Graco 333282B Color Change And Remote Mix Manifold Kits Users Manual 333282B, Kits, Instructions/Parts, English

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Instructions/Parts

Color Change and Remote Mix

Manifold Kits 333282B

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

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

Troubleshooting.................................................. 32

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

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

Dimensions ........................................................ 71

Technical Data ................................................... 75

Graco Standard Warranty.................................... 76

2333282B

Related Manuals

Related Manuals

Current manuals are available at www.graco.com.

Manual No. Description

332458 PD2K Proportioner, Installation

Manual, Systems for Automatic

Spray Applications

332564 PD2K Proportioner Operation

Manual, Systems for Automatic

Spray Applications

332565 PD2K Proportioner Repair-Parts

Manual, Systems for Automatic

Spray Applications

Manual No. Description

332709 Pump Repair-Parts Manual

332454 Color Change Valve Repair-Parts

Manual

332456 3rd and 4th Pump Kits

Instructions-Parts Manual

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 Identification Label

Kit No. Series Kit Description 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)

4333282B

Models

Kit No. Series Kit DescriptionMaximum 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)

24R964A4colo

r100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar)

24R965 A 6 color 100 psi(0.7MPa,7.0bar) 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 Kit Identification Label

0359 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 Catalyst + Solvent Valves

Number of Color + Solvent Valves

12

4

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).

13–1824V163

13–24 24V164

13–30 24V165

6333282B

Models

Table 2 . Low Pressure, Circulating Remote Mix Manifold Kits

Maximum Fluid Working Pressure: 300 psi (2.07 MPa, 20.7 bar)

Number of Catalyst + Solvent Valves

Number of Color + Solvent Valves

12

4

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 Catalyst + Solvent Valves

Number of Color + Solvent Valves

12

4

1 24V359

2 24V360 24V381

4 24V361 24V382 24V396

6 24V362 24V383 24V397

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 Catalyst + Solvent Valves

Number of Color + Solvent Valves

124

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.

8333282B

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 backtothese

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).

•Keepwork

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.

•Useonly

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.

• Keepaw

orking fire extinguisher in the work area.

ELECTRIC SHOCK HAZARD

This equipment must be grounded. Improper grounding, setup, or usage of the system can

cause electric shock.

•Turn

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

WARNING

INTRINSIC SAFETY

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.).

•Tohelpprev

ent fire and explosion:

• Do not install equipment approved only for a non-hazardous location in a hazardous

location. See model ID label for the intrinsic safety rating of your model.

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

• 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.

•Donotp

ut 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.

•Tight

en 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.

•Pres

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

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

TOXICFLUIDORFUMES

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.

•St

ore 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:

•Protectivee

yewear, 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.

•Usefluids

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 youareusingit.

•Useequ

ipment 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.

•Keepc

hildren 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

Spraying or dispensing materials containing

isocyanates creates potentially harmful mists,

vapors, and atomized particulates.

Read and understand material manufacturer’s

warnings and material MSDS to know specific

hazards and precautions related to isocyanates.

Prevent inhalation of isocyanate mists, vapors,

and atomized particulates by providing sufficient

ventilation in the work area. If sufficient ventilation

is not available, a supplied-air respirator is required

foreveryoneintheworkarea.

To prevent contact with isocyanates, appropriate

personal protective equipment, including

chemically impermeable gloves, boots, aprons,

and goggles, is also required for everyone in the

work area.

Keep Components A and B Separate

Cross-contamination can result in cured

material in fluid lines which could cause serious

injury or damage equipment. To prevent

cross-contamination:

•Never interchange component A and component

B wetted parts.

• Never use solvent on one side if it has been

contaminated from the other side.

Moisture Sensitivity of Isocyanates

Exposure to moisture (such as humidity) will cause

ISO to partially cure; forming small, hard, abrasive

crystals, which become suspended in the fluid.

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.

• 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

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.

•Alw

ays clean the fluid inlet strainers after

flushing.

•Che

ck with your material manufacturer for

chemical compatibility.

•Wh

en 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.

12333282B

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 Change Control Modules, Colors, and Catalysts

Color

Pump(s)

Catalyst

Pump(s)

Total

Pumps

Module 1

(Colors

1–8)

Module 2

(Colors

9–16)

Module

3(Colors

17–24)

Module 4

(Colors

25–30)

Catalyst

1–2

Catalyst

3–4

1 0 1 Not Applicable

112 Pump # 1 Pump # 1 Module # 5

Pump # 2

213 Module # 5

Pump # 2

2 0 2 Not Applicable

224

Pump # 3

Module

#5

Pump # 2

Module

#6

Pump # 4

314 Module # 5

Pump # 2

303

Pump#1

Not Applicable

404

Pump#1

Pump#2

Pump # 3

Pump # 4

Not Applicable

333282B 13

Setup the Modules

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.

1. Remove electrical power from the system.

2. Open the color change module. Locate switches

S4, S5, and S6onthecontrolmoduleboard.The

switches are shipped in the OFF position.

3. For each module, set the switches to ON or OFF,

as shown in the following table.

Non-IS Control Module Switch Settings

Control

Module

S6 S5 S4

Module 1

OFF

ON

OFF

ON

OFF

ON

Module 2

OFF

ON

OFF

ON

OFF

ON

Module 3

OFF

ON

OFF

ON

OFF

ON

Module 4

OFF

ON

OFF

ON

OFF

ON

Module 5

OFF

ON

OFF

ON

OFF

ON

Module 6

OFF

ON

OFF

ON

OFF

ON

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

14333282B

Setup the Modules

Non-IS Control Module 1

Inlet ManifoldOutlet Manifold

Solenoid Valve Solenoid Valve

1Solvent 1Dump

2Color 1 2Color 1

3Color 2 3Color 2

4Color 3 4Color 3

5Color 4 5Color 4

6Color 5 6Color 5

7Color 6 7Color 6

8Color 7 8Color 7

9Color 8 9Color 8

Non-IS Control Module 2

Inlet Manifold Outlet Manifold

Solenoid Valve Solenoid Valve

1(Solvent)* 1(Dump)*

2Color 9 2Color 9

3Color 10 3Color 10

4Color 11 4Color 11

5Color 12 5Color 12

6Color 13 6Color 13

7Color 14 7Color 14

8Color 15 8Color 15

9Color 16 9Color 16

Non-IS Control Module 3

Inlet Manifold Outlet Manifold

Solenoid Valve Solenoid Valve

1(Solvent)* 1(Dump)*

2Color 17 2Color 17

3Color 18 3Color 18

4Color 19 4Color 19

5Color 20 5Color 20

6Color 21 6Color 21

7Color 22 7Color 22

8Color 23 8Color 23

9Color 24 9Color 24

Non-IS Control Module 4

Inlet ManifoldOutlet Manifold

Solenoid Valve Solenoid Valve

1(Solvent)* 1(Dump)*

2Color 25 2Color 25

3Color 26 3Color 26

4Color 27 4Color 27

5Color 28 5Color 28

6Color 29 6Color 29

7Color 30 7Color 30

8 Not Used 8 Not Used

9NotUse

d9NotUse

d

Non-IS Control Module 5

Inlet Manifold Outlet Manifold

Solenoid Valve Solenoid Valve

1(Solvent)* 1(Dump)*

2Catalyst 1 2Catalyst 1

3Catalyst 2 3Catalyst 2

4Catalyst 3 4Catalyst 3

5Catalyst 4 5Catalyst 4

6 Not Used 6 Not Used

7Not Used 7Not Used

8 Not Used 8 Not Used

9 Not Used 9 Not Used

Non-IS Control Module 6

Inlet Manifold Outlet Manifold

Solenoid Valve Solenoid Valve

1(Solvent)* 1(Dump)*

2Catalyst 3 2Catalyst 3

3Catalyst 4 3Catalyst 4

4 Not Used 4 Not Used

5Not Used 5Not Used

6 Not Used 6 Not Used

7Not Used 7Not Used

8 Not Used 8 Not Used

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.

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.

3. For each module, set the switches to ON or OFF,

as shown in the following table.

IS Control Module Switch Settings

Control

Module

S6 S5 S4

Module 7

OFF

ON

OFF

ON

OFF

ON

Module 8

OFF

ON

OFF

ON

OFF

ON

4. Use the following figure and tables to determine

the solenoid valve assigned to each valve in the

valve manifold.

Figure 2 IS Control Module

16 333282B

Setup the Modules

IS Control Module 7

Solenoid Valve Solenoid Valve

1Color

Solvent

1Catalyst

Solvent

2Color 1 2Catalyst 1

3Color 2 3Catalyst 2

4Color 3 4Catalyst 3

5Color 4 5Catalyst 4

6Color 5 6Color 9

7Color 6 7Color 10

8Color 7 8Color 11

9Color 8 9Color 12

IS Control Module 8

Solenoid Valve Solenoid Valve

1Color 13 1Color 22

2Color 14 2Color 23

3Color 15 3Color 24

4Color 16 4Color 25

5Color 17 5Color 26

6Color 18 6Color 27

7Color 19 7Color 28

8Color 20 8Color 29

9Color 219Color 30

333282B 17

Installation

Installation

• To avoid electric shock, turn off power at

the main circuit breaker before opening the

enclosure.

• All electrical wiring must be done by a qualified

electrician and comply with all local codes and

regulations.

• Do not substitute or modify system components

as this may impair intrinsic safety.

• Do not install equipment approved only for

non-hazardous location in a hazardous location.

See the identification label for the intrinsic safety

rating for your model.

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.

3. Using the equipment as a template, mark the

mounting holes on the wall at a convenient height

for the operator and so the equipment is easily

accessible for maintenance.

NOTE: The smaller color change control modules

must be mounted in the Non-IS area. The larger

remote color change module may be mounted

in the IS area.

4. Drill mounting holes in the wall. Install anchors

as needed.

5. Bolt the equipment securely.

Air Supply

Connect a clean and dry air supply to the air inlet

fitting (317) of each color change control module in

the non-hazardous area and each remote module in

the hazardous area. The fitting is for 1/4 in. (6 mm)

ODtubing. Usea5micronfilter. Regulatetheair

pressure to 85–100 psi (0.6–0.7 MPa, 6.0–7.0 bar).

Grounding

This equipment must be grounded to reduce the

risk of static sparking and electric shock. Electric

or static sparking can cause fumes to ignite or

explode. Improper grounding can cause electric

shock. Grounding provides an escape wire for the

electric current.

Connect a ground wire from each color change

module in the non-hazardous area to a true earth

ground.

Intrinsically safe remote color change modules

located in the hazardous area must be connected to

a true earth ground in the hazardous area.

18 333282B

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.

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 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.

7. To install additional color control modules (six

maximum), mount the module(s) as described in

Mounting the Control Modules, page 18. Connect

a 5–pin CAN cable from J11 of the previous color

control module to J7 of the next control module.

8. Replace the cover of the PD2K electrical control

box before turning on power to the system.

Figure 4 Cable Connection at PD2K Electrical

Control Box

Figure 5 Detail of Isolation Board Cable Connections

333282B 19

Installation

Install the Valve Manifolds

NOTE: Always label the color connections to prevent

cross-connections. Label the inlet manifold, outlet

manifold, and each color valve with its assigned color.

The solvent and dump valves should be furthest from

the manifold stack primary inlet or outlet.

1. Install a 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.

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

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.

Figure 6 Install the Valve Manifolds

20 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.

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.

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

facing nipple (121).

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

Connect the Fluid Lines, page 26.

Figure 7 Install Back Pressure Regulator at Dump

Valve of Outlet Stack

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.

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 8 Intrinsically Safe Cable Connections

3. Connect the hazardous location cable (C1) to J7

on the remote color control module (108).

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 theISsideoftheisolationboardinthe

electrical control box. Connect the cable (C1) to

J4. See Electrical Schematics, page 36.

22333282B

Installation

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

J11onthefirst color control module to J7 on the

second module.

6. Replace the cover of the PD2K electrical control

box before turning on power to the system.

Install the Remote Valve Manifolds

1. Using the equipment as a template, mark the

mounting holes on the wall at a convenient height

for the operator and so the equipment is easily

accessible for maintenance. Mount the remote

valve manifolds near the remote color module

and the automatic dispensing device.

2. Install the mounting brackets for the color valve

manifolds and the catalyst valve manifolds. See

Dimensions, page 71. Use bolts to attach the

equipment securely.

3. Install the color and catalyst valve manifolds to

the brackets with four screws, washers, and nuts.

4. Connect the air lines from the solenoids to the

valves. See Connect the Valve Air Lines, page 24.

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

Connect the Fluid Lines, page 26.

333282B 23

Installation

Install the Remote Mix Manifold

1. Using the equipment as a template, mark the

mounting holes on the wall or robot arm, near the

automatic dispensing device.

2. Install the remote mix manifold. See

Dimensions, page 71. Use two bolts to attach

the equipment securely.

3. Install the remote mix manifold to the bracket

with four screws.

4. Connect the fluid supply lines to the remote mix

valve. See Connect the Fluid Lines, page 26.

Connect the Valve Air Lines

Non-Hazardous Area

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. SeeSetup 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.

24333282B

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. Usethetopvalveoftheoutlet valve stack as the

dump valve (D). Connect a waste dump line to

the 1/4 npt(m) dump valve outlet on the color and

catalyst valve stacks.

3. Connect the supply line for each color to the

corresponding color valve fitting (C1, C2, etc.) on

the inlet color valve stack.

4. Connect a supply line from the bottom fitting of

the inlet color valve stack to the inlet manifold of

the material A dosing pump.

5. Connect a supply line from the outlet manifold of

the material A dosing pump to the bottom fitting

of the outlet color valve stack.

Hazardous

Area

Remote

Color and

Catalyst

Valve

Manifolds

Non-

Hazardous

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

valvefittingontheremotecolorstack.

7. Connect a supply line from the outlet valve on

the bottom of the remote color valve stack to inlet

A on the remote mix manifold.

8. Connect the supply line for each catalyst to the

corresponding catalyst valve fitting on the inlet

catalyst valve stack.

9. Connect a supply line from the bottom fitting of

the inlet catalyst valve stack to the inlet manifold

of the material B dosing pump.

10. Connect a supply line from the outlet manifold of

the material B dosing pump to the bottom fitting

of the outlet catalyst valve stack.

11. Connect a dedicated supply line for each catalyst

to the corresponding catalyst valve fitting on the

outlet catalyst valve stack. Connect the other

end of each line to the corresponding catalyst

valve fitting on the remote catalyst valve stack.

NOTE: If your system uses more colors than

catalysts, branch the catalyst line to connect it to

each mix manifold. Install a check valve on each

branch of the catalyst line.

NOTE: For ease of maintenance, install a ball

valve at all fluid line tees.

12. Connect a supply line from the outlet valve of

the remote catalyst valve stack to inlet B on the

remote mix manifold.

13. Connect the static mixer to the outlet valve of the

remote mix manifold.

14. Connect a fluid line from the static mixer to the

automatic dispense device.

Figure 11 Color Change Connections

(Non-Circulating System)

KEY

A Air inlet

WSeal weepand

lubrication port

S Solvent fitting

C1 Color 1 fitting

C2 Color 2fitting

333282B 27

Installation

Connect Circulating Fluid Lines

Circulation valves enable constant circulation of a

color when that color is not being sprayed:

•Whenacolorva

lve 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.

• 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.

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.

b. Connect a dedicated fluid supply line for

each color to the corresponding color valve

(C1, C2, etc.) on the outlet color valve stack.

Connect the other end of each line to the

corresponding color valve on the remote

color stack.

c. Connect a 1/4 npt(f) circulation line from the

circulation port on each remote valve back to

thefluidsupp

ly container.

Figure 12 Valve Manifold Connections (Circulating

System)

KEY

DDump valve fitting

S Solvent fitting

C1 Color 1 fitting

C2 Color 2 fitting

R1 Color 1 circulation fitting

R2 Color 2 circulation fitting

28 333282B

Installation

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

KEY

AColor supply

BInletcolo

rstack

C Outlet color stack

DRemoteco

lor stack

ERemote mix manifold

F Automatic spray gun

G Return line to fluid supply

333282B 29

Installation

Install an Expansion Kit

Expansion Kits are available to add valves or

manifolds to your system. For each additional

color/catalyst desired, order a Non-IS Expansion

Kit and a corresponding IS Expansion Kit. See

Expansion Kits, page 69 for available kits.

NOTE: Remember that you may need up to 6 Non-IS

control modules and up to 2 IS control modules.

Follow Steps 1–7 to install solenoids, manifolds, and

valves, first in the Non-IS area, and then in the IS

area.

1. Remove electrical power from the system.

2. Relieve pressure as described in your PD2K

Operation Manual.

3. Open the control module cover. Install the

solenoid(s) and air fitting(s) at the appropriate

position(s) in the solenoid manifold. See

Setup the Modules, page 13. Connect one end

of the tubing to the solenoid’s air fitting.

4. Connect the solenoid wires to the appropriate

pins on the control module board. See

Electrical Schematics, page 36.

NOTE: If installing a one valve kit, it is not

necessary to disassemble the manifold stack as

shown in the figure. Skip step 5 and go on to

step 6.

5. If your kit is adding a manifold block (1), remove

the screws (10). Slide the existing manifolds off

the rods (15, 16), keeping the manifolds in the

correct order. Install the new manifold block (1).

The new block must be in the bottom position to

maintain correct location of the solvent and dump

valves. Screw the rods (16) included in the kit

into the existing rods. Slide the existing manifold

blocks onto the rods, being sure that they are in

the same positions as before. Ensure all o-rings

(6,17)areinplace,theninstallthescrews(10).

6. Install the valves as follows:

a. For a one valve kit, remove the plug

(4) and o-ring (2). Install a new o-ring

(2), the valve (3), and retainer (5),

using the valve installation tool. See

Replace a Color Valve, page 43.

b. For a manifold kit with one valve, install

the o-ring (2), valve (3), and retainer (5),

using the valve installation tool. See

Replace a Color Valve, page 43.Installthe

plug (4) in the unused manifold port.

c. For a manifold kit with two valves, install

the o-rings (2), valves (3), and retainers

(5), using the valve installation tool. See

Replace a Color Valve, page 43.

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

8. For each color/catalyst, connect fluid lines from

the source to the input color/catalyst stack. Then,

connect fluid lines from each output valve to the

corresponding remote color change valve.Install

the air fitting(s) (14).

9. Connect the tubing from the solenoid valve(s)

(see step 3) to the fitting(s) in both the IS and

and Non-IS areas.

10. Install the control module covers.

11. Return the unit to service.

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 fromthe

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.

Ifthereisnov

oltage 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.

2 POSITION

SWITCH

(16U725)

TERMINAL BLOCK

(114095)

LINE FILTER

(16V446)

24V

POWER

SUPPLY

(16T660)

CAN

IS BOARD

(24M485)

GUN TRIGGER INPUTS

GFB

INTERFACES

SWITCH (120278)

SOLVENT METER (258718)

LIGHT

TOWER

(15X472)

ADVANCED

DISPLAY MODULE

(24E451)

BARRIER

BOARD

(248192)

BREAKOUT MODULE PUMP 1

(24N527)

GCA

MODULE

EFCM

(24N913)

BREAKOUT MODULE PUMP 2

(24N527)

BREAKOUT MODULE PUMP 3

(24N527)

BREAKOUT MODULE PUMP 4

(24N527)

119159

119159

119159

119159

SOLENOID (121324)

PRESSURE SW (121323)

COLOR CHANGE

MODULE 1

(24N935)

COLOR CHANGE MODULE 7

(24R219)

COLOR CHANGE MODULE 8

(24R219)

BOOTH CONTROL (24M731)

HAZARDOUS LOCATION

NON-HAZARDOUS LOCATION

48V-10A POWER SUPPLY

(16U820)

SPLITTER

(16P243)

RELAY

POWER IN

FLOW RATE ANALOG IN

FLOW RATE ANALOG IN

FLOW RATE ANALOG IN

FLOW RATE ANALOG IN COLOR CHANGE

MODULE 2

(24N935)

COLOR CHANGE

MODULE 3

(24N935)

COLOR CHANGE

MODULE 4

(24N935)

CATALYST CHANGE

MODULE 6

(24N935)

CATALYST CHANGE

MODULE 5

(24N935)

TERMINAL BLOCKS WITH FUSES

CABLE (16T659)

CABLE (16T659)

CABLE (16T659)

CABLE (16T659)

CABLE

(16T280)

CABLE

(121003)

CABLE

(15V206)

CABLE (16V429)

CABLE

(15V206)

CABLE

(15V206) CABLE

(15V206) CABLE

(15V206)

CABLE

(16V426)

CABLE

(16V426)

POWER MODULE

(24R257)

CABLE

(121227) CABLE

(121227)

AWI

GATEWAY

(24R910)

5

16T072

CABLE (15V206)

INTEGRATION

GATEWAY

5

CABLE

(121001)

CABLE

16T658

CABLE

16H078

16W159

16W159

16W159

16W159

065161, 065159

SOLVENT

FLOW

INPUTS

SWITCH (120278)

SAFETY INTERLOCK SWITCH

SOLVENT CUTOFF (121324)

MAC SERIES 46

SOLENOID

(16P812)

ENCODER AND MOTOR

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

UP

DOWN

FLOW SENSOR

(120278)

OR G3000 METER

(239716, 258718

16M510, 16M519)

FAN

(24P658)

PUMP V/P FOR

FLUID REG.

MAC SERIES 46

SOLENOID

(16P812)

ENCODER AND MOTOR

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

UP

DOWN

FLOW SENSOR

(120278)

OR G3000 METER

(239716, 258718

16M510, 16M519)

FAN

(24P658)

PUMP V/P FOR

FLUID REG.

MAC SERIES 46

SOLENOID

(16P812)

ENCODER AND MOTOR

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

UP

DOWN

FLOW SENSOR

(120278)

OR G3000 METER

(239716, 258718

16M510, 16M519)

FAN

(24P658)

PUMP V/P FOR

FLUID REG.

MAC SERIES 46

SOLENOID

(16P812)

ENCODER AND MOTOR

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

UP

DOWN

FLOW SENSOR

(120278)

OR G3000 METER

(239716, 258718

16M510, 16M519)

FAN

(24P658)

PUMP V/P FOR

FLUID REG.

1

22

222

3

7

7

6

6

6

6

6

6

1

1

2

33

4

3

Figure 15 Electrical Schematic, Sheet 1

36 333282B

Electrical Schematics

+24VDC

COM

+24VDC

COM

PWR (RED)

SIG (WHITE)

COM (BLACK)

SHIELD/GRN

MANIFOLD

GROUND BAR

INLET TRANSDUCER

PUMP 1

(16P289 OR 16P290)

OUTLET TRANSDUCER

PUMP 1

(16P289 OR 16P290)

MAC SERIES 46

(16P812 QTY 2)

PUMP 1

UP

PUMP 1

DOWN

G3000

METER

PUMP 1

(EITHER, 239716,

258718,16M510,

OR 16M519)

24V

POWER

SUPPLY

(16T660)

1

2

3

1 2 3 4 5

CAN IS BOARD

1 2 3

UNUSED

UNUSED

BARRIER

BOARD

(248192)

BREAKOUT MODULE PUMP 1 (24N527)

252423222120191817161413121110 15987654321 252423222120191817161413121110 15987654321

1

2

345

252423222120191817161413121110 15987654321

UNUSED

CONTINUED ON PAGE 3

1

2

3

4

5

1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 6 7 8

GCA MODULE

EFCM

(24N913)

CONTINUED ON PAGE 3

(NON IS)

(IS)

5

4

3

2

1

UNUSED

UNUSED

UNUSED

14

SPLITTER

(16P243)

25 PIN D-SUB CABLE

(16T659)

+48V

COM

1 2 3 4

V/P FOR FLUID REG.

PUMP 1

1

2

3

4

5

6

7

8

9

10

11

12

48V-10A

POWER SUPPLY

(16U820)

PWR (RED)

SIG (WHITE)

COM (BLACK)

SHIELD/GRN

SOLVENT

METER

(258718)

UNUSED

UNUSED

+12VDC

COM

GFB INTERFACE

(121324)

+ - + - + - + -

+ -

+ - + - + - + -

F1

F2

F3

F4

+24VDC

COM

+24VDC

COM

MANIFOLD

INLET TRANSDUCER

PUMP 2

(16P289 OR 16P290)

OUTLET TRANSDUCER

PUMP 2

(16P289 OR 16P290)

MAC SERIES 46

(16P812 QTY 2)

PUMP 2

UP

PUMP 2

DOWN

G3000

METER

PUMP 2

(EITHER, 239716,

258718,16M510,

OR 16M519)

BREAKOUT MODULE PUMP 2 (24N527)

252423222120191817161413121110 15987654321

1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 6 7 8

+48V

COM

1 2 3 4

V/P FOR FLUID REG.

PUMP 2

POWER MODULE

(24R257)

PWR (RED)

SIG (WHITE)

COM (BLACK)

SHIELD/GRN

UNUSED

1

2

3

4

5

1

2

3

4

5

1

2

3

4

5

1

2

3

4

5

CABLE

(121227) INTEGRATION

GATEWAY

5

AWI

GATEWAY

(24R910)

5

CABLE

(121001)

CABLE (121227)

1 2 3 4 5 1 2 3 4 5

16T072

25 PIN

D-SUB CABLE

(16T659)

+12VDC

COM

SOLVENT CUTOFF (121324)

GRND

SCREW GRND

SCREW

+12VDC

COM

N L GRND

13 A1(+) A2(-)

RELAY

1 2 3 4 5 (24M485)

UNUSED

UNUSED

UNUSED CABLE (16V429)

CABLE

(15V206)

1 2 3 4

+48V

COM

FAN PUMP 2

(24P658)

1 2 3 4

+48V

COM

FAN PUMP 1

(24P658)

CABLE

(16T280)

TWISTED PAIR CABLE (16W159) TWISTED PAIR CABLE (16W159)

RED WIRE (065161)

BLACK WIRE (065159)

1 2 3 4 5 1 2 3 4

2 POSITION

SWITCH

(16U725)

N04 N04

TERMINAL

BLOCK

(114095)

L N GRND

LINE

FILTER

(16V446)

L N

CABLE

(16H078)

CABLE

(16T658)

POWER IN

N03 N03

L (BROWN)

N (BLUE)

L N GRND

L GRND N

GRND (GRN/YEL)

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 1

SEE DETAIL A OR B

1 2 3 4 5 1 2 3 4

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 2

SEE DETAIL A OR B

1

234567

12

5

1

234567

8

10

4

4

3

3

1

2

3

4

3

1

2

88

PUMP ENCODER AND MOTOR

(16P037)

BREAKOUT MODULE

(24N527)

1 2 3 4 5 1 2 3 4

MOTOR

MOUNTING

SCREW

DRAIN/FOIL

WIRE HARNESS

(24P684)

1 2 3 4 5 6 7 8 9 1011 12 1 2 3 4 5 6 7 8 9 10

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

DRAIN/FOIL

DETAIL A, LOW PRESSURE

PUMPS (24M706, 24M714)

23

PUMP ENCODER AND MOTOR

(16P036)

BREAKOUT MODULE

(24N527)

1 2 3 4 5 1 2 3 4

MOTOR

MOUNTING

SCREW

DRAIN/FOIL

WIRE HARNESS

(24P685)

1 2 3 4 5 6 7 8 9 1011 12 1 2 3 4 5 6 7 8 9 10

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

DRAIN/FOIL

DETAIL B, HIGH PRESSURE

PUMPS (24M707, 24M715)

1 2

23

P3 P3

P4 P4

Figure 16 Electrical Schematic, Sheet 2, Part 1

CONTINUED ON THE NEXT PAGE

333282B 37

Electrical Schematics

GUN TRIGGER INPUTS

GFB PRESSURE SWITCH (121323)

SOLVENT FLOW SWITCH 1 (120278)

1

2

3

4

5

1

2

3

4

5

LIGHT

TOWER

(15X472)

ADVANCED

DISPLAY MODULE

(24E451)

252423222120191817161413121110 15987654321 252423222120191817161413121110 15987654321

1

2

3

4

5

6

7

8

9

10

11

12

SIG

COM

GCA MODULE

EFCM

(24N913)

1

2

3

4

5

SIG

COM

SIG

COM

SIG

COM

SIG

COM

SIG

COM

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

COM

SIG

COM

25 PIN D-SUB CABLE

(16T659)

CABLE

(121003)

+24VDC

COM

+24VDC

COM

MANIFOLD

INLET TRANSDUCER

PUMP 3

(16P289 OR 16P290)

OUTLET TRANSDUCER

PUMP 3

(16P289 OR 16P290)

MAC SERIES 46

(16P812 QTY 2)

PUMP 3

UP

PUMP 3

DOWN

G3000

METER

PUMP 3

(EITHER, 239716,

258718,16M510,

OR 16M519)

BREAKOUT MODULE PUMP 3 (24N527)

252423222120191817161413121110 15987654321

1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 6 7 8

+48V

COM

1 2 3 4

V/P FOR FLUID REG.

PUMP 3

+24VDC

COM

+24VDC

COM

MANIFOLD

INLET TRANSDUCER

PUMP 4

(16P289 OR 16P290)

OUTLET TRANSDUCER

PUMP 4

(16P289 OR 16P290)

MAC SERIES 46

(16P812 QTY 2)

PUMP 4

UP

PUMP 4

DOWN

G3000

METER

PUMP 4

(EITHER, 239716,

258718,16M510,

OR 16M519)

BREAKOUT MODULE PUMP 4 (24N527)

252423222120191817161413121110 15987654321

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

3 4 5 6 7 8

+48V

COM

1 2 3 4

V/P FOR FLUID REG.

PUMP 4

PWR (RED)

SIG (WHITE)

COM (BLACK)

SHIELD/GRN

PWR (RED)

SIG (WHITE)

COM (BLACK)

SHIELD/GRN

25 PIN

D-SUB CABLE

(16T659)

GRND

SCREW GRND

SCREW

+48V

COM

FAN PUMP 4

(24P658)

1 2 3 4

+48V

COM

FAN PUMP 3

(24P658)

119159

TWISTED PAIR CABLE (16W159) TWISTED PAIR CABLE (16W159)

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

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 3

SEE DETAIL A OR B

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 4

SEE DETAIL A OR B

SOLVENT FLOW SWITCH 2 (120278)

SAFETY INTERLOCK SWITCH

34

6

7

1

234567

1

2345678

9

4

4

3

8

Figure 17 Electrical Schematic, Sheet 2, Part 2

CONTINUED ON THE NEXT PAGE

38 333282B

Electrical Schematics

COLOR

CHANGE

MODULE 1

(COLORS

1 THRU 8)

J8

J15

J14

J9

J10

J16

12345

12345

COLOR

CHANGE

MODULE 2

(COLORS

9 THRU 16)

J8

J15

J14

J9

J10

J16

12345

12345

COLOR

CHANGE

MODULE 3

(COLORS

17 THRU 24)

J8

J15

J14

J9

J10

J16

12345

COLOR

CHANGE

MODULE 4

(COLORS

25 THRU 32)

J8

J15

J14

J9

J10

J16

12345

1

2

3

4

5

FLUSH

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

FROM CAN IS BOARD (24M485) ON PAGE 2

CABLE (15V206)

CABLE (15V206)

CABLE

(15V206)

CABLE

(15V206)

DUMP

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

*FLUSH

COLOR 9

COLOR 10

COLOR 11

COLOR 12

COLOR 13

COLOR 14

COLOR 15

COLOR 16

DUMP*

COLOR 9

COLOR 10

COLOR 11

COLOR 12

COLOR 13

COLOR 14

COLOR 15

COLOR 16

*FLUSH

COLOR 25

COLOR 26

COLOR 27

COLOR 28

COLOR 29

COLOR 30

DUMP*

COLOR 25

COLOR 26

COLOR 27

COLOR 28

COLOR 29

COLOR 30

*FLUSH

COLOR 17

COLOR 18

COLOR 19

COLOR 20

COLOR 21

COLOR 22

COLOR 23

COLOR 24

DUMP*

COLOR 17

COLOR 18

COLOR 19

COLOR 20

COLOR 21

COLOR 22

COLOR 23

COLOR 24

12345

CATALYST

CHANGE

MODULE 5

(CATALYST

1 THRU 4)

J8

J15

J14

J9

J10

J16

12345

CABLE

(15V206)

FLUSH

CATALYST 1

CATALYST 2

CATALYST 3

CATALYST 4

DUMP

CATALYST 1

CATALYST 2

CATALYST 3

CATALYST 4

FROM CAN IS BOARD (24M485) ON PAGE 2

1

2

3

4

5

6

MANIFOLD

1

2

3

4

5

6

1

2

3

4

5

6

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

+12VDC

COM

+12VDC

COM

UNUSED

UNUSED

+12VDC

COM

+12VDC

COM

+12VDC

COM

6

5

4

3

2

1

6

5

4

3

2

1

6

5

4

3

2

1

COM

+12VDC

COM

+12VDC

COM

+12VDC

MANIFOLD

COM

+12VDC

COM

+12VDC

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

1

2

3

4

5

6

MANIFOLD

1

2

3

4

5

6

1

2

3

4

5

6

+12VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

6

5

4

3

2

1

6

5

4

3

2

1

6

5

4

3

2

1

COM

+12VDC

COM

+12VDC

COM

+12VDC

MANIFOLD

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

UNUSED

UNUSED

UNUSED

UNUSED

2

2

2

2

22

6

6

6

6

6

1

2

3

4

5

6

MANIFOLD

1

2

3

4

5

6

1

2

3

4

5

6

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

6

5

4

3

2

1

6

5

4

3

2

1

6

5

4

3

2

1

COM

+12VDC

COM

+12VDC

COM

+12VDC

MANIFOLD

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

1

2

3

4

5

6

MANIFOLD

1

2

3

4

5

6

1

2

3

4

5

6

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

6

5

4

3

2

1

6

5

4

3

2

1

6

5

4

3

2

1

COM

+12VDC

COM

+12VDC

COM

+12VDC

MANIFOLD

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

1

2

3

4

5

6

MANIFOLD

1

2

3

4

5

6

1

2

3

4

5

6

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

6

5

4

3

2

1

6

5

4

3

2

1

6

5

4

3

2

1

COM

+12VDC

COM

+12VDC

COM

+12VDC

MANIFOLD

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

Figure 18 Electrical Schematic, Sheet 3

* May be unused in some configurations.

CONTINUED ON THE NEXT PAGE

333282B 39

Electrical Schematics

CATALYST

CHANGE

MODULE 5

(CATALYST

1 THRU 2)

J8

J15

J14

J9

J10

J16

1

2

3

4

5

12345

CATALYST

CHANGE

MODULE 6

(CATALYST

3 THRU 4)

J8

J15

J14

J9

J10

J16

CABLE

(15V206)

FLUSH

CATALYST 1

CATALYST 2

DUMP

CATALYST 1

CATALYST 2

FLUSH

CATALYST 3

CATALYST 4

DUMP

CATALYST 3

CATALYST 4

12345

12345

CABLE

(15V206)

COLOR

CHANGE

MODULE 4

(COLORS

25 THRU 32)

22

2

6

6

1

2

3

4

5

6

MANIFOLD

1

2

3

4

5

6

1

2

3

4

5

6

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

+12VDC

COM

+12VDC

COM

+12VDC

COM

6

5

4

3

2

1

6

5

4

3

2

1

6

5

4

3

2

1

COM

+12VDC

COM

+12VDC

COM

+12VDC

MANIFOLD

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

1

2

3

4

5

6

MANIFOLD

1

2

3

4

5

6

1

2

3

4

5

6

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

+12VDC

COM

+12VDC

COM

+12VDC

COM

6

5

4

3

2

1

6

5

4

3

2

1

6

5

4

3

2

1

COM

+12VDC

COM

+12VDC

COM

+12VDC

MANIFOLD

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

Figure 19 Electrical Schematic, Sheet 3, Alternate

Configuration for Catalyst Change Control

CONTINUED ON THE NEXT PAGE

40 333282B

Electrical Schematics

NON-HAZARDOUS LOCATION

HAZARDOUS LOCATION

FROM CAN IS BOARD (24M485) ON PAGE 2

BOOTH CONTROL

(24M731)

COLOR

CHANGE

MODULE 7

(COLORS

33 THRU 40)

J8

J15

J14

J9

J10

J16

12345

12345

COLOR

CHANGE

MODULE 8

(COLORS

41 THRU 48)

J8

J15

J14

J9

J10

J16

12345

1

2

3

4

5

1

2

3

4

5

CABLE

(16V426)

CABLE

(16V426)

COLOR FLUSH

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

CATALYST FLUSH

CATALYST 1

CATALYST 2

CATALYST 3

CATALYST 4

COLOR 9

COLOR 10

COLOR 11

COLOR 12

COLOR 13

COLOR 14

COLOR 15

COLOR 16

COLOR 17

COLOR 18

COLOR 19

COLOR 20

COLOR 21

COLOR 22

COLOR 23

COLOR 24

COLOR 25

COLOR 26

COLOR 27

COLOR 28

COLOR 29

COLOR 30

1

1

7

7

1

2

3

4

5

6

MANIFOLD

1

2

3

4

5

6

1

2

3

4

5

6

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

6

5

4

3

2

1

6

5

4

3

2

1

6

5

4

3

2

1

COM

+12VDC

COM

+12VDC

COM

+12VDC

MANIFOLD

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

1

2

3

4

5

6

MANIFOLD

1

2

3

4

5

6

1

2

3

4

5

6

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

6

5

4

3

2

1

6

5

4

3

2

1

6

5

4

3

2

1

COM

+12VDC

COM

+12VDC

COM

+12VDC

MANIFOLD

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

Figure 20 Electrical Schematic, Sheet 3, Hazardous

Location

333282B 41

Electrical Schematics

Optional Cables and Modules

NOTE: Thetotallengthofallcableusedinthesystemmustnotexceed150ft(45m). See the

Electrical Schematics, page 36.

M12 CAN Cables, for Hazardous Locations

NOTE: The total length of cable used in the

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

Cable Part 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

LocationsOnly

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. Lengthft(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)

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

usewiththesekits.

Alternates for Color Change Modules

by Part Number (Factory Configuration), for

Non-Hazardous Locations Only, see page 61

Module PartNo. 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 8 color/2 catalyst, 13–24

color

24T774 12 color/2 catalyst

24T775 4 color/4 catalyst

24T776 6 color/4 catalyst

24T777 8 color/4 catalyst

24T778 12 color/4 catalyst, 13–30

color

24T779 13–18 color

42333282B

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

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.

1. Flush and relieve pressure as described in your

PD2K operation manual.

2. Engage the pins of the tool (114) with the notches

in the retainer (5) and unscrew the retainer.

Figure 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.

Figure 22 Remove the Valve

NOTE: See manual 332454 to repair the valve.

4. Install the valve in the reverse order of

disassembly. Be sure all o-rings are in place

and lubricated, and that the valve is seated

completely in the manifold.

5. Return the system to service.

333282B 43

Repair

Replace a Solenoid

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.

Replace the Color Change Board

Fuse

NOTE: Replacing the fuse with a non-Graco fuse

voids the IS system safety approval.

Fuse Part No. Description

F1 123690 Fuse; 125 mA,

intrinsically safe

1. Remove electrical power from the system.

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.

44333282B

Repair

Replace the 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.

1. Remove electrical power from the system.

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.

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

101 24U237 BRACKET, mounting 1

102 ◆KIT, manifold, valve 2

103 100157 SCREW, cap, hex head;

1/4–20 x 0.375in.(10mm)

4

104 103195 SCREW, cap, hex head;

1/4–20 x 4.0 in. (101 mm)

4

105 100016 WASHER, lock; 1/4 4

106 100015 NUT, hex; 1/4–20 4

107 24N346 HOSE, fluid; 1/4 npsm (fbe);

2.5 ft (0.76 m); ptfe

2

108 ◆KIT, module, control 1

109 15V206 CABLE, CAN; 5–pin female;

10 ft (3.05m)

1

110 16V819 GROMMET, cable 1

111 24U236 TOOL, repair, valve (not

shown)

1

114 ◆TOOL, installation, valve (not

shown)

1

Ref.

No.

Part

No.

Description Qty

115 598095 TUBE; nylon; 5/32 in. (4 mm)

OD

◆

120 222200 REGULATOR, back pressure;

used on high pressure kits

only (see detail drawing); see

manual 307892

1

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

used on high pressure kits

only (see detail drawing)

2

122 110290 TEE; 1/4 npt(f); sst; used on

high pressure kits only (see

detail drawing)

1

123 112564 GAUGE, pressure, fluid; used

on high pressure kits only (see

detail drawing)

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 4col

or 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 ChangeKits

Ref.

No.

Part No. Description Qty

101 ◆KIT, manifold, valve; . See

Valve Manifold Kits, page

53 for available kits.

2

103 24V351 MANIFOLD, mix, remote 1

104 24N346 HOSE, coupled, 2.5 ft. 2

HOSE, static mixer

16W564 Low Pressure

105

16W563 High Pressure

1

106◆KIT, module, control 1

107 16Y954 BRACKET, manifold 2

108 100015 NUT, hex 4

SCREW, cap, hex

104429 Low Pressure

109

113469 High Pressure

4

Ref.

No.

Part No. Description Qty

TOOL, repair, color change

valve, not shown

24U236 Low Pressure

110

24R124 High Pressure

1

TOOL, installation, color

change valve, not shown

24U239 Low Pressure

111

24U240 High Pressure

1

112 223547 WIRE,assembly,25ft. 2

113 100016 WASHER, lock 4

114 16V429 CABLE, CAN, 50 ft (15.2 m);

not shown

1

◆ See the following tables for the part number used

in your color change kit.

50 333282B

Parts

Low Pressure IS Kits

Kit No. Kit Description Standard Valve Man-

ifold 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

24V3434colo

rs and 4 catalysts 24T460 (2) 24T775

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

24V345 8col

ors 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 6c

olors 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 2colors 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 Man-

ifold 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

24V3964colo

rs and 4 catalysts 24T650 (2) 24T775

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

24V398 8col

ors 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 6c

olors 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 2colors 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 ManifoldKits

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

Kit No. Series Kit Description

24T457 A 2 valves

24T458 A 3 valves

24T459 A 4 valves

24T460 A 5 valves

24T461 A 6 valves

24T462 A 7 valves

24T463 A 8 valves

24T464 A 9 valves

24T465 A 10 valves

24T466 A 11 valves

24T467 A 12 valves

24T468A13val

ves

24T469 A 14 valves

24T470 A 15 valves

24T471 A16va

lves

24T472 A 17 valves

24T473 A 18 valves

24T474 A19v

alves

24T475 A 20 valves

24T476 A 21 valves

24T477 A22

valves

24T478 A 23 valves

24T479 A 24 valves

24T480 A2

5valves

24T481 A 26 valves

24T482 A 27 valves

24T483 A 28 valves

24T484 A 29 valves

24T485 A 30 valves

24T486 A 31 valves

Circulating Valve Manifold Kits

Kit No. Series Kit Description

24T487 A 2 valves

24T488 A 3 valves

24T489 A 4 valves

24T490 A 5 valves

24T491 A 6 valves

24T492 A 7 valves

24T493 A 8 valves

24T494 A 9 valves

24T495 A 10 valves

24T496 A 11 valves

24T497 A 12 valves

24T498A13val

ves

24T499 A 14 valves

24T500 A 15 valves

24T501 A16va

lves

24T502 A 17 valves

24T503 A 18 valves

24T504 A19v

alves

24T505 A 20 valves

24T506 A 21 valves

24T507 A22

valves

24T508 A 23 valves

24T509 A 24 valves

24T510 A2

5valves

24T511 A 26 valves

24T512 A 27 valves

24T513 A 28 valves

24T514 A 29 valves

24T515 A 30 valves

24T516 A 31 valves

333282B 53

Parts

Valve Manifold Kit Parts

54 333282B

Parts

Ref.

No.

Part No. Description Qty

1 16P259 MANIFOLD

2111450 O-RING; chemically resistant

24T441 VALVE, for non-circulating

kits; includes item 2

3

24T442 VALVE, for circulating kits;

includes item 2

4 24R051 PLUG, cc valve

516N256 RETAINER, nut

6 111457 O-RING; ptfe

724T521 PLATE, outlet, manifold

8 24T522 PLATE, end, manifold

9 157974 WASHER, plain

10 104092 SCREW, cap, socket head;

10–24 x 0.625 in. (16 mm)

11 100179 NUT, hex; 10–24

★

Ref.

No.

Part No. Description Qty

12 104893 O-RING; ptfe

13 24T523 FITTING, fluid; 7/16–20 x 1/4

npt(m)

14 111328 CONNECTOR, tube;

10–32(m) x 5/32 in. (4

mm) OD tube

15 24T525 ROD, connecting; 3 in. (76

mm)

16 24T524 ROD, connecting; 1.5 in. (38

mm)

17 111504 O-RING; chemically resistant

18 557716 PLUG; 7/16–20

19 104644 PLUG, screw; 10–32 x 0.156

in. (4 mm)

★

★ 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

Reference Numbers

Kit No.

12345678 101213141516171819

24T457 12202211333203120

24T45824314311344330152

24T459 24404311355430140

24T460 3 6 516411366533172

24T461 36606411377633160

24T462 48718511388760192

24T463 48808511399860180

24T464 510 9 1 10 6 1 1 3 10 10 9 6 3 1 11 2

24T465 510100106113111110631100

24T466 612 11 1 12 7113121211901132

24T467 6121201

271131

313129011

20

24T468 714131148113141413931152

24T469 714140148113151514931140

24T470 816 15 1 16 9 1 1 3 16 16 15 12 0 1 17 2

24T471 816 16 0 16 9 1 1 3 17 17 16 12 0 1 16 0

24T472 918 17 1 18 10 1 1 3 18 18 17 12 3 1 19 2

24T473 918 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

Reference Numbers

Kit No.

12345678 101213141516171819

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

Reference Numbers

Kit No.

12345678 101213141516171819

24T487 12202211355203100

24T488 24314311377330122

24T489 24404311399430100

24T490 3 6 51641131111

533122

24T491 3660641131313633100

24T492 4871851131515

760122

24T493 4880851131717860100

24T494 510911061131919963122

24T495 51010010611321211063100

24T496 612 11 1 12 711323231190122

24T497 612 12 0 12 711325251290100

24T498 71413114811327271393122

24T499 71414014811329291493100

24T500 816151 169 1 1 3 313115120 1 2 2

24T501 816160 169 1 1 3 333316120 1 0 0

24T502 918171 18101 1 3 353517123 1 2 2

24T503 918180 18101 1 3 373718123 1 0 0

24T50410 20191 20111 1 3 393919150 1 2 2

24T505 10 20200 20111 1 3 414120150 1 0 0

24T506 11 22211 22121 1 3 434321153 1 2 2

24T507 11 22220 22121 1 3 454522153 1 0 0

24T508 12 24231 24131 1 3 474723180 1 2 2

24T509 12 24240 24131 1 3 494924180 1 0 0

24T510 13 26251 26141 1 3 515125183 1 2 2

24T511 13 26260 26141 1 3 535326183 1 0 0

24T512 14 28 27 1 28 15 1 1 3 55 55 27210122

24T513 14282802

81511357 57 28210100

24T514 15 30291 30161 1 3 595929213 1 2 2

24T515 15 30300 30161 1 3 616130213 1 0 0

24T516 16 32311 32171 1 3 636331240 1 2 2

333282B 57

Parts

High Pressure Valve Manifold Kits

Non-Circulating Valve Manifold Kits

Kit No. Series Kit Description

24T647 A 2 valves

24T648 A 3 valves

24T649 A 4 valves

24T650 A 5 valves

24T651 A 6 valves

24T652 A 7 valves

24T653 A 8 valves

24T654 A 9 valves

24T655 A 10 valves

24T656 A 11 valves

24T657 A 12 valves

24T658 A 13 valves

24T659 A 14 valves

24T660 A 15 valves

24T661 A 16 valves

24T662 A 17 valves

24T663 A 18 valves

24T664A19val

ves

24T665 A 20 valves

24T666 A 21 valves

24T667 A22va

lves

24T668 A 23 valves

24T669 A 24 valves

24T670 A25

valves

24T671 A 26 valves

24T672 A 27 valves

24T673 A2

8valves

24T674 A 29 valves

24T675 A 30 valves

24T676 A 31 valves

24T845 (acid-

catalyzed)

A3valves

24T846 (acid-

catalyzed)

A5valves

Circulating Valve Manifold Kits

Kit No. Series Kit Description

24T677 A 2 valves

24T678 A 3 valves

24T679 A 4 valves

24T680 A 5 valves

24T681 A 6 valves

24T682 A 7 valves

24T683 A 8 valves

24T684 A 9 valves

24T685 A 10 valves

24T686 A 11 valves

24T687 A 12 valves

24T688 A 13 valves

24T689 A 14 valves

24T690 A 15 valves

24T691 A 16 valves

24T692 A 17 valves

24T693 A 18 valves

24T694A19val

ves

24T695 A 20 valves

24T696 A 21 valves

24T697 A22va

lves

24T698 A 23 valves

24T699 A 24 valves

24T700 A25

valves

24T701 A 26 valves

24T702 A 27 valves

24T703 A2

8valves

24T704 A 29 valves

24T705 A 30 valves

24T706 A 31 valves

58 333282B

Parts

Valve Manifold Kit Parts

333282B 59

Parts

Ref.

No.

Part No. Description Qty

116N271 MANIFOLD, for circulating

kits

2111450 O-RING; chemically

resistant

24T581 VALVE, for non-circulating

kits; includes item 2

24T582 VALVE, for circulating kits;

includes item 2

3

24T583 VALVE, for non-circulating,

acid compatible kits;

includes item 2

4 24R052 PLUG, cc valve

516N269 RETAINER, nut

6 111457 O-RING; ptfe

724T725 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

★

Ref.

No.

Part No. Description Qty

13 24T523 FITTING, fluid; 7/16–20 x

1/4 npt(m)

14 111328 CONNECTOR, tube;

10–32(m) x 5/32 in. (4

mm) OD tube

15 24T729 ROD, connecting; 3.290 in.

(84 mm)

16 24T728 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)

★

★ 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

Reference Numbers

Kit No.

12345678 1012131415161819

24T647 1220221133320100

24T648 2431431134431012

24T649 2440431135541000

24T650 3 6 51641136651112

24T651 3660641137761100

24T652 4871851138872012

24T653 4880851139982000

24T654 51091106113101092112

24T655 510100 106 1 1 3 1111102 1 0 0

24T656 612 11 1 12 71131212113012

24T657 6121201

271131

313123000

24T658 714131 148 1 1 3 1414133 1 1 2

24T659 714140 148 1 1 3 1515143 1 0 0

24T660 816151 169 1 1 3 1616154 0 1 2

24T661 816160 169 1 1 3 1717164 0 0 0

24T662 918171 18101 1 3 1818174 1 1 2

60 333282B

Parts

Reference Numbers

Kit No.

12345678 1012131415161819

24T663 918 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 5012

24T665 10 20 20 0 20 11 1 1 3 21 21 20 5000

24T666 11 22 21 1 22 12 1 1 3 22 22 21 5112

24T667 11 22 22 0 22 12 1 1 3 23 23 22 5100

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 7012

24T673 14 28 28 0 28 15 1 1 3 29 29 28 7000

24T674 15 30 29 1 30 16 1 1 3 30 30 29 7112

24T675 15 30 30 0 30 16 1 1 3 31 31 30 7100

24T676 16 32 31 1 32 17 1 1 3 32 32 31 8 0 1 2

24T845 2431431134431012

24T846 3651641136651112

333282B 61

Parts

High Pressure Circulating Valve Manifold Kit Part Quantities

Reference Numbers

Kit No.

12345678 1012131415161819

24T677 1220221135520100

24T678 2431431137731022

24T679 2440431139941000

24T680 3 6 51641131111

51122

24T681 366064113131361100

24T682 4871851131515

72022

24T683 488085113171782000

24T684 510 9 1 10 6 1 1 3 19 19 9 2 1 2 2

24T685 510 10 0 10 6 1 1 3 21 21 10 2 1 0 0

24T686 612 11 1 12 71132323113022

24T687 612 12 0 12 71132525123000

24T688 714 13 1 14 8 1 1 3 27 27 13 3 1 2 2

24T689 714 14 0 14 8 1 1 3 29 29 14 3 1 0 0

24T690 816 15 1 16 9 1 1 3 31 31 15 4 0 2 2

24T691 816 16 0 16 9 1 1 3 33 33 16 4 0 0 0

24T692 918 17 1 18 10 1 1 3 35 35 17 4 1 2 2

24T693 918 18 0 18 10 1 1 3 37 37 18 4 1 0 0

24T69410 20 19 1 20 11 1 1 3 39 39 19 5022

24T695 10 20 20 0 20 11 1 1 3 41 41 20 5000

24T696 11 22 21 1 22 12 1 1 3 43 43 21 5122

24T697 11 22 22 0 22 12 1 1 3 45 45 22 5100

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 7022

24T703 14282802

81511357 57 287000

24T704 15 30 29 1 30 16 1 1 3 59 59 29 7122

24T705 15 30 30 0 30 16 1 1 3 61 61 30 7100

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

301 ——— PANEL 1

302 24T566 BOARD, circuit 1

302a 123690 FUSE; 125 mA 1

303 112324 SCREW, machine, pan head;

4–40 x 0.25 in. (6 mm)

6

304 24T562 COVER 1

305 119162 CONNECTOR, 6–position ★

307 116343 SCREW, ground; M5 x 0.8 1

308 123691 HOLDER, fuse 1

309 24T563 MANIFOLD 2

310 16P316 SOLENOID ★

311 117831 SCREW, machine, pan head;

6–32 x 0.5 in. (13 mm)

4

312 103833 SCREW, machine, pan head;

10–32 x 0.375 in. (10 mm)

8

313 24T565 PLUG; 5/8–32; includes item

314

★

314 113418 O-RING; buna-N 14

315 100139PLUG, pipe; 1/8 npt 3

Ref.

No.

Part

No.

Description Qty

316 C06061 MUFFLER 2

317 115671 FITTING, connector; 1/8

npt(m) x 1/4 in. (6 mm) OD

tube

1

318 112698 ELBOW; 1/8 npt(m) x 1/4 in.

(6 mm) OD tube

2

319 590332 TUBE; polyethylene; 1/4 in. (6

mm) OD

1

320 598095 TUBE; nylon; 5/32 in. (4 mm)

OD

1

321 ——— STRAP, tie ★

322 ——— FERRULE ★

324 114263 FITTING, connector; 1/8

npt(m) x 5/32 in. (4 mm) OD

tube

★

332 151395 WASHER 4

★ See the following table to determine the quantity of

each part in your control module kit.

Parts labeled — — — are not available separately.

Non-IS Control Module Part Quantities

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

quantity used in your control module kit.

Kit No. Kit

Description

6–Position

Connector

(305)

Solenoid

(310)

Plug (313) Tie Strap

(321)

Ferrule

(322)

Connector

Fitting

(324)

24T557 2 color 2 6 12 4 12 6

24T558 4 color 4 10 8 4 20 10

24T559 6 color 6 14 4 4 28 14

24T560 8 color 6 18 0 4 36 18

333282B 65

Parts

IS Color Change Control Modules

66 333282B

Parts

Ref.

No.

Part

No.

Description Qty

301 ——— PANEL 1

302 24T566 BOARD, circuit 1

302a 123690 FUSE; 125 mA 1

303 112324 SCREW, machine, pan head;

4–40 x 0.25 in. (6 mm)

6

304 24U567 COVER 1

305 119162 CONNECTOR, 6–position 6

307 116343 SCREW, ground; M5 x 0.8 1

308 123691 HOLDER, fuse 1

309 15T636 MANIFOLD 2

310 121324 SOLENOID ★

311 16M00

7

SCREW, machine, serrated

head; 10–32 x 0.5 in. (13 mm)

4

312 103833 SCREW, machine, pan head;

10–32 x 0.375 in. (10 mm)

4

313 121628 SCREW, self-sealing; 4–40 x

0.25 in. (6 mm)

★

315 100139 PLUG, pipe; 1/8 npt 3

316 C06061MUFFLER 2

317 115671 FITTING, connector; 1/8

npt(m) x 1/4 in. (6 mm) OD

tube

1

Ref.

No.

Part

No.

Description Qty

318 112698 ELBOW; 1/8 npt(m) x 1/4 in.

(6 mm) OD tube

2

319 590332 TUBE; polyethylene; 1/4 in. (6

mm) OD

1

320 598095 TUBE; nylon; 5/32 in. (4 mm)

OD

1

321 ——— STRAP, tie 2

322 ——— FERRULE ★

324 109193 ELBOW, connector; 10–32

(m) x 5/32 in. (4 mm) OD tube

★

331 16U743 SPACER 6

332 16U744 PLATE, non-conductive 1

333 16U745 PLATE, ground 1

334 16U746 SCREW, pan-head; 4–40 3

335 16W50

1

LABEL, instructions 1

339 102794 NUT, hex7

340 101764 WASHER, lock 7

341 188773 WASHER, flat 7

★ 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 inthetoprowtofindthepart

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

624

30 ft (9.1 m) 12 6

24T572 4 color and 2

catalyst

820

40 ft (12.2 m) 16 8

24T573 6c

olor 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 80ft(24.4m) 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

24T443 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.

With Manifold

24T445 Manifold with one non-circulating

valve. Includes valve, plug,

solenoid, fittings, and tubing.

24T446 Manifold with one circulating valve.

Includes valve, plug, solenoid,

fittings, and tubing.

24T447 Manifold with two non-circulating

valves. Includes valves, solenoids,

fittings, and tubing.

24T448Manifold with two circulating

valves. Includes valves, solenoids,

fittings, and tubing.

High Pressure Expansion Kits

Kit No. Kit Description

Without Manifold

24T584 One non-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

24T586 Manifold with one non-circulating

valve. Includes valve, plug,

solenoid, fittings, and tubing.

24T587 Manifold with one circulating valve.

Includes valve, plug, solenoid,

fittings, and tubing.

24T588 Manifold with two non-circulating

valves. Includes valves, solenoids,

fittings, and tubing.

24T589Manifold 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 acid-

compatible valve (replaces a

plug). Includes valve, solenoid,

fittings, and tubing.

With Manifold

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.

333282B 69

Parts

IS Expansion Kits

The following kits are available to add color valves in an IS area. Order a kit without a manifold if you have

roomforavalveonanexistingmanifold.Orderakitwithamanifoldifallports on your existing manifolds have

valves already. See Install an Expansion Kit, page 30 for instructions.

Low Pressure Expansion Kits

Kit No. Kit Description

Without Manifold

24T449 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.

With Manifold

24T451 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.

24T453 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.

High Pressure Expansion Kits

Kit No. Kit Description

Without Manifold

24T712 One non-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

24T714 Manifold with one non-circulating

valve. Includes valve, plug, IS

solenoid, fittings, and tubing.

24T715 Manifold with one circulating valve.

Includes valve, plug, IS solenoid,

fittings, and tubing.

24T716 Manifold with two non-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 acid-

compatible valve (replaces a

plug). Includes valve, IS solenoid,

fittings, and tubing.

With Manifold

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.

70 333282B

Dimensions

Dimensions

Figure 24 Non-IS Control Module

ABCDEF

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

ABCDEF

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 TUV

3.84 in. (98

mm)

11.44 in. (291

mm)

0.312 in. (8

mm) diameter

72333282B

Dimensions

Figure 27 IS Valve Manifold Bracket

ABCDEF

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)

GHJKLM

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

NP

4 x 0.28 in (7

mm)

2 x 0.41 in (10

mm)

333282B 73

Dimensions

Figure 28 Remote Mix Manifold Bracket

ABCDEF

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)

GHJK

1.25 in (32 mm) 0.11(3mm) 4x0.22in(6

mm)

2x0.41(10

mm)

74333282B

Technical Data

Technical Data

Color Change Kits U.S. Metric

Maximum fluid working

pressure:

Low pressure kits 300 psi 2.1 MPa, 21 bar

High pressure kits 1500 psi 10.5 MPa, 105bar

Maximum working air

pressure:

100 psi 0.7 MPa, 7.0 bar

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

Viscosity range of fluid: 20–5000 centipoise

Fluid inlet size: 1/4 npt(f)

Fluid outlet size: 1/4 npt(f)

Air inletsize: 5/32 in. OD tube 4 mm OD tube

Wetted parts:

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

Valve See valve manual 332454.

333282B 75

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its

name to be free from defects in material and workmanship on the date of sale to the original purchaser for use.

With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of

twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be

defective. This warranty applies only when the equipment is installed, operated and maintained in accordance

with 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