable. WARNING FIRE AND EXPLOSION HAZARD Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion: • Use equipment only in well ventilated area. • Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc). • Keep work area free of debris, including solvent, rags and gasoline. • Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present. • Ground all equipment in the work area. See Grounding instructions. • Use only grounded hoses. • Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they are antistatic or conductive. • Stop operation immediately if static sparking occurs or you feel a shock, Do not use equipment until you identify and correct the problem. • Keep a working fire extinguisher in the work area. ELECTRIC SHOCK HAZARD This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric shock. • Turn off and disconnect power at main switch before disconnecting any cables and before servicing or installing equipment. • Connect only to grounded power source. • All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations. 333282B 9 Warnings INTRINSIC SAFETY WARNING Intrinsically safe equipment that is installed improperly or connected to non-intrinsically safe equipment will create a hazardous condition and can cause fire, explosion, or electric shock. Follow local regulations and the following safety requirements. • 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.). • To help prevent 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. • Equipment that comes in contact with the intrinsically safe terminals must be rated for Intrinsic Safety. This includes DC voltage meters, ohmmeters, cables, and connections. Remove the unit from the hazardous area when troubleshooting. SKIN INJECTION HAZARD High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment. • • • • Do not point dispensing device at anyone or at any part of the body. Do not put your hand over the fluid outlet. 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. • Tighten all fluid connections before operating the equipment. • Check hoses and couplings daily. Replace worn or damaged parts immediately. MOVING PARTS HAZARD Moving parts can pinch, cut or amputate fingers and other body parts. • Keep clear of moving parts. • Do not operate equipment with protective guards or covers removed. • Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources. TOXIC FLUID OR FUMES Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed. • Read MSDSs to know the specific hazards of the fluids you are using. • Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines. • Always wear chemically impermeable gloves when spraying, dispensing, or cleaning equipment. 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: • Protective eyewear, and hearing protection. • Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer. EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. • Do not operate the unit when fatigued or under the influence of drugs or alcohol. • Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals. • Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer. • Do not leave the work area while equipment is energized or under pressure. • Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use. • Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only. • Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards. • Make sure all equipment is rated and approved for the environment in which you are using it. • Use equipment only for its intended purpose. Call your distributor for information. • Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces. • Do not kink or over bend hoses or use hoses to pull equipment. • Keep children and animals away from work area. • Comply with all applicable safety regulations. 333282B 11 Important Isocyanate (ISO) Information Important Isocyanate (ISO) Information Isocyanates (ISO) are catalysts used in two component materials. Isocyanate Conditions Eventually a film will form on the surface and the ISO will begin to gel, increasing in viscosity. NOTICE Partially cured ISO will reduce performance and the life of all wetted parts. 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 for everyone in the work area. 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. Keep Components A and B Separate • 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. Changing Materials NOTICE 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. 12 Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime. • When changing materials, flush the equipment multiple times to ensure it is thoroughly clean. • Always clean the fluid inlet strainers after flushing. • Check with your material manufacturer for chemical compatibility. • When changing between epoxies and urethanes or polyureas, disassemble and clean all fluid components and change hoses. Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the A (resin) side. 333282B Setup the Modules Setup the Modules Setup Non-IS Control Modules 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. 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. Table 5 . Relationship of Non-IS Color Change Control Modules to Pumps System Pump Configuration Color Pump(s) Catalyst Pump(s) Total Pumps 1 0 1 1 1 2 2 1 3 2 0 2 Color Change Control Modules, Colors, and Catalysts Module 1 (Colors 1–8) 2 4 3 1 4 3 0 3 4 0 4 333282B Module 3 (Colors 17–24) Module 4 (Colors 25–30) Catalyst 1–2 Catalyst 3–4 Not Applicable Pump # 1 Pump # 1 Module # 5 Pump # 2 Module # 5 Pump # 2 Pump # 1 2 Module 2 (Colors 9–16) Pump # 3 Pump # 1 Pump # 3 Pump # 4 Pump # 2 Not Applicable Module # 5 Pump # 2 Module # 6 Pump # 4 Module # 5 Pump # 2 Not Applicable Not Applicable 13 Setup the Modules Configure each module according to its designated number, as follows: NOTICE Non-IS Control Module Switch Settings Control Module To avoid damaging the circuit boards, wear Part No. 112190 grounding strap on your wrist and ground appropriately. Module 1 To avoid electrical component damage, remove all system power before plugging any connectors. Module 2 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 are shipped in the OFF position. Module 3 Module 4 Module 5 3. For each module, set the switches to ON or OFF, as shown in the following table. Module 6 S6 S5 S4 ON ON ON OFF OFF OFF ON ON ON OFF OFF OFF ON ON ON OFF OFF OFF ON ON ON OFF OFF OFF ON ON ON OFF OFF OFF ON ON ON OFF OFF 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 14 333282B Setup the Modules Non-IS Control Module 1 Inlet Manifold Non-IS Control Module 4 Outlet Manifold Inlet Manifold Outlet Manifold Solenoid Valve Solenoid Valve Solenoid Valve Solenoid Valve 1 Solvent 1 Dump 1 (Solvent)* 1 (Dump)* 2 Color 1 2 Color 1 2 Color 25 2 Color 25 3 Color 2 3 Color 2 3 Color 26 3 Color 26 4 Color 3 4 Color 3 4 Color 27 4 Color 27 5 Color 4 5 Color 4 5 Color 28 5 Color 28 6 Color 5 6 Color 5 6 Color 29 6 Color 29 7 Color 6 7 Color 6 7 Color 30 7 Color 30 8 Color 7 8 Color 7 8 Not Used 8 Not Used 9 Color 8 9 Color 8 9 Not Used 9 Not Used Non-IS Control Module 2 Inlet Manifold Non-IS Control Module 5 Outlet Manifold Inlet Manifold Outlet Manifold Solenoid Valve Solenoid Valve Solenoid Valve Solenoid Valve 1 (Solvent)* 1 (Dump)* 1 (Solvent)* 1 (Dump)* 2 Color 9 2 Color 9 2 Catalyst 1 2 Catalyst 1 3 Color 10 3 Color 10 3 Catalyst 2 3 Catalyst 2 4 Color 11 4 Color 11 4 Catalyst 3 4 Catalyst 3 5 Color 12 5 Color 12 5 Catalyst 4 5 Catalyst 4 6 Color 13 6 Color 13 6 Not Used 6 Not Used 7 Color 14 7 Color 14 7 Not Used 7 Not Used 8 Color 15 8 Color 15 8 Not Used 8 Not Used 9 Color 16 9 Color 16 9 Not Used 9 Not Used Non-IS Control Module 3 Inlet Manifold Non-IS Control Module 6 Outlet Manifold Inlet Manifold Outlet Manifold Solenoid Valve Solenoid Valve Solenoid Valve Solenoid Valve 1 (Solvent)* 1 (Dump)* 1 (Solvent)* 1 (Dump)* 2 Color 17 2 Color 17 2 Catalyst 3 2 Catalyst 3 3 Color 18 3 Color 18 3 Catalyst 4 3 Catalyst 4 4 Color 19 4 Color 19 4 Not Used 4 Not Used 5 Color 20 5 Color 20 5 Not Used 5 Not Used 6 Color 21 6 Color 21 6 Not Used 6 Not Used 7 Color 22 7 Color 22 7 Not Used 7 Not Used 8 Color 23 8 Color 23 8 Not Used 8 Not Used 9 Color 24 9 Color 24 9 Not Used 9 Not Used * There should be only one solvent valve and one dump valve per pump. 333282B 15 Setup the Modules Setup IS Control 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 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 electrical component damage, remove all system power before plugging any connectors. 3. For each module, set the switches to ON or OFF, as shown in the following table. IS Control Module Switch Settings Control Module Module 7 Module 8 S6 S5 S4 ON ON ON OFF OFF OFF ON ON ON OFF OFF OFF 4. Use the following figure and tables to determine the solenoid valve assigned to each valve in the valve manifold. 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. Figure 2 IS Control Module 16 333282B Setup the Modules IS Control Module 7 IS Control Module 8 Solenoid Valve Solenoid Valve Solenoid Valve Solenoid Valve 1 Color Solvent 1 Catalyst Solvent 1 Color 13 1 Color 22 2 Color 1 2 Catalyst 1 2 Color 14 2 Color 23 3 Color 2 3 Catalyst 2 3 Color 15 3 Color 24 4 Color 3 4 Catalyst 3 4 Color 16 4 Color 25 5 Color 4 5 Catalyst 4 5 Color 17 5 Color 26 6 Color 5 6 Color 9 6 Color 18 6 Color 27 7 Color 6 7 Color 10 7 Color 19 7 Color 28 8 Color 7 8 Color 11 8 Color 20 8 Color 29 9 Color 8 9 Color 12 9 Color 21 9 Color 30 333282B 17 Installation Installation 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. • 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. 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) OD tubing. Use a 5 micron filter. Regulate the air pressure to 85–100 psi (0.6–0.7 MPa, 6.0–7.0 bar). Grounding 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. 18 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. 333282B Installation 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. 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. 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). Figure 4 Cable Connection at PD2K Electrical Control Box 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. 333282B Figure 5 Detail of Isolation Board Cable Connections 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 mounting bracket (101) on the PD2K with four screws (103). High pressure systems: For stability, be sure to fasten the bottom screws (103) to the 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 20 Figure 6 Install the Valve Manifolds 333282B Installation Install the Back Pressure Regulator (High Pressure Systems Only) 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. 5. Connect the fluid supply lines to the valves. See Connect the Fluid Lines, page 26. Install the back pressure regulator (120) and attaching hardware at the dump valve of the outlet manifold stack. 1. Install the gauge (123) in the open port of the tee (122). 2. Screw the tee (122) onto the dump valve fitting of the outlet manifold stack. 3. Assemble the two nipples (121) to the back pressure regulator (120). Screw the regulator assembly into the tee (122) as shown. Figure 7 Install Back Pressure Regulator at Dump Valve of Outlet Stack 4. Connect a 1/4 npt(f) dump line to the downward facing nipple (121). 333282B 21 Installation Hazardous Location Connect Remote 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. Figure 9 Cable Connectors J7 and J11 at IS Color Control Module 4. Remove the cover from the PD2K electrical control box. Install the grommet (G) on the supplied cable (C1) and secure the grommet to the side of the electrical control box. Locate J4 on the IS side of the isolation board in the electrical control box. Connect the cable (C1) to J4. See Electrical Schematics, page 36. 22 333282B Installation J11 on the first 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 333282B 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. 23 Installation Install the Remote Mix Manifold Connect the Valve Air Lines 1. Using the equipment as a template, mark the mounting holes on the wall or robot arm, near the automatic dispensing device. Non-Hazardous Area 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. 24 1. Connect 5/32 in. (4 mm) OD air tubes from the inlet solenoids to the air inlets of each inlet valve, using the label inside of the color control module as a guide. See Setup the Modules, page 13. 2. Repeat for the outlet valves. 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. 333282B Installation Notes 333282B 25 Installation Connect the Fluid 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 pressure systems, see Install the Back Pressure Regulator (High Pressure Systems Only), page 21. 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. 2. Use the top valve of the outlet 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 and Catalyst Valve Manifolds Hazardous Area NonHazardous Area Non-IS inlet and outlet color and catalyst valve manifolds Valve Manifold Stack Schematic 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 valve fitting on the remote color stack. 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. 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. Figure 11 Color Change Connections (Non-Circulating System) KEY A Air inlet W Seal weep and lubrication port S Solvent fitting C1 Color 1 fitting C2 Color 2 fitting 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 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. Circulation valves enable constant circulation of a color when that color is not being sprayed: • When a color valve is closed, the system bypasses the dosing pump by directing that color from the inlet color valve to the outlet color valve to the remote color valve, through a circulation line, then back to the color supply. c. • When a color valve is open, the circulation line is shut off. The color is directed through the material A dosing pump and out to the remote color valve stack and mix manifold, as in normal operation. Connect a 1/4 npt(f) circulation line from the circulation port on each remote valve back to the fluid supply container. 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 high pressure systems, see Install the Back Pressure Regulator (High Pressure Systems Only), page 21. 1. Connect all fluid lines as described in Connect Non-Circulating Fluid Lines, page 26. These lines are used during normal mixing and spraying. 2. Connect the circulation lines as follows: 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. 28 Figure 12 Valve Manifold Connections (Circulating System) KEY D Dump valve fitting S Solvent fitting C1 Color 1 fitting C2 Color 2 fitting R1 Color 1 circulation fitting R2 Color 2 circulation fitting 333282B Installation Fluid Flow Schematic Diagram in Circulating Mode (Pump Not Shown for Clarity) KEY A Color supply B Inlet color stack C Outlet color stack D Remote color stack E Remote mix manifold F Automatic spray gun G Return line to fluid supply 333282B 29 Installation Install an Expansion Kit 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. Install the plug (4) in the unused manifold port. 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. c. 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. 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) are in place, then install the screws (10). 30 333282B Installation Figure 13 Install an Expansion Kit (Low Pressure Valve Manifold Shown) 333282B 31 Troubleshooting 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. 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). 2. Air or electrical lines damaged or connections are loose. Visually inspect air and electrical lines for kinks, damage, or loose connections. Service or replace as needed. 3. Solenoid failure. Check the applicable solenoid’s LED; see Color Change Board, page 34. If lit, 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 from the air line for the corresponding solenoid when the valve is actuated. Clear the restriction. 32 333282B Troubleshooting Cause Solution 4. Control board or cable failure. If there is no voltage across the pins on the board or it is less than 9 Vdc, check LEDs D8, D9, and D10. If they are lit and functioning properly, or other solenoids in the module are working properly, replace the color change board. 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 blinking: • 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 the cable is disconnected or damaged. • Check the isolation board. See the PD2K Repair-Parts manual. 333282B 33 Troubleshooting Color 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. Figure 14 Color Change Board 34 333282B Troubleshooting Color Change Board Diagnostics ID Component or Indicator Function D8 LED (green) Blinks (heartbeat) during normal operation. D9 LED (green) Turns on when power is supplied to the board. D10 LED (yellow) Turns on when board is communicating with electronic control. D27–D39, D41, D43–D46 LED (green) Turn on when a signal is sent to actuate the related solenoid valve. F1 Fuse, 0.125 A, 125 V 333282B 35 Electrical Schematics Electrical Schematics 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. CABLE 16H078 AWI GATEWAY (24R910) UP DOWN FLOW SENSOR (120278) OR G3000 METER (239716, 258718 16M510, 16M519) PUMP INLET TRANSDUCER (16P289, 16P290) PUMP OUTLET TRANSDUCER (16P289, 16P290) PUMP V/P FOR FLUID REG. MAC SERIES 46 SOLENOID (16P812) MAC SERIES 46 SOLENOID (16P812) PUMP V/P FOR FLUID REG. BREAKOUT MODULE PUMP 3 (24N527) FAN (24P658) ENCODER AND MOTOR (16P036, 16P037) WIRE HARNESS (24P684, 24P685) UP DOWN FLOW SENSOR (120278) OR G3000 METER (239716, 258718 16M510, 16M519) CATALYST CHANGE MODULE 6 6 (24N935) CATALYST CHANGE MODULE 5 6 (24N935) COLOR CHANGE MODULE 4 6 (24N935) COLOR CHANGE MODULE 3 6 (24N935) COLOR CHANGE MODULE 2 6 (24N935) SOLVENT CUTOFF (121324) SWITCH (120278) SWITCH (120278) CABLE (16T659) CABLE (16T659) CABLE (16T659) CABLE (16T659) SOLVENT FLOW INPUTS SOLVENT METER (258718) SAFETY INTERLOCK SWITCH 1 ADVANCED DISPLAY MODULE (24E451) CABLE (16V429) LIGHT TOWER (15X472) COLOR CHANGE MODULE 7 (24R219) 7 1 3 CABLE (121003) 4 GFB INTERFACES CABLE (16V426) BARRIER BOARD (248192) GCA MODULE EFCM (24N913) PRESSURE SW (121323) FLOW RATE ANALOG IN FLOW SENSOR (120278) OR G3000 METER (239716, 258718 16M510, 16M519) SPLITTER (16P243) SOLENOID (121324) FLOW RATE ANALOG IN UP DOWN FAN (24P658) PUMP OUTLET TRANSDUCER (16P289, 16P290) CABLE (15V206) 119159 119159 119159 119159 FLOW RATE ANALOG IN PUMP V/P FOR FLUID REG. ENCODER AND MOTOR (16P036, 16P037) WIRE HARNESS (24P684, 24P685) PUMP INLET TRANSDUCER (16P289, 16P290) 2 GUN TRIGGER INPUTS FLOW RATE ANALOG IN FLOW SENSOR (120278) OR G3000 METER (239716, 258718 16M510, 16M519) PUMP OUTLET TRANSDUCER (16P289, 16P290) MAC SERIES 46 SOLENOID (16P812) MAC SERIES 46 SOLENOID (16P812) UP PUMP INLET TRANSDUCER (16P289, 16P290) CABLE (16T280) ENCODER AND MOTOR (16P036, 16P037) WIRE HARNESS (24P684, 24P685) BREAKOUT MODULE PUMP 2 (24N527) ENCODER AND MOTOR (16P036, 16P037) WIRE HARNESS (24P684, 24P685) COLOR CHANGE MODULE 8 (24R219) 7 BOOTH CONTROL (24M731) BREAKOUT MODULE PUMP 4 (24N527) FAN (24P658) BREAKOUT MODULE PUMP 1 (24N527) FAN (24P658) DOWN CABLE (15V206) 16T072 CAN IS BOARD (24M485) PUMP V/P FOR FLUID REG. 2 1 CABLE (16V426) 16W159 16W159 16W159 16W159 TERMINAL BLOCKS WITH FUSES POWER IN PUMP OUTLET TRANSDUCER (16P289, 16P290) CABLE (15V206) 3 CABLE (121227) TERMINAL BLOCK (114095) PUMP INLET TRANSDUCER (16P289, 16P290) 2 CABLE (15V206) 2 5 3 CABLE (121001) 48V-10A POWER SUPPLY (16U820) 3 CABLE (121227) LINE FILTER (16V446) 5 24V POWER SUPPLY (16T660) CABLE (15V206) CABLE 16T658 INTEGRATION GATEWAY COLOR CHANGE MODULE 1 6 (24N935) POWER MODULE (24R257) 2 2 CABLE (15V206) 065161, 065159 RELAY 2 POSITION SWITCH (16U725) HAZARDOUS LOCATION NON-HAZARDOUS LOCATION Figure 15 Electrical Schematic, Sheet 1 36 333282B Electrical Schematics CONTINUED ON PAGE 3 CONTINUED ON PAGE 3 2 3 CABLE (15V206) 1 2 3 4 5 8 3 1 2 3 4 5 6 7 8 9 10 11 12 5 (121001) GCA MODULE EFCM (24N913) 5 3 12345 SOLVENT CUTOFF (121324) PWR (RED) SIG (WHITE) COM (BLACK) SHIELD/GRN SOLVENT +12VDC COM UNUSED UNUSED +12VDC COM +12VDC COM UNUSED 1 RED WIRE (065161) GROUND BAR BLACK WIRE (065159) 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 METER (258718) 4 25 PIN D-SUB CABLE (16T659) 24V POWER SUPPLY (16T660) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 7 12 34 8 12 34 5678 1 2 3 1234 4 12345 5 12345 6 1234 7 12 34 8 12 34 5678 PUMP 2 UP MANIFOLD MAC SERIES 46 (16P812 QTY 2) +-+-+-+- LINE FILTER (16V446) PWR (RED) SIG (WHITE) COM (BLACK) SHIELD/GRN SEE DETAIL A OR B INLET TRANSDUCER PUMP 2 (16P289 OR 16P290) FAN PUMP 1 (24P658) +24VDC COM +24VDC COM PUMP 1 UP ENCODER/MOTOR AND WIRE HARNESS PUMP 2 PUMP 1 DOWN V/P FOR FLUID REG. PUMP 1 PWR (RED) SIG (WHITE) COM (BLACK) SHIELD/GRN +48V COM +48V COM 12345 MANIFOLD MAC SERIES 46 (16P812 QTY 2) F2 F1 F4 F3 OUTLET TRANSDUCER PUMP 1 (16P289 OR 16P290) SEE DETAIL A OR B +-+-+-+- N 1234 POWER MODULE (24R257) N04 CABLE (16T658) L ENCODER/MOTOR AND WIRE HARNESS PUMP 1 + - 2 POSITION SWITCH (16U725) N04 6 5 12345 INLET TRANSDUCER PUMP 1 (16P289 OR 16P290) N (BLUE) L (BROWN) GRND 48V-10A POWER SUPPLY (16U820) N03 4 12345 RELAY 14 N L 1234 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 BREAKOUT MODULE PUMP 2 (24N527) +48V COM +48V COM 3 2 12345 13 A1(+) A2(-) N03 1 BREAKOUT MODULE PUMP 1 (24N527) GRND (GRN/YEL) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 4 25 PIN D-SUB CABLE (16T659) UNUSED UNUSED GFB INTERFACE (121324) BARRIER BOARD (248192) UNUSED 1 2 3 4 5 INTEGRATION GATEWAY 5 1 CABLE (16T280) 54 3 2 1 3 P4 123 1 2 3 UNUSED P3 +24VDC COM +24VDC COM (24M485) (121227) 1 2 3 4 5 PUMP 2 DOWN 4 1 2 3 4 5 CABLE V/P FOR FLUID REG. PUMP 2 1 (NON IS) (IS) 12345 UNUSED UNUSED AWI GATEWAY (24R910) 12345 CAN IS BOARD 2 P4 P3 16T072 12345 SPLITTER (16P243) 1 2 3 4 5 10 UNUSED CABLE OUTLET TRANSDUCER PUMP 2 (16P289 OR 16P290) CABLE (16V429) CABLE (121227) 5 4 3 2 1 G3000 METER PUMP 1 (EITHER, 239716, 258718,16M510, OR 16M519) GRND SCREW TWISTED PAIR CABLE (16W159) G3000 METER PUMP 2 (EITHER, 239716, 258718,16M510, OR 16M519) GRND SCREW TWISTED PAIR CABLE (16W159) L GRND N 12 10 PUMP ENCODER AND MOTOR (16P037) MOTOR MOUNTING SCREW 123456789 10 11 12 DRAIN/FOIL UNUSED UNUSED UNUSED UNUSED 123456789 DRAIN/FOIL 10 11 12 UNUSED UNUSED UNUSED 123456789 MOTOR MOUNTING SCREW DRAIN/FOIL UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED DRAIN/FOIL L N GRND 3 1234 WIRE HARNESS (24P685) 123456789 UNUSED UNUSED 12345 1234 WIRE HARNESS (24P684) UNUSED UNUSED 12345 BREAKOUT MODULE (24N527) 2 3 UNUSED 2 UNUSED UNUSED UNUSED BREAKOUT MODULE (24N527) TERMINAL BLOCK (114095) UNUSED L N GRND POWER IN DETAIL B, HIGH PRESSURE PUMPS (24M707, 24M715) DETAIL A, LOW PRESSURE PUMPS (24M706, 24M714) UNUSED UNUSED UNUSED UNUSED UNUSED CABLE (16H078) 10 PUMP ENCODER AND MOTOR (16P036) Figure 16 Electrical Schematic, Sheet 2, Part 1 CONTINUED ON THE NEXT PAGE 333282B 37 FAN PUMP 2 (24P658) UNUSED UNUSED Electrical Schematics GUN TRIGGER INPUTS SIG COM SIG COM SIG COM SIG COM SIG COM SIG COM 7 1 2 3 4 5 6 7 8 9 10 11 12 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 SOLVENT FLOW SWITCH 2 (120278) COM SIG SAFETY INTERLOCK SWITCH COM 9 1 2 3 4 5 6 GCA MODULE EFCM (24N913) 3 4 LIGHT TOWER (15X472) 3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1 BREAKOUT MODULE PUMP 3 (24N527) 4 5 12345 6 1234 7 12 34 8 12 34 5678 2 12345 3 1234 4 12345 5 12345 6 1234 7 12 34 8 12 34 5678 PWR (RED) SIG (WHITE) COM (BLACK) SHIELD/GRN +24VDC COM +24VDC COM PUMP 4 UP MANIFOLD MAC SERIES 46 (16P812 QTY 2) MAC SERIES 46 (16P812 QTY 2) MANIFOLD PUMP 4 DOWN V/P FOR FLUID REG. PUMP 4 OUTLET TRANSDUCER PUMP 4 (16P289 OR 16P290) SEE DETAIL A OR B INLET TRANSDUCER PUMP 4 (16P289 OR 16P290) FAN PUMP 3 (24P658) PWR (RED) SIG (WHITE) COM (BLACK) SHIELD/GRN +24VDC COM +24VDC COM PUMP 3 UP ENCODER/MOTOR AND WIRE HARNESS PUMP 4 PUMP 3 DOWN V/P FOR FLUID REG. PUMP 3 SEE DETAIL A OR B OUTLET TRANSDUCER PUMP 3 (16P289 OR 16P290) ENCODER/MOTOR AND WIRE HARNESS PUMP 3 INLET TRANSDUCER PUMP 3 (16P289 OR 16P290) +48V COM +48V COM 12345 BREAKOUT MODULE PUMP 4 (24N527) +48V COM +48V COM 3 1234 (121003) 1 2 3 4 5 ADVANCED DISPLAY MODULE (24E451) FAN PUMP 4 (24P658) 1 2 1 2 3 4 5 4 25 PIN D-SUB CABLE (16T659) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 12345 GFB PRESSURE SWITCH (121323) SOLVENT FLOW SWITCH 1 (120278) CABLE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 4 25 PIN D-SUB CABLE (16T659) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 119159 1 2 3 4 5 6 7 8 9 10 11 12 G3000 METER PUMP 3 (EITHER, 239716, 258718,16M510, OR 16M519) GRND SCREW G3000 METER PUMP 4 (EITHER, 239716, 258718,16M510, OR 16M519) GRND SCREW TWISTED PAIR CABLE (16W159) TWISTED PAIR CABLE (16W159) Figure 17 Electrical Schematic, Sheet 2, Part 2 CONTINUED ON THE NEXT PAGE 38 333282B Electrical Schematics FROM CAN IS BOARD (24M485) ON PAGE 2 FROM CAN IS BOARD (24M485) ON PAGE 2 2 CABLE (15V206) MANIFOLD FLUSH COLOR 1 COLOR 2 COLOR 3 COLOR 4 COLOR 5 COLOR 6 COLOR 7 COLOR 8 12 34 5 COLOR CHANGE MODULE 1 (COLORS 1 THRU 8) +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 J8 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 J15 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 J14 J9 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC J16 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC 6 J10 MANIFOLD DUMP COLOR 1 COLOR 2 COLOR 3 COLOR 4 COLOR 5 COLOR 6 COLOR 7 COLOR 8 MANIFOLD *FLUSH COLOR 9 COLOR 10 COLOR 11 COLOR 12 COLOR 13 COLOR 14 COLOR 15 COLOR 16 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 12 34 5 COLOR CHANGE MODULE 2 (COLORS 9 THRU 16) J8 J9 6 5 4 3 2 1 J16 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC 6 J15 J14 J10 COM +12VDC COM +12VDC COM +12VDC MANIFOLD MANIFOLD DUMP* FLUSH COLOR 9 CATALYST 1 COLOR 10 CATALYST 2 COLOR 11 CATALYST 3 COLOR 12 CATALYST 4 COLOR 13 COLOR 14 COLOR 15 COLOR 16 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 +12VDC COM +12VDC COM UNUSED UNUSED 1 2 3 4 5 6 UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED 1 2 3 4 5 6 COLOR 17 COLOR 18 COLOR 19 COLOR 20 COLOR 21 COLOR 22 COLOR 23 COLOR 24 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 12 34 5 COLOR CHANGE MODULE 3 (COLORS 17 THRU 24) J8 J14 2 J9 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC J16 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC 6 J15 J9 COM +12VDC COM +12VDC COM +12VDC J16 6 5 4 3 2 1 COM +12VDC COM +12VDC UNUSED UNUSED J10 6 5 4 3 2 1 UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED 6 J15 J14 J10 MANIFOLD MANIFOLD *FLUSH DUMP* COLOR 17 COLOR 25 COLOR 18 COLOR 26 COLOR 19 COLOR 27 COLOR 20 COLOR 28 COLOR 21 COLOR 29 COLOR 22 COLOR 30 COLOR 23 COLOR 24 54 3 2 1 CABLE (15V206) 2 CABLE MANIFOLD J8 6 5 4 3 2 1 MANIFOLD DUMP CATALYST 1 CATALYST 2 CATALYST 3 CATALYST 4 12 34 5 12 34 5 *FLUSH CATALYST CHANGE MODULE 5 (CATALYST 1 THRU 4) (15V206) 2 CABLE (15V206) 12 34 5 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 +12VDC COM UNUSED UNUSED UNUSED UNUSED 1 2 3 4 5 6 12 34 5 COLOR CHANGE MODULE 4 (COLORS 25 THRU 32) J8 J9 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC J16 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC J10 6 5 4 3 2 1 COM +12VDC UNUSED UNUSED UNUSED UNUSED 6 J15 J14 MANIFOLD DUMP* COLOR 25 COLOR 26 COLOR 27 COLOR 28 COLOR 29 COLOR 30 12 34 5 2 CABLE (15V206) Figure 18 Electrical Schematic, Sheet 3 * May be unused in some configurations. CONTINUED ON THE NEXT PAGE 333282B 39 Electrical Schematics MANIFOLD FLUSH CATALYST 3 CATALYST 4 CATALYST CHANGE MODULE 6 (CATALYST 3 THRU 4) +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 J8 UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED 1 2 3 4 5 6 J15 UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED 1 2 3 4 5 6 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC J16 6 5 4 3 2 1 UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED J10 6 5 4 3 2 1 UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED J9 6 J14 MANIFOLD DUMP CATALYST 3 CATALYST 4 2 CABLE (15V206) 12 34 5 MANIFOLD FLUSH CATALYST 1 CATALYST 2 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED 1 2 3 4 5 6 UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED 1 2 3 4 5 6 5 4 3 2 1 CATALYST CHANGE MODULE 5 (CATALYST 1 THRU 2) J8 J9 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC J16 6 5 4 3 2 1 UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED J10 6 5 4 3 2 1 UNUSED UNUSED UNUSED UNUSED UNUSED UNUSED 6 J15 J14 MANIFOLD DUMP CATALYST 1 CATALYST 2 (15V206) 2 CABLE 12 34 5 12 34 5 COLOR CHANGE MODULE 4 (COLORS 25 THRU 32) Figure 19 Electrical Schematic, Sheet 3, Alternate Configuration for Catalyst Change Control CONTINUED ON THE NEXT PAGE 40 333282B Electrical Schematics FROM CAN IS BOARD (24M485) ON PAGE 2 NON-HAZARDOUS LOCATION HAZARDOUS LOCATION MANIFOLD COLOR FLUSH COLOR 1 COLOR 2 COLOR 3 COLOR 4 COLOR 5 COLOR 6 COLOR 7 COLOR 8 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 12 34 5 COLOR CHANGE MODULE 7 (COLORS 33 THRU 40) J8 J9 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC J16 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC 7 J15 J14 J10 MANIFOLD CATALYST FLUSH CATALYST 1 CATALYST 2 CATALYST 3 CATALYST 4 COLOR 9 COLOR 10 COLOR 11 COLOR 12 1 CABLE (16V426) 12 34 5 MANIFOLD COLOR 13 COLOR 14 COLOR 15 COLOR 16 COLOR 17 COLOR 18 COLOR 19 COLOR 20 COLOR 21 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 +12VDC COM +12VDC COM +12VDC COM 1 2 3 4 5 6 12 34 5 COLOR CHANGE MODULE 8 (COLORS 41 THRU 48) J8 J9 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC J16 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC 6 5 4 3 2 1 COM +12VDC COM +12VDC COM +12VDC 7 J15 J14 J10 MANIFOLD COLOR 22 COLOR 23 COLOR 24 COLOR 25 COLOR 26 COLOR 27 COLOR 28 COLOR 29 COLOR 30 (16V426) 1 CABLE 5 4 3 2 1 5 4 3 2 1 BOOTH CONTROL (24M731) Figure 20 Electrical Schematic, Sheet 3, Hazardous Location 333282B 41 Electrical Schematics Optional Cables and Modules NOTE: The total length of all cable used in the system must not exceed 150 ft (45 m). 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 No. Length ft (m) 16V423 2.0 (0.6) 16V424 3.0 (1.0) 16V425 6.0 (2.0) 16V426 10.0 (3.0) 16V427 15.0 (5.0) 16V428 25.0 (8.0) 16V429 50.0 (16.0) 16V430 100.0 (32.0) M12 CAN Cables, for Non-Hazardous Locations Only 15U531 2.0 (0.6) 15U532 3.0 (1.0) 15V205 6.0 (2.0) 15V206 10.0 (3.0) 15V207 15.0 (5.0) 15V208 25.0 (8.0) 15U533 50.0 (16.0) 15V213 100.0 (32.0) CAN Cables, for Non-Hazardous Locations Only Cable Part No. Length ft (m) 125306 1.0 (0.3) 123422 1.3 (0.4) 121000 1.6 (0.5) 121227 2.0 (0.6) 121001 3.0 (1.0) 121002 5.0 (1.5) 121003 10.0 (3.0) 120952 13.0 (4.0) 121201 20.0 (6.0) 121004 25.0 (8.0) 121228 50.0 (15.0) 42 25 Pin D-SUB Cables, for Non-Hazardous Locations Only 16T659 2.5 (0.8) 16V659 6.0 (1.8) Alternates for Communication Module 24R910, for Non-Hazardous Locations Only Module Part No. Module Part No. CGMDN0*, DeviceNet CGMPB0*, Profibus CGMEP0*, Ethernet IP CGMPN0*, Profinet * You must purchase Map Token Kit 17C087 for use with these kits. Alternates for Color Change Modules by Part Number (Factory Configuration), for Non-Hazardous Locations Only, see page 61 Module Part No. Description 24T557 2 color/2 catalyst 24T558 4 color/4 catalyst 24T559 6 color/6 catalyst 24T560 8 color/8 catalyst Alternates for Color Change Modules by Part Number (Factory Configuration), for Hazardous Locations Only, see page 62 24T571 2 color/2 catalyst 24T572 4 color/2 catalyst 24T573 6 color/2 catalyst 24T574 24T774 8 color/2 catalyst, 13–24 color 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 color 13–18 color 24T779 333282B Repair 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 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 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. 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. Figure 22 Remove the Valve NOTE: See manual 332454 to repair the valve. 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. 333282B 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. 43 Repair Replace a Solenoid Replace the Color Change Board Fuse 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. 44 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. 333282B Repair Replace the Color Change Board 2. Remove the color change module cover (304). 3. Note where each cable is connected, then disconnect all cables from the color change board connectors. 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. 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. Figure 23 Control Module Repair (Non-IS Module Shown) 333282B 45 Parts Parts Non-IS Color Change Kits Detail of Back Pressure Regulator (High Pressure Outlet Stack only) 46 333282B Parts Ref. No. Part No. Description Qty Ref. No. Part No. Description Qty 101 24U237 BRACKET, mounting 1 115 598095 ◆ 102 ◆ KIT, manifold, valve 2 TUBE; nylon; 5/32 in. (4 mm) OD 103 100157 SCREW, cap, hex head; 1/4–20 x 0.375 in. (10 mm) 4 120 222200 1 104 103195 SCREW, cap, hex head; 1/4–20 x 4.0 in. (101 mm) 4 REGULATOR, back pressure; used on high pressure kits only (see detail drawing); see manual 307892 105 100016 WASHER, lock; 1/4 4 121 113070 2 106 100015 NUT, hex; 1/4–20 4 NIPPLE; 3/8 npt x 1/4 npt; sst; used on high pressure kits only (see detail drawing) 107 24N346 HOSE, fluid; 1/4 npsm (fbe); 2.5 ft (0.76 m); ptfe 2 122 110290 1 108 ◆ TEE; 1/4 npt(f); sst; used on high pressure kits only (see detail drawing) KIT, module, control 1 123 112564 15V206 CABLE, CAN; 5–pin female; 10 ft (3.05 m) 1 GAUGE, pressure, fluid; used on high pressure kits only (see detail drawing) 1 109 110 16V819 GROMMET, cable 1 111 24U236 TOOL, repair, valve (not shown) 1 114 ◆ TOOL, installation, valve (not shown) 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 all available kits] Control Module Kit (108) [see Non-IS Color Change Control Modules, page 64 for parts] Tool (114) Tube Length (115) Low Pressure Non-Circulating Color Change Kits 24R915 2 color or 2 catalyst 24T458 24T557 24U239 60 ft (18.3 m) 24R916 4 color or 4 catalyst 24T460 24T558 24U239 120 ft (36.6 m) 24R917 6 color 24T462 24T559 24U239 210 ft (64.05 m) 24R918 8 color 24T464 24T560 24U239 360 ft (109.8 m) Low Pressure Circulating Color Change Kits 24R919 2 color 24T488 24T557 24U239 60 ft (18.3 m) 24R920 4 color 24T490 24T558 24U239 120 ft (36.6 m) 24R921 6 color 24T492 24T559 24U239 210 ft (64.05 m) 24R922 8 color 24T494 24T560 24U239 360 ft (109.8 m) 333282B 47 Parts High Pressure Non-IS Kits Kit No. Kit Description Standard Valve Manifold Kits (102) [see High Pressure Valve Manifold Kits, page 58 for all available kits] Control Module Kit (108) [see Non-IS Color Change Control Modules, page 64 for parts] Tool (114) Tube Length (115) High Pressure Non-Circulating Color Change Kits 24R959 2 color or 2 catalyst 24T648 24T557 24U240 60 ft (18.3 m) 24R960 4 color or 4 catalyst 24T650 24T558 24U240 120 ft (36.6 m) 24R961 6 color 24T652 24T559 24U240 210 ft (64.05 m) 24R962 8 color 24T654 24T560 24U240 360 ft (109.8 m) High Pressure Acid Compatible Non-Circulating Catalyst Change Kits 24T579 2 catalyst 24U182 24T557 24U240 60 ft (18.3 m) 24T580 4 catalyst 24U183 24T558 24U240 120 ft (36.6 m) High Pressure Circulating Color Change Kits 24R963 2 color 24T678 24T557 24U240 60 ft (18.3 m) 24R964 4 color 24T680 24T558 24U240 120 ft (36.6 m) 24R965 6 color 24T682 24T559 24U240 210 ft (64.05 m) 24R966 8 color 24T684 24T560 24U240 360 ft (109.8 m) 48 333282B Parts Notes 333282B 49 Parts IS Color Change Kits Ref. No. Part No. Description Qty Ref. No. 101 ◆ KIT, manifold, valve; . See Valve Manifold Kits, page 53 for available kits. 2 110 103 24V351 MANIFOLD, mix, remote 1 104 24N346 HOSE, coupled, 2.5 ft. 2 HOSE, static mixer 1 105 Part No. Description Qty TOOL, repair, color change valve, not shown 1 24U236 Low Pressure 24R124 High Pressure 111 1 TOOL, installation, color change valve, not shown 16W564 Low Pressure 24U239 Low Pressure 16W563 High Pressure 24U240 High Pressure 106 ◆ KIT, module, control 1 112 223547 WIRE, assembly, 25 ft. 2 107 16Y954 BRACKET, manifold 2 113 100016 WASHER, lock 4 108 100015 NUT, hex 4 114 16V429 1 SCREW, cap, hex 4 CABLE, CAN, 50 ft (15.2 m); not shown 109 50 104429 Low Pressure 113469 High Pressure ◆ See the following tables for the part number used in your color change kit. 333282B Parts Low Pressure IS Kits Kit No. Kit Description Standard Valve Manifold Kits (101) [see Low Pressure Valve Manifold Kits, page 53 for all available kits] Control Module Kit (106) [see IS Color Change Control Modules, page 66 for parts] Low Pressure Non-Circulating Color Change Kits 24V157 1 color and 1 catalyst 24T457 (2) 24T571 24V158 2 colors and 1 catalyst 24T458, 24T457 24T571 24V159 4 colors and 1 catalyst 24T460, 24T457 24T572 24V160 6 colors and 1 catalyst 24T462, 24T457 24T573 24V161 8 colors and 1 catalyst 24T464, 24T457 24T574 24V162 12 colors and 1 catalyst 24T468, 24T369 24T774 24V331 2 colors and 2 catalysts 24T458 (2) 24T571 24V332 4 colors and 2 catalysts 24T460, 24T458 24T572 24V333 6 colors and 2 catalysts 24T462, 24T458 24T573 24V334 8 colors and 2 catalysts 24T464, 24T458 24T574 24V335 12 colors and 2 catalysts 24T468, 24T458 24T774 24V343 4 colors and 4 catalysts 24T460 (2) 24T775 24V344 6 colors and 4 catalysts 24T462, 24T460 24T776 24V345 8 colors and 4 catalysts 24T464, 24T460 24T777 24V346 12 colors and 4 catalysts 24T468, 24T460 24T778 Low Pressure Circulating Color Change Kits 24V166 1 color and 1 catalyst 24T487 (2) 24T571 24V167 2 colors and 1 catalyst 24T488, 24T487 24T571 24V308 4 colors and 1 catalyst 24T490, 24T487 24T572 24V309 6 colors and 1 catalyst 24T492, 24T487 24T573 24V326 8 colors and 1 catalyst 24T494, 24T487 24T574 24V327 12 colors and 1 catalyst 24T498, 24T487 24T774 24V336 2 colors and 2 catalysts 24T488 (2) 24T571 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 24T490 (2) 24T775 24V348 6 colors and 4 catalysts 24T492, 24T490 24T776 24V349 8 colors and 4 catalysts 24T494, 24T490 24T777 24V350 12 colors and 4 catalysts 24T498, 24T490 24T778 333282B 51 Parts High Pressure IS Kits Kit No. Kit Description Standard Valve Manifold Kits (101) [see Low Pressure Valve Manifold Kits, page 53 for all available kits] Control Module Kit (106) [see IS Color Change Control Modules, page 66 for parts] High Pressure Non-Circulating Color Change Kits 24V359 1 color and 1 catalyst 24T647 (2) 24T571 24V360 2 colors and 1 catalyst 24T648, 24T647 24T571 24V361 4 colors and 1 catalyst 24T650, 24T647 24T572 24V362 6 colors and 1 catalyst 24T652, 24T647 24T573 24V363 8 colors and 1 catalyst 24T654, 24T647 24T574 24V364 12 colors and 1 catalyst 24T658, 24T647 24T774 24V381 2 colors and 2 catalysts 24T648 (2) 24T571 24V382 4 colors and 2 catalysts 24T650, 24T648 24T572 24V383 6 colors and 2 catalysts 24T652, 24T648 24T573 24V384 8 colors and 2 catalysts 24T654, 24T648 24T574 24V385 12 colors and 2 catalysts 24T658, 24T648 24T774 24V396 4 colors and 4 catalysts 24T650 (2) 24T775 24V397 6 colors and 4 catalysts 24T652, 24T650 24T776 24V398 8 colors and 4 catalysts 24T654, 24T650 24T777 24V399 12 colors and 4 catalysts 24T658, 24T650 24T778 High Pressure Circulating Color Change Kits 24V369 1 color and 1 catalyst 24T677(2) 24T571 24V370 2 colors and 1 catalyst 24T678, 24T677 24T571 24V371 4 colors and 1 catalyst 24T680, 24T677 24T572 24V372 6 colors and 1 catalyst 24T682, 24T677 24T573 24V373 8 colors and 1 catalyst 24T684, 24T677 24T574 24V374 12 colors and 1 catalyst 24T688, 24T677 24T774 24V389 2 colors and 2 catalysts 24T678 (2) 24T571 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 24T680 (2) 24T775 24V403 6 colors and 4 catalysts 24T682, 24T680 24T776 24V404 8 colors and 4 catalysts 24T684, 24T680 24T777 24V405 12 colors and 4 catalysts 24T688, 24T680 24T778 52 333282B Parts Valve Manifold Kits 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. Low Pressure Valve Manifold Kits Non-Circulating Valve Manifold Kits Circulating Valve Manifold Kits Kit No. Series Kit Description Kit No. Series Kit Description 24T457 A 2 valves 24T487 A 2 valves 24T458 A 3 valves 24T488 A 3 valves 24T459 A 4 valves 24T489 A 4 valves 24T460 A 5 valves 24T490 A 5 valves 24T461 A 6 valves 24T491 A 6 valves 24T462 A 7 valves 24T492 A 7 valves 24T463 A 8 valves 24T493 A 8 valves 24T464 A 9 valves 24T494 A 9 valves 24T465 A 10 valves 24T495 A 10 valves 24T466 A 11 valves 24T496 A 11 valves 24T467 A 12 valves 24T497 A 12 valves 24T468 A 13 valves 24T498 A 13 valves 24T469 A 14 valves 24T499 A 14 valves 24T470 A 15 valves 24T500 A 15 valves 24T471 A 16 valves 24T501 A 16 valves 24T472 A 17 valves 24T502 A 17 valves 24T473 A 18 valves 24T503 A 18 valves 24T474 A 19 valves 24T504 A 19 valves 24T475 A 20 valves 24T505 A 20 valves 24T476 A 21 valves 24T506 A 21 valves 24T477 A 22 valves 24T507 A 22 valves 24T478 A 23 valves 24T508 A 23 valves 24T479 A 24 valves 24T509 A 24 valves 24T480 A 25 valves 24T510 A 25 valves 24T481 A 26 valves 24T511 A 26 valves 24T482 A 27 valves 24T512 A 27 valves 24T483 A 28 valves 24T513 A 28 valves 24T484 A 29 valves 24T514 A 29 valves 24T485 A 30 valves 24T515 A 30 valves 24T486 A 31 valves 24T516 A 31 valves 333282B 53 Parts Valve Manifold Kit Parts 54 333282B Parts Ref. No. Part No. Description Ref. No. Part No. Description 1 16P259 MANIFOLD 12 104893 O-RING; ptfe 2 111450 O-RING; chemically resistant 13 24T523 24T441 VALVE, for non-circulating kits; includes item 2 FITTING, fluid; 7/16–20 x 1/4 npt(m) 3 14 111328 24T442 VALVE, for circulating kits; includes item 2 CONNECTOR, tube; 10–32(m) x 5/32 in. (4 mm) OD tube 4 24R051 PLUG, cc valve 15 24T525 ROD, connecting; 3 in. (76 mm) 5 16N256 RETAINER, nut 16 24T524 6 111457 O-RING; ptfe ROD, connecting; 1.5 in. (38 mm) 7 24T521 PLATE, outlet, manifold 17 111504 O-RING; chemically resistant 8 24T522 PLATE, end, manifold 18 557716 PLUG; 7/16–20 9 157974 WASHER, plain 19 104644 10 104092 SCREW, cap, socket head; 10–24 x 0.625 in. (16 mm) PLUG, screw; 10–32 x 0.156 in. (4 mm) 11 100179 NUT, hex; 10–24 Qty ★ Qty ★ ★ See the following tables to determine the quantity of each part in your valve manifold kit. Low Pressure Non-Circulating Valve Manifold Kit Part Quantities Kit No. Reference Numbers 1 2 3 4 5 6 7 8 10 12 13 14 15 16 17 18 19 24T457 1 2 2 0 2 2 1 1 3 3 3 2 0 3 1 2 0 24T458 2 4 3 1 4 3 1 1 3 4 4 3 3 0 1 5 2 24T459 2 4 4 0 4 3 1 1 3 5 5 4 3 0 1 4 0 24T460 3 6 5 1 6 4 1 1 3 6 6 5 3 3 1 7 2 24T461 3 6 6 0 6 4 1 1 3 7 7 6 3 3 1 6 0 24T462 4 8 7 1 8 5 1 1 3 8 8 7 6 0 1 9 2 24T463 4 8 8 0 8 5 1 1 3 9 9 8 6 0 1 8 0 24T464 5 10 9 1 10 6 1 1 3 10 10 9 6 3 1 11 2 24T465 5 10 10 0 10 6 1 1 3 11 11 10 6 3 1 10 0 24T466 6 12 11 1 12 7 1 1 3 12 12 11 9 0 1 13 2 24T467 6 12 12 0 12 7 1 1 3 13 13 12 9 0 1 12 0 24T468 7 14 13 1 14 8 1 1 3 14 14 13 9 3 1 15 2 24T469 7 14 14 0 14 8 1 1 3 15 15 14 9 3 1 14 0 24T470 8 16 15 1 16 9 1 1 3 16 16 15 12 0 1 17 2 24T471 8 16 16 0 16 9 1 1 3 17 17 16 12 0 1 16 0 24T472 9 18 17 1 18 10 1 1 3 18 18 17 12 3 1 19 2 24T473 9 18 18 0 18 10 1 1 3 19 19 18 12 3 1 18 0 24T474 10 20 19 1 20 11 1 1 3 20 20 19 15 0 1 21 2 24T475 10 20 20 0 20 11 1 1 3 21 21 20 15 0 1 20 0 333282B 55 Parts Kit No. Reference Numbers 1 2 3 4 5 6 7 8 10 12 13 14 15 16 17 18 19 24T476 11 22 21 1 22 12 1 1 3 22 22 21 15 3 1 23 2 24T477 11 22 22 0 22 12 1 1 3 23 23 22 15 3 1 22 0 24T478 12 24 23 1 24 13 1 1 3 24 24 23 18 0 1 25 2 24T479 12 24 24 0 24 13 1 1 3 25 25 24 18 0 1 24 0 24T480 13 26 25 1 26 14 1 1 3 26 26 25 18 3 1 27 2 24T481 13 26 26 0 26 14 1 1 3 27 27 26 18 3 1 26 0 24T482 14 28 27 1 28 15 1 1 3 28 28 27 21 0 1 29 2 24T483 14 28 28 0 28 15 1 1 3 29 29 28 21 0 1 28 0 24T484 15 30 29 1 30 16 1 1 3 30 30 29 21 3 1 31 2 24T485 15 30 30 0 30 16 1 1 3 31 31 30 21 3 1 30 0 24T486 16 32 31 1 32 17 1 1 3 32 32 31 24 0 1 33 2 56 333282B Parts Low Pressure Circulating Valve Manifold Kit Part Quantities Kit No. Reference Numbers 1 2 3 4 5 6 7 8 10 12 13 14 15 16 17 18 19 24T487 1 2 2 0 2 2 1 1 3 5 5 2 0 3 1 0 0 24T488 2 4 3 1 4 3 1 1 3 7 7 3 3 0 1 2 2 24T489 2 4 4 0 4 3 1 1 3 9 9 4 3 0 1 0 0 24T490 3 6 5 1 6 4 1 1 3 11 11 5 3 3 1 2 2 24T491 3 6 6 0 6 4 1 1 3 13 13 6 3 3 1 0 0 24T492 4 8 7 1 8 5 1 1 3 15 15 7 6 0 1 2 2 24T493 4 8 8 0 8 5 1 1 3 17 17 8 6 0 1 0 0 24T494 5 10 9 1 10 6 1 1 3 19 19 9 6 3 1 2 2 24T495 5 10 10 0 10 6 1 1 3 21 21 10 6 3 1 0 0 24T496 6 12 11 1 12 7 1 1 3 23 23 11 9 0 1 2 2 24T497 6 12 12 0 12 7 1 1 3 25 25 12 9 0 1 0 0 24T498 7 14 13 1 14 8 1 1 3 27 27 13 9 3 1 2 2 24T499 7 14 14 0 14 8 1 1 3 29 29 14 9 3 1 0 0 24T500 8 16 15 1 16 9 1 1 3 31 31 15 12 0 1 2 2 24T501 8 16 16 0 16 9 1 1 3 33 33 16 12 0 1 0 0 24T502 9 18 17 1 18 10 1 1 3 35 35 17 12 3 1 2 2 24T503 9 18 18 0 18 10 1 1 3 37 37 18 12 3 1 0 0 24T504 10 20 19 1 20 11 1 1 3 39 39 19 15 0 1 2 2 24T505 10 20 20 0 20 11 1 1 3 41 41 20 15 0 1 0 0 24T506 11 22 21 1 22 12 1 1 3 43 43 21 15 3 1 2 2 24T507 11 22 22 0 22 12 1 1 3 45 45 22 15 3 1 0 0 24T508 12 24 23 1 24 13 1 1 3 47 47 23 18 0 1 2 2 24T509 12 24 24 0 24 13 1 1 3 49 49 24 18 0 1 0 0 24T510 13 26 25 1 26 14 1 1 3 51 51 25 18 3 1 2 2 24T511 13 26 26 0 26 14 1 1 3 53 53 26 18 3 1 0 0 24T512 14 28 27 1 28 15 1 1 3 55 55 27 21 0 1 2 2 24T513 14 28 28 0 28 15 1 1 3 57 57 28 21 0 1 0 0 24T514 15 30 29 1 30 16 1 1 3 59 59 29 21 3 1 2 2 24T515 15 30 30 0 30 16 1 1 3 61 61 30 21 3 1 0 0 24T516 16 32 31 1 32 17 1 1 3 63 63 31 24 0 1 2 2 333282B 57 Parts High Pressure Valve Manifold Kits Non-Circulating Valve Manifold Kits Circulating Valve Manifold Kits Kit No. Series Kit Description Kit No. Series Kit Description 24T647 A 2 valves 24T677 A 2 valves 24T648 A 3 valves 24T678 A 3 valves 24T649 A 4 valves 24T679 A 4 valves 24T650 A 5 valves 24T680 A 5 valves 24T651 A 6 valves 24T681 A 6 valves 24T652 A 7 valves 24T682 A 7 valves 24T653 A 8 valves 24T683 A 8 valves 24T654 A 9 valves 24T684 A 9 valves 24T655 A 10 valves 24T685 A 10 valves 24T656 A 11 valves 24T686 A 11 valves 24T657 A 12 valves 24T687 A 12 valves 24T658 A 13 valves 24T688 A 13 valves 24T659 A 14 valves 24T689 A 14 valves 24T660 A 15 valves 24T690 A 15 valves 24T661 A 16 valves 24T691 A 16 valves 24T662 A 17 valves 24T692 A 17 valves 24T663 A 18 valves 24T693 A 18 valves 24T664 A 19 valves 24T694 A 19 valves 24T665 A 20 valves 24T695 A 20 valves 24T666 A 21 valves 24T696 A 21 valves 24T667 A 22 valves 24T697 A 22 valves 24T668 A 23 valves 24T698 A 23 valves 24T669 A 24 valves 24T699 A 24 valves 24T670 A 25 valves 24T700 A 25 valves 24T671 A 26 valves 24T701 A 26 valves 24T672 A 27 valves 24T702 A 27 valves 24T673 A 28 valves 24T703 A 28 valves 24T674 A 29 valves 24T704 A 29 valves 24T675 A 30 valves 24T705 A 30 valves 24T676 A 31 valves 24T706 A 31 valves 24T845 (acidcatalyzed) A 3 valves 24T846 (acidcatalyzed) A 5 valves 58 333282B Parts Valve Manifold Kit Parts 333282B 59 Parts Ref. No. Part No. Description Ref. No. Part No. Description 1 16N271 MANIFOLD, for circulating kits 13 24T523 FITTING, fluid; 7/16–20 x 1/4 npt(m) 2 111450 O-RING; chemically resistant 14 111328 24T581 VALVE, for non-circulating kits; includes item 2 CONNECTOR, tube; 10–32(m) x 5/32 in. (4 mm) OD tube 3 15 24T729 24T582 VALVE, for circulating kits; includes item 2 ROD, connecting; 3.290 in. (84 mm) 16 24T728 24T583 VALVE, for non-circulating, acid compatible kits; includes item 2 ROD, connecting; 1.645 in. (42 mm) 18 557716 PLUG; 7/16–20 19 104644 PLUG, screw; 10–32 x 0.156 in. (4 mm) Qty 4 24R052 PLUG, cc valve 5 16N269 RETAINER, nut 6 111457 O-RING; ptfe 7 24T725 PLATE, outlet, manifold 8 24T726 PLATE, end, manifold 10 111820 SCREW, cap, socket head; 10–24 x 0.75 in. (19 mm) 12 104893 O-RING; ptfe ★ Qty ★ ★ See the following tables to determine the quantity of each part in your valve manifold kit. High Pressure Non-Circulating Valve Manifold Kit Part Quantities Kit No. Reference Numbers 1 2 3 4 5 6 7 8 10 12 13 14 15 16 18 19 24T647 1 2 2 0 2 2 1 1 3 3 3 2 0 1 0 0 24T648 2 4 3 1 4 3 1 1 3 4 4 3 1 0 1 2 24T649 2 4 4 0 4 3 1 1 3 5 5 4 1 0 0 0 24T650 3 6 5 1 6 4 1 1 3 6 6 5 1 1 1 2 24T651 3 6 6 0 6 4 1 1 3 7 7 6 1 1 0 0 24T652 4 8 7 1 8 5 1 1 3 8 8 7 2 0 1 2 24T653 4 8 8 0 8 5 1 1 3 9 9 8 2 0 0 0 24T654 5 10 9 1 10 6 1 1 3 10 10 9 2 1 1 2 24T655 5 10 10 0 10 6 1 1 3 11 11 10 2 1 0 0 24T656 6 12 11 1 12 7 1 1 3 12 12 11 3 0 1 2 24T657 6 12 12 0 12 7 1 1 3 13 13 12 3 0 0 0 24T658 7 14 13 1 14 8 1 1 3 14 14 13 3 1 1 2 24T659 7 14 14 0 14 8 1 1 3 15 15 14 3 1 0 0 24T660 8 16 15 1 16 9 1 1 3 16 16 15 4 0 1 2 24T661 8 16 16 0 16 9 1 1 3 17 17 16 4 0 0 0 24T662 9 18 17 1 18 10 1 1 3 18 18 17 4 1 1 2 60 333282B Parts Kit No. Reference Numbers 1 2 3 4 5 6 7 8 10 12 13 14 15 16 18 19 24T663 9 18 18 0 18 10 1 1 3 19 19 18 4 1 0 0 24T664 10 20 19 1 20 11 1 1 3 20 20 19 5 0 1 2 24T665 10 20 20 0 20 11 1 1 3 21 21 20 5 0 0 0 24T666 11 22 21 1 22 12 1 1 3 22 22 21 5 1 1 2 24T667 11 22 22 0 22 12 1 1 3 23 23 22 5 1 0 0 24T668 12 24 23 1 24 13 1 1 3 24 24 23 6 0 1 2 24T669 12 24 24 0 24 13 1 1 3 25 25 24 6 0 0 0 24T670 13 26 25 1 26 14 1 1 3 26 26 25 6 1 1 2 24T671 13 26 26 0 26 14 1 1 3 27 27 26 6 1 0 0 24T672 14 28 27 1 28 15 1 1 3 28 28 27 7 0 1 2 24T673 14 28 28 0 28 15 1 1 3 29 29 28 7 0 0 0 24T674 15 30 29 1 30 16 1 1 3 30 30 29 7 1 1 2 24T675 15 30 30 0 30 16 1 1 3 31 31 30 7 1 0 0 24T676 16 32 31 1 32 17 1 1 3 32 32 31 8 0 1 2 24T845 2 4 3 1 4 3 1 1 3 4 4 3 1 0 1 2 24T846 3 6 5 1 6 4 1 1 3 6 6 5 1 1 1 2 333282B 61 Parts High Pressure Circulating Valve Manifold Kit Part Quantities Kit No. Reference Numbers 1 2 3 4 5 6 7 8 10 12 13 14 15 16 18 19 24T677 1 2 2 0 2 2 1 1 3 5 5 2 0 1 0 0 24T678 2 4 3 1 4 3 1 1 3 7 7 3 1 0 2 2 24T679 2 4 4 0 4 3 1 1 3 9 9 4 1 0 0 0 24T680 3 6 5 1 6 4 1 1 3 11 11 5 1 1 2 2 24T681 3 6 6 0 6 4 1 1 3 13 13 6 1 1 0 0 24T682 4 8 7 1 8 5 1 1 3 15 15 7 2 0 2 2 24T683 4 8 8 0 8 5 1 1 3 17 17 8 2 0 0 0 24T684 5 10 9 1 10 6 1 1 3 19 19 9 2 1 2 2 24T685 5 10 10 0 10 6 1 1 3 21 21 10 2 1 0 0 24T686 6 12 11 1 12 7 1 1 3 23 23 11 3 0 2 2 24T687 6 12 12 0 12 7 1 1 3 25 25 12 3 0 0 0 24T688 7 14 13 1 14 8 1 1 3 27 27 13 3 1 2 2 24T689 7 14 14 0 14 8 1 1 3 29 29 14 3 1 0 0 24T690 8 16 15 1 16 9 1 1 3 31 31 15 4 0 2 2 24T691 8 16 16 0 16 9 1 1 3 33 33 16 4 0 0 0 24T692 9 18 17 1 18 10 1 1 3 35 35 17 4 1 2 2 24T693 9 18 18 0 18 10 1 1 3 37 37 18 4 1 0 0 24T694 10 20 19 1 20 11 1 1 3 39 39 19 5 0 2 2 24T695 10 20 20 0 20 11 1 1 3 41 41 20 5 0 0 0 24T696 11 22 21 1 22 12 1 1 3 43 43 21 5 1 2 2 24T697 11 22 22 0 22 12 1 1 3 45 45 22 5 1 0 0 24T698 12 24 23 1 24 13 1 1 3 47 47 23 6 0 2 2 24T699 12 24 24 0 24 13 1 1 3 49 49 24 6 0 0 0 24T700 13 26 25 1 26 14 1 1 3 51 51 25 6 1 2 2 24T701 13 26 26 0 26 14 1 1 3 53 53 26 6 1 0 0 24T702 14 28 27 1 28 15 1 1 3 55 55 27 7 0 2 2 24T703 14 28 28 0 28 15 1 1 3 57 57 28 7 0 0 0 24T704 15 30 29 1 30 16 1 1 3 59 59 29 7 1 2 2 24T705 15 30 30 0 30 16 1 1 3 61 61 30 7 1 0 0 24T706 16 32 31 1 32 17 1 1 3 63 63 31 8 0 2 2 62 333282B Parts Notes 333282B 63 Parts Color Change Control Module Kits Non-IS Color Change Control Modules 64 333282B Parts Ref. No. Part No. Description Qty Ref. No. Part No. Description Qty 301 ——— PANEL 1 316 C06061 MUFFLER 2 302 24T566 BOARD, circuit 1 317 115671 1 302a 123690 FUSE; 125 mA 1 303 112324 SCREW, machine, pan head; 4–40 x 0.25 in. (6 mm) 6 FITTING, connector; 1/8 npt(m) x 1/4 in. (6 mm) OD tube 318 112698 2 304 24T562 COVER 1 ELBOW; 1/8 npt(m) x 1/4 in. (6 mm) OD tube 305 119162 CONNECTOR, 6–position ★ 319 590332 TUBE; polyethylene; 1/4 in. (6 mm) OD 1 307 116343 SCREW, ground; M5 x 0.8 1 320 598095 1 308 123691 HOLDER, fuse 1 TUBE; nylon; 5/32 in. (4 mm) OD 309 24T563 MANIFOLD 2 321 ——— STRAP, tie ★ 310 16P316 SOLENOID ★ 322 ——— FERRULE ★ 311 117831 SCREW, machine, pan head; 6–32 x 0.5 in. (13 mm) 4 324 114263 FITTING, connector; 1/8 npt(m) x 5/32 in. (4 mm) OD tube ★ 312 103833 SCREW, machine, pan head; 10–32 x 0.375 in. (10 mm) 8 332 151395 WASHER 4 313 24T565 PLUG; 5/8–32; includes item 314 ★ ★ See the following table to determine the quantity of each part in your control module kit. 314 113418 O-RING; buna-N 14 315 100139 PLUG, pipe; 1/8 npt 3 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 in the top row to find the part 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. Part No. Description Qty Ref. No. Part No. Description Qty 301 ——— PANEL 1 318 112698 2 302 24T566 BOARD, circuit 1 ELBOW; 1/8 npt(m) x 1/4 in. (6 mm) OD tube 302a 123690 FUSE; 125 mA 1 319 590332 1 303 112324 SCREW, machine, pan head; 4–40 x 0.25 in. (6 mm) 6 TUBE; polyethylene; 1/4 in. (6 mm) OD 320 598095 1 304 24U567 COVER 1 TUBE; nylon; 5/32 in. (4 mm) OD 119162 CONNECTOR, 6–position 6 321 ——— 305 STRAP, tie 2 116343 SCREW, ground; M5 x 0.8 1 322 ——— 307 FERRULE ★ 308 123691 HOLDER, fuse 1 324 109193 ELBOW, connector; 10–32 (m) x 5/32 in. (4 mm) OD tube ★ 309 15T636 MANIFOLD 2 331 16U743 SPACER 6 310 121324 SOLENOID ★ 332 16U744 PLATE, non-conductive 1 311 16M00 7 SCREW, machine, serrated head; 10–32 x 0.5 in. (13 mm) 4 333 16U745 PLATE, ground 1 334 16U746 SCREW, pan-head; 4–40 3 312 103833 SCREW, machine, pan head; 10–32 x 0.375 in. (10 mm) 4 335 16W50 1 LABEL, instructions 1 313 121628 SCREW, self-sealing; 4–40 x 0.25 in. (6 mm) ★ 339 102794 NUT, hex 7 315 100139 PLUG, pipe; 1/8 npt 3 340 101764 WASHER, lock 7 316 C06061 MUFFLER 2 341 188773 WASHER, flat 7 317 115671 FITTING, connector; 1/8 npt(m) x 1/4 in. (6 mm) OD tube 1 ★ See the following table to determine the quantity of each part in your control module kit. Parts labeled — — — are not available separately. IS Control Module Part Quantities Find your module kit no. in the left column and the desired reference number in the top row to find the part quantity used in your control module kit. Kit No. Kit Description Solenoid (310) Plug (313) Tube (320) Ferrule (322) Connector Fitting (324) 24T571 2 color and 2 catalyst 6 24 30 ft (9.1 m) 12 6 24T572 4 color and 2 catalyst 8 20 40 ft (12.2 m) 16 8 24T573 6 color and 2 catalyst 10 16 50 ft (15.2 m) 20 10 24T574 8 color and 2 catalyst 12 12 60 ft (18.3 m) 24 12 24T774 12 color and 2 catalyst; 13–24 color 16 4 80 ft (24.4 m) 32 16 24T775 4 color and 4 catalyst 10 16 50 ft (15.2 m) 20 10 333282B 67 Parts Kit No. Kit Description Solenoid (310) Plug (313) Tube (320) Ferrule (322) Connector Fitting (324) 24T776 6 color and 4 catalyst 12 12 60 ft (18.3 m) 24 12 24T777 8 color and 4 catalyst 14 8 70 ft (21.3 m) 28 14 24T778 12 color and 4 catalyst; 13–30 color 18 0 90 ft (27.4 m) 36 18 24T779 13–18 color 6 24 30 ft. (9.1 m) 12 6 68 333282B Parts Expansion Kits To add colors/catalysts, order the correct Non-IS Expansion Kit. Also order the corresponding IS Expansion Kit. See IS Expansion Kits, page 70. Non-IS Expansion Kits The following kits are available to add color valves in a non-IS area. Order a kit without a manifold if you have room for a valve on an existing manifold. Order a kit with a manifold if all ports on your existing manifolds have valves already. See Install an Expansion Kit, page 30 for instructions. Low Pressure Expansion Kits Kit No. Kit Description Without Manifold High Pressure Expansion Kits Kit No. Kit Description Without Manifold 24T443 One non-circulating valve (replaces a plug). Includes valve, solenoid, fittings, and tubing. 24T584 One non-circulating valve (replaces a plug). Includes valve, solenoid, fittings, and tubing. 24T444 One circulating valve (replaces a plug). Includes valve, solenoid, fittings, and tubing. 24T585 One circulating valve (replaces a plug). Includes valve, solenoid, fittings, and tubing. With Manifold With Manifold 24T445 Manifold with one non-circulating valve. Includes valve, plug, solenoid, fittings, and tubing. 24T586 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. 24T587 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. 24T588 Manifold with two non-circulating valves. Includes valves, solenoids, fittings, and tubing. 24T448 Manifold with two circulating valves. Includes valves, solenoids, fittings, and tubing. 24T589 Manifold with two circulating valves. Includes valves, solenoids, fittings, and tubing. High Pressure Acid-Compatible Expansion Kits Kit No. Kit Description Without Manifold 24T590 One non-circulating acidcompatible valve (replaces a plug). Includes valve, solenoid, fittings, and tubing. With Manifold 333282B 24T591 Manifold with one non-circulating acid-compatible valve. Includes valve, plug, solenoid, fittings, and tubing. 24T592 Manifold with two non-circulating acid-compatible valves. Includes valves, solenoids, fittings, and tubing. 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 room for a valve on an existing manifold. Order a kit with a manifold if all ports on your existing manifolds have valves already. See Install an Expansion Kit, page 30 for instructions. Low Pressure Expansion Kits Kit No. Kit Description Without Manifold High Pressure Expansion Kits Kit No. Kit Description Without Manifold 24T449 One non-circulating valve (replaces a plug). Includes valve, IS solenoid, fittings, and tubing. 24T712 One non-circulating valve (replaces a plug). Includes valve, IS solenoid, fittings, and tubing. 24T450 One circulating valve (replaces a plug). Includes valve, IS solenoid, fittings, and tubing. 24T713 One circulating valve (replaces a plug). Includes valve, IS solenoid, fittings, and tubing. With Manifold With Manifold 24T451 Manifold with one non-circulating valve. Includes valve, plug, IS solenoid, fittings, and tubing. 24T714 Manifold with one non-circulating valve. Includes valve, plug, IS solenoid, fittings, and tubing. 24T452 Manifold with one circulating valve. Includes valve, plug, IS solenoid, fittings, and tubing. 24T715 Manifold with one circulating valve. Includes valve, plug, IS solenoid, fittings, and tubing. 24T453 Manifold with two non-circulating valves. Includes valves, IS solenoids, fittings, and tubing. 24T716 Manifold with two non-circulating valves. Includes valves, IS solenoids, fittings, and tubing. 24T454 Manifold with two circulating valves. Includes valves, IS solenoids, fittings, and tubing. 24T717 Manifold with two circulating valves. Includes valves, IS solenoids, fittings, and tubing. High Pressure Acid-Compatible Expansion Kits Kit No. Kit Description Without Manifold 24T718 One non-circulating acidcompatible valve (replaces a plug). Includes valve, IS solenoid, fittings, and tubing. With Manifold 70 24T719 Manifold with one non-circulating acid-compatible valve. Includes valve, plug, IS solenoid, fittings, and tubing. 24T720 Manifold with two non-circulating acid-compatible valves. Includes valves, IS solenoids, fittings, and tubing. 333282B Dimensions Dimensions Figure 24 Non-IS Control Module A B C D E F 11.30 in. (1478 mm) 7.67 in. (195 mm) 9.8 in. (249 mm) 5.70 in. (145 mm) 0.31 in. (8 mm) 5.80 in. (147 mm) Figure 25 IS Control Module A B C D E F 16.57 in. (421 mm) 8.22 in. (209 mm) 15.07 in. (383 mm) 6.70 in. (170 mm) 0.31 in. (8 mm) 4.52 in. (115 mm) 333282B 71 Dimensions Figure 26 Manifold Mounting Bracket, Non-IS 72 T U V 3.84 in. (98 mm) 11.44 in. (291 mm) 0.312 in. (8 mm) diameter 333282B Dimensions Figure 27 IS Valve Manifold Bracket A B C D E F 5.63 in (168 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 mm) G H J K L M 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) N P 4 x 0.28 in (7 mm) 2 x 0.41 in (10 mm) 333282B 73 Dimensions Figure 28 Remote Mix Manifold Bracket A B C D E F 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 H J K 1.25 in (32 mm) 0.11 (3 mm) 4 x 0.22 in (6 mm) 2 x 0.41 (10 mm) 74 333282B Technical Data Technical Data U.S. Metric Low pressure kits 300 psi 2.1 MPa, 21 bar High pressure kits 1500 psi 10.5 MPa, 105 bar 100 psi 0.7 MPa, 7.0 bar 85–100 psi 0.6–0.7 MPa, 6.0–7.0 bar Color Change Kits Maximum fluid working pressure: Maximum working air pressure: Air supply: 20–5000 centipoise Viscosity range of fluid: Fluid inlet size: 1/4 npt(f) Fluid outlet size: 1/4 npt(f) Air inlet size: 5/32 in. OD tube 4 mm OD tube Wetted parts: Valve manifold Valve 333282B Glass-filled polyphenylene sulfide, 316 SST, PTFE, chemically resistant o-rings See valve manual 332454. 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 Graco’s written recommendations. This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco. This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation. THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale. GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties. In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise. FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées. Graco Information For the latest information about Graco products, visit www.graco.com. 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 Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001. www.graco.com Revision B, September 2014
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