Graco 333282B Repair Parts Manual


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Graco 333282B Repair Parts Manual | Manualzz

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.

2

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

333282B

Related Manuals

Related Manuals

Current manuals are available at www.graco.com.

Manual No.

332458

332564

332565

Description

PD2K Proportioner, Installation

Manual, Systems for Automatic

Spray Applications

PD2K Proportioner Operation

Manual, Systems for Automatic

Spray Applications

PD2K Proportioner Repair-Parts

Manual, Systems for Automatic

Spray Applications

Manual No.

Description

332709 Pump Repair-Parts Manual

332454

332456

Color Change Valve Repair-Parts

Manual

3rd and 4th Pump Kits

Instructions-Parts Manual

333282B 3

4

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.

24R915

24R916

24R917

24R918

24R919

24R920

24R921

24R922

Series

A

A

A

A

Kit Description Maximum Air Working Pressure

(Control Module)

Maximum Fluid Working

Pressure (Valves)

Low Pressure Non-Circulating Color Change Kits

2 color or 2 catalyst 100 psi (0.7 MPa, 7.0 bar) 300 psi (2.068 MPa, 20.68 bar)

4 color or 4 catalyst

6 color

8 color

100 psi (0.7 MPa, 7.0 bar)

100 psi (0.7 MPa, 7.0 bar)

100 psi (0.7 MPa, 7.0 bar)

Low Pressure Circulating Color Change Kits

300 psi (2.068 MPa, 20.68 bar)

300 psi (2.068 MPa, 20.68 bar)

300 psi (2.068 MPa, 20.68 bar)

A

A

A

A

2 color

4 color

6 color

8 color

100 psi (0.7 MPa, 7.0 bar)

100 psi (0.7 MPa, 7.0 bar)

100 psi (0.7 MPa, 7.0 bar)

100 psi (0.7 MPa, 7.0 bar)

300 psi (2.068 MPa, 20.68 bar)

300 psi (2.068 MPa, 20.68 bar)

300 psi (2.068 MPa, 20.68 bar)

300 psi (2.068 MPa, 20.68 bar)

333282B

Models

Kit No.

24R959

24R960

24R961

24R962

24T579

24T580

24R963

24R964

24R965

24R966

Series

A

A

A

A

Kit Description Maximum Air Working Pressure

(Control Module)

Maximum Fluid Working

Pressure (Valves)

High Pressure Non-Circulating Color Change Kits

2 color or 2 catalyst 100 psi (0.7 MPa, 7.0 bar) 1500 psi (10.34 MPa, 103.4 bar)

4 color or 4 catalyst

6 color

8 color

100 psi (0.7 MPa, 7.0 bar)

100 psi (0.7 MPa, 7.0 bar)

100 psi (0.7 MPa, 7.0 bar)

1500 psi (10.34 MPa, 103.4 bar)

1500 psi (10.34 MPa, 103.4 bar)

1500 psi (10.34 MPa, 103.4 bar)

High Pressure Acid Compatible Non-Circulating Catalyst Change Kits

A

A

2 catalyst (acid compatible)

4 catalyst (acid compatible)

100 psi (0.7 MPa, 7.0 bar)

100 psi (0.7 MPa, 7.0 bar)

1500 psi (10.34 MPa, 103.4 bar)

1500 psi (10.34 MPa, 103.4 bar)

A

A

A

A

2 color

4 color

6 color

8 color

High Pressure Circulating Color Change Kits

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

100 psi (0.7 MPa, 7.0 bar)

100 psi (0.7 MPa, 7.0 bar)

100 psi (0.7 MPa, 7.0 bar)

1500 psi (10.34 MPa, 103.4 bar)

1500 psi (10.34 MPa, 103.4 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)

4

6

1

2

Number of Color + Solvent Valves Number of Catalyst + Solvent Valves

1 2

24V157

24V158

24V159

24V160

24V331

24V332

24V333

24V343

24V344

4

8

12

24V161

24V162

24V334

24V335

24V345

24V346

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

13–18

13–24

13–30

24V163

24V164

24V165

6 333282B

Models

Table 2 . Low Pressure, Circulating Remote Mix Manifold Kits

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

4

6

8

1

2

Number of Color + Solvent Valves Number of Catalyst + Solvent Valves

1 2

24V166

24V167

24V308

24V309

24V326

24V336

24V337

24V338

24V339

24V347

24V348

24V349

4

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

13–30

24V329

24V330

Table 3 . High-Pressure, Non-Circulating Remote Mix Manifold Kits

Maximum Fluid Working Pressure: 1500 psi (10.34 MPa, 103.4 bar)

Number of Color + Solvent Valves Number of Catalyst + Solvent Valves

1 2 4

1

2

4

6

8

12

24V359

24V360

24V361

24V362

24V363

24V364

24V381

24V382

24V383

24V384

24V385

24V396

24V397

24V398

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

13–30

24V366

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)

4

6

8

1

2

Number of Color + Solvent Valves Number of Catalyst + Solvent Valves

1 2

24V369

24V370

24V371

24V372

24V373

24V389

24V390

24V391

24V392

24V402

24V403

24V404

4

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

13–30

24V376

24V377

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

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

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

Expansion Kits, page 69

.

8 333282B

Warnings

Warnings

The following warnings are for the setup, use, grounding, maintenance and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these

Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

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

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

• Use only grounded hoses.

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

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

• Keep a working fire extinguisher in the work area.

ELECTRIC SHOCK HAZARD

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

• Turn off and disconnect power at main switch before disconnecting any cables and before servicing or installing equipment.

• Connect only to grounded power source.

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

333282B 9

10

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.).

• To help prevent fire and explosion:

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

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

• Equipment that comes in contact with the intrinsically safe terminals must be rated for Intrinsic

Safety. This includes DC voltage meters, ohmmeters, cables, and connections. Remove the unit from the hazardous area when troubleshooting.

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.

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

• Do not put your hand over the fluid outlet.

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

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

• Tighten all fluid connections before operating the equipment.

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

MOVING PARTS HAZARD

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

• Keep clear of moving parts.

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

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure and disconnect all power sources.

TOXIC FLUID OR FUMES

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

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

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

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

333282B

333282B

Warnings

WARNING

PERSONAL PROTECTIVE EQUIPMENT

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

• Protective eyewear, and hearing protection.

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

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

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

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

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

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

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

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

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

• Make sure all equipment is rated and approved for the environment in which you are using it.

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

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

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

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

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 for everyone in the work area.

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

Keep Components A and B Separate

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.

• Always clean the fluid inlet strainers after flushing.

• Check with your material manufacturer for chemical compatibility.

• When changing between epoxies and urethanes or polyureas, disassemble and clean all fluid components and change hoses. Epoxies often have amines on the B (hardener) side. Polyureas often have amines on the A (resin) side.

12 333282B

Setup the Modules

Setup the Modules

Setup Non-IS Control Modules

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

All Non-IS modules ship from the factory as Module

1 (Colors 1–8). Labels for Modules 2 through 6 are provided with the module kit. Affix the labels according to your system configuration.

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

System Pump Configuration

Color

Pump(s)

Catalyst

Pump(s)

Total

Pumps

1

1

2

2

2

3

3

4

0

1

1

0

2

1

0

0

1

2

3

2

4

4

3

4

Module 1

(Colors

1–8)

Color Change Control Modules, Colors, and Catalysts

Module 2

(Colors

9–16)

Module

3 (Colors

17–24)

Module 4

(Colors

25–30)

Catalyst

1–2

Catalyst

3–4

Pump # 1 Pump # 1

Not Applicable

Module # 5

Pump # 2

Pump # 1

Pump # 1

Pump # 2

Pump # 3

Pump # 3

Pump # 4

Module # 5

Pump # 2

Not Applicable

Module

# 5

Pump # 2

Module

# 6

Pump # 4

Module # 5

Pump # 2

Not Applicable

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 S6 on the control module board. 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.

Inlet Manifold

Non-IS Control Module Switch Settings

Control

Module

S6 S5 S4

Module 1

ON ON 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

OFF OFF OFF

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

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

Outlet Manifold

Figure 1 Non-IS Control Module

14 333282B

Setup the Modules

8

9

6

7

4

5

2

3

Non-IS Control Module 1

Inlet Manifold Outlet Manifold

Solenoid

1

Valve

Solvent

Solenoid

1

Valve

Dump

Color 1

Color 2

Color 3

Color 4

2

3

4

5

Color 1

Color 2

Color 3

Color 4

Color 5

Color 6

Color 7

Color 8

8

9

6

7

Color 5

Color 6

Color 7

Color 8

6

7

4

5

8

9

Non-IS Control Module 2

Inlet Manifold

Solenoid Valve

1

2

(Solvent)*

Color 9

1

2

3 Color 10

Outlet Manifold

Solenoid Valve

3

(Dump)*

Color 9

Color 10

Color 11

Color 12

Color 13

Color 14

Color 15

Color 16

4

5

6

7

8

9

Color 11

Color 12

Color 13

Color 14

Color 15

Color 16

8

9

6

7

4

5

2

3

4

5

6

7

2

3

Non-IS Control Module 4

Inlet Manifold Outlet Manifold

Solenoid

1

Valve

(Solvent)*

Solenoid

1

Valve

(Dump)*

Solenoid

1

8

9

Color 25

Color 26

Color 27

Color 28

Color 29

Color 30

Not Used 8

Not Used 9

Non-IS Control Module 5

Inlet Manifold Outlet Manifold

Valve

(Solvent)*

Catalyst 1

Catalyst 2

Catalyst 3

Catalyst 4

Not Used

Not Used

2

3

4

5

6

7

Solenoid

1

2

3

4

5

Not Used 6

Not Used 7

8

9

Color 25

Color 26

Color 27

Color 28

Color 29

Color 30

Not Used

Not Used

Valve

(Dump)*

Catalyst 1

Catalyst 2

Catalyst 3

Catalyst 4

Not Used

Not Used

Not Used

Not Used

8

9

6

7

2

3

4

5

Non-IS Control Module 3

Inlet Manifold Outlet Manifold

Solenoid

1

Valve

(Solvent)*

Solenoid

1

Valve

(Dump)*

Color 17

Color 18

Color 19

Color 20

2

3

4

5

Color 17

Color 18

Color 19

Color 20

Color 21

Color 22

Color 23

Color 24

8

9

6

7

Color 21

Color 22

Color 23

Color 24

2

3

4

5

Solenoid

1

6

7

8

9

Non-IS Control Module 6

Inlet Manifold Outlet Manifold

Valve

(Solvent)*

Catalyst 3

Catalyst 4

Not Used

Not Used

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

Solenoid

1

2

3

4

5

Not Used 6

Not Used 7

Not Used 8

Not Used 9

Valve

(Dump)*

Catalyst 3

Catalyst 4

Not Used

Not Used

Not Used

Not Used

Not Used

Not Used

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.

Control

Module

IS Control Module Switch Settings

S6 S5 S4

Module 7

ON ON ON

Module 8

OFF

ON

OFF

ON

OFF

ON

OFF OFF OFF

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

Figure 2 IS Control Module

16 333282B

8

9

6

7

4

5

2

3

Solenoid

1

IS Control Module 7

Valve Solenoid

Color

Solvent

1

Color 1

Color 2

Color 3

Color 4

2

3

4

5

Color 5

Color 6

Color 7

Color 8

8

9

6

7

Valve

Catalyst

Solvent

Catalyst 1

Catalyst 2

Catalyst 3

Catalyst 4

Color 9

Color 10

Color 11

Color 12

Setup the Modules

6

7

4

5

8

9

2

3

Solenoid

1

IS Control Module 8

Valve Solenoid

Color 13

Color 14

1

2

Color 15

Color 16

Color 17

Color 18

3

4

5

6

Color 19

Color 20

Color 21

7

8

9

Valve

Color 22

Color 23

Color 24

Color 25

Color 26

Color 27

Color 28

Color 29

Color 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.

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)

OD tubing. Use a 5 micron filter. Regulate the air pressure to 85–100 psi (0.6–0.7 MPa, 6.0–7.0 bar).

Grounding

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the

Pressure Relief Procedure in the PD2K Operation

Manual before installing the kit.

Mounting the Control Modules

1. See

Dimensions, page 71 .

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

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).

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 3 Cable Connector J7 at Non-IS Color

Control Module

NOTICE

To avoid damaging the circuit boards, wear

Part No. 112190 grounding strap on your wrist and ground appropriately.

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

3. Remove electrical power from the system.

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

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

6. Connect the cable (109) to J2 on the non-IS side of the isolation board inside the electrical control box. See

Electrical Schematics, page 36

for a list of M12 CAN cables for use in a non-hazardous area.

Figure 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.

with 16 valve positions (14 colors). On high pressure systems, the supplied bracket (101) will accommodate a manifold with 14 valve positions

(12 colors). A larger valve stack will require a customer supplied/sourced bracket.

3. Repeat for the opposite side of the PD2K.

4. Connect the air lines from the solenoids to the valves. See

Connect the Valve Air Lines, page 24

.

NOTE: On high pressure systems, see

Install the Back Pressure Regulator (High

Pressure Systems Only), page 21 .

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

Connect the Fluid Lines, page 26 .

2. Install the inlet and outlet valve manifolds (102) on the mounting bracket (101) with four screws

(104), washers (105), and nuts (106).

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

Figure 6 Install the Valve Manifolds

20 333282B

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 the IS side of the isolation board in the electrical control box. Connect the cable (C1) to

J4. See

Electrical Schematics, page 36

.

22 333282B

Installation

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

J11 on the first color control module to J7 on the second module.

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

Install the Remote Valve Manifolds

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

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

Dimensions, page 71 . Use bolts to attach the

equipment securely.

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. See

Setup the Modules, page 13

.

2. Repeat for the outlet valves.

Hazardous Area

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

Setup the Modules, page 13

.

24 333282B

Notes

Installation

333282B 25

Installation

Connect the Fluid Lines

Connect Non-Circulating Fluid Lines

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

NOTE: On high pressure systems, see

Install the Back Pressure Regulator (High Pressure

Systems Only), page 21 .

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

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

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

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

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

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 valve fitting on the remote color stack.

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

W

S

C1

C2

Air inlet

Seal weep and lubrication port

Solvent fitting

Color 1 fitting

Color 2 fitting

333282B 27

Installation

Connect Circulating Fluid Lines

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

• When a color valve is closed, the system bypasses the dosing pump by directing that color from the inlet color valve to the outlet color valve to the remote color valve, through a circulation line, then back to the color supply.

• 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 the fluid supply container.

Figure 12 Valve Manifold Connections (Circulating

System)

KEY

D

S

Dump valve fitting

Solvent fitting

C1 Color 1 fitting

C2 Color 2 fitting

R1 Color 1 circulation fitting

R2 Color 2 circulation fitting

28 333282B

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

KEY

A Color supply

B Inlet color stack

C Outlet color stack

D Remote color stack

E Remote mix manifold

F Automatic spray gun

G Return line to fluid supply

Installation

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) are in place, then install the screws (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 . Install the

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

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

2. Air or electrical lines damaged or connections are loose.

3. Solenoid failure.

Solution

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

Visually inspect air and electrical lines for kinks, damage, or loose connections.

Service or replace as needed.

Check the applicable solenoid’s LED; see

Color Change Board, page 34

proceed with the following checks. If not lit, go to Cause 4.

. If lit,

Remove the connector for the applicable solenoid and measure voltage across the pins on the board:

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

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

Test the valves as explained under Maintenance Screen 4 in your PD2K

Operation manual. Valves should open and close quickly. If the valves actuate slowly, it could be caused by:

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

• Solenoid is clogged. Make sure the air supply has a 5 micron filter installed.

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

32 333282B

Troubleshooting

Cause

4. Control board or cable failure.

Solution

If there is no voltage across the pins on the board or it is less than 9 Vdc, check

LEDs D8, D9, and D10. If they are lit and functioning properly, or other solenoids in the module are working properly, replace the color change board.

If D9 is not lit:

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

Replace the Color Change Board Fuse, page 44

.

• Check if the cable is disconnected or damaged.

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

If D8 is not blinking:

• Cycle the system power.

• Check if the cable is disconnected or damaged.

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

If D10 is not occasionally blinking:

• Check if the cable is disconnected or damaged.

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

333282B 33

Troubleshooting

Color Change Board

NOTICE

To avoid damaging the circuit boards, wear Part

No. 112190 grounding strap on your wrist and ground appropriately.

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

Figure 14 Color Change Board

34 333282B

Color Change Board Diagnostics

ID

D8

D9

Component or Indicator

LED (green)

LED (green)

D10 LED (yellow)

D27–D39,

D41, D43–D46

F1

LED (green)

Fuse, 0.125 A, 125 V

Troubleshooting

Function

Blinks (heartbeat) during normal operation.

Turns on when power is supplied to the board.

Turns on when board is communicating with electronic control.

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

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.

FAN

(24P658)

ENCODER AND MOTOR

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

PUMP V/P FOR

FLUID REG.

SOLENOID (16P812)

UP

DOWN

FLOW SENSOR

(120278)

OR G3000 METER

(239716, 258718

16M510, 16M519)

2 POSITION

SWITCH

(16U725)

CABLE

16T658

LINE FILTER

(16V446)

CABLE

16H078

TERMINAL BLOCK

(114095)

POWER IN

24V

POWER

SUPPLY

(16T660)

FAN

(24P658)

ENCODER AND MOTOR

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

PUMP V/P FOR

FLUID REG.

SOLENOID (16P812)

UP

DOWN

FLOW SENSOR

(120278)

OR G3000 METER

(239716, 258718

16M510, 16M519)

RELAY

POWER MODULE

(24R257)

48V-10A POWER SUPPLY

(16U820)

TERMINAL BLOCKS WITH FUSES

065161, 065159

INTEGRATION

GATEWAY

5

CABLE (121227)

16T072

CAN

IS BOARD

(24M485)

CABLE (121227)

AWI

GATEWAY

(24R910)

5

CABLE (121001)

SPLITTER

(16P243)

CABLE (16T280)

BARRIER

BOARD

(248192)

4

CABLE (16T659)

CABLE (16T659)

CABLE (16T659)

CABLE (16T659)

FAN

(24P658)

ENCODER AND MOTOR

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

PUMP V/P FOR

FLUID REG.

FAN

(24P658)

ENCODER AND MOTOR

(16P036, 16P037)

WIRE HARNESS

(24P684, 24P685)

PUMP INLET

TRANSDUCER

(16P289, 16P290)

PUMP OUTLET

TRANSDUCER

(16P289, 16P290)

PUMP V/P FOR

FLUID REG.

SOLENOID (16P812)

UP

DOWN

SOLENOID (16P812)

UP

DOWN

FLOW SENSOR

(120278)

OR G3000 METER

(239716, 258718

16M510, 16M519)

FLOW SENSOR

(120278)

OR G3000 METER

(239716, 258718

16M510, 16M519)

Figure 15 Electrical Schematic, Sheet 1

2

CABLE

(15V206)

2 CABLE

(15V206)

MODULE 1 (24N935)

2

CABLE

(15V206)

MODULE 2 (24N935)

GCA

MODULE

EFCM

(24N913)

MODULE 3 (24N935) MODULE 4 (24N935) MODULE 5 (24N935) MODULE 6 (24N935)

2

CABLE

(15V206)

2

GUN TRIGGER INPUTS

119159

119159

119159

119159

CABLE

(15V206)

SOLENOID (121324)

PRESSURE SW (121323)

GFB

INTERFACES

SOLVENT CUTOFF (121324)

SWITCH (120278)

SWITCH (120278)

SOLVENT

FLOW

INPUTS

SOLVENT METER (258718)

SAFETY INTERLOCK SWITCH

3

CABLE

(121003)

ADVANCED

DISPLAY MODULE

(24E451)

LIGHT

TOWER

(15X472)

1

CABLE (16V429) CABLE (16V426)

COLOR CHANGE MODULE 7

(24R219)

7

COLOR CHANGE MODULE 8

(24R219)

7

BOOTH CONTROL (24M731)

HAZARDOUS LOCATION

NON-HAZARDOUS LOCATION

CABLE (16V426)

36 333282B

Electrical Schematics

SPLITTER

(16P243)

5 4 3 2 1

UNUSED UNUSED UNUSED

UNUSED

CONTINUED ON PAGE 3

3

CABLE (121227)

1 2 3 4 5

2

4

1 2 3 4 5

CABLE (15V206)

16T072

1 2 3 4 5

CAN IS BOARD

(NON IS)

(IS)

(24M485)

3

1 2 3 4 5

1

CABLE (16T280)

1 2 3

UNUSED UNUSED

BARRIER

BOARD

(248192)

CONTINUED ON PAGE 3

P3 P4

AWI

GATEWAY

(24R910)

5

CABLE

(121227)

3

P3

GFB INTERFACE

(121324)

SOLVENT CUTOFF (121324)

PWR (RED)

SIG (WHITE)

SOLVENT

METER

(258718)

COM (BLACK)

SHIELD/GRN

P4

INTEGRATION

GATEWAY

5

UNUSED

UNUSED

10

UNUSED

CABLE

(121001)

3

+12VDC

COM

UNUSED

UNUSED

+12VDC

COM

+12VDC

COM

UNUSED

8

GCA MODULE

EFCM

(24N913)

7

8

5

6

3

4

1

2

9

10

5

1 2 3 4 5 6 7 8

1

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1 2 3 4 5 6 7 8

2

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

RED WIRE (065161)

BLACK WIRE (065159)

GROUND BAR

4

25 PIN D-SUB CABLE

(16T659)

24V

POWER

SUPPLY

(16T660)

L (BROWN) N (BLUE)

N03 N03

2 POSITION

SWITCH

(16U725)

N04 N04

CABLE

(16T658)

L N

LINE

FILTER

(16V446)

L GRND N

CABLE

(16H078)

L N GRND

TERMINAL

BLOCK

(114095)

L N GRND

GRND (GRN/YEL)

13 A1(+) A2(-)

RELAY

14

N L GRND

48V-10A

POWER SUPPLY

+ -

+ - + - + - + -

+ - + - + - + -

DETAIL A, LOW PRESSURE

PUMPS (24M706, 24M714)

2

1 2 3 4 5

BREAKOUT MODULE

(24N527)

3

1 2 3 4

WIRE HARNESS

(24P684) DRAIN/FOIL

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

1

BREAKOUT MODULE PUMP 1 (24N527)

2

1 2 3 4 5

3

1 2 3 4

4

1 2 3 4 5

5

1 2 3 4 5

6

1 2 3 4 1 2 3 4

7

5 6 7 8

8

1 2 3 4

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

1

BREAKOUT MODULE PUMP 2 (24N527)

2

1 2 3 4 5

3

1 2 3 4

4

1 2 3 4 5

5

1 2 3 4 5

6

1 2 3 4 1 2 3 4

7

5 6 7 8

8

1 2 3 4

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 1

SEE DETAIL A OR B

TRANSDUCER PUMP TRANSDUCER PUMP

TWISTED PAIR CABLE (16W159)

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

1 UP

MANIFOLD

MAC SERIES 46 (16P812 QTY

G3000

METER

PUMP 1

(EITHER, 239716,

258718,16M510,

OR 16M519)

GRND

SCREW

+48V COM +48V COM

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 2

SEE DETAIL A OR B

TRANSDUCER PUMP TRANSDUCER PUMP

TWISTED PAIR CABLE (16W159)

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

2 UP

MANIFOLD

MAC SERIES 46 (16P812 QTY

G3000

METER

PUMP 2

(EITHER, 239716,

258718,16M510,

OR 16M519)

GRND

SCREW

+48V COM +48V COM

DETAIL B, HIGH PRESSURE

PUMPS (24M707, 24M715)

2

1 2 3 4 5

BREAKOUT MODULE

(24N527)

3

1 2 3 4

WIRE HARNESS

(24P685) DRAIN/FOIL

MOTOR

MOUNTING

SCREW

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

PUMP ENCODER AND MOTOR

(16P037)

10

MOTOR

MOUNTING

SCREW

1 2

Figure 16 Electrical Schematic, Sheet 2, Part 1

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

PUMP ENCODER AND MOTOR

(16P036)

CONTINUED ON THE NEXT PAGE

10

333282B 37

Electrical Schematics

GUN TRIGGER INPUTS

GCA MODULE

EFCM

(24N913)

1 2 3 4 5 6 7 8 9

3

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 1 2 3 4 5 6 7 8 9 10

9

4

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

6

11

12

8

9

3

4

2

1

5

6

7

3

4

2

1

5

6

10

11

8

9

12

4

5

2

3

SIG

COM

SIG

COM

SIG

COM

COM

SIG

COM

GFB PRESSURE SWITCH (121323)

SOLVENT FLOW SWITCH 1 (120278)

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

SOLVENT FLOW SWITCH 2 (120278)

SAFETY INTERLOCK SWITCH

CABLE

(121003)

3

4

5

2

3

ADVANCED

DISPLAY MODULE

(24E451)

3

4

1

2

5

LIGHT

TOWER

(15X472)

4

25 PIN D-SUB CABLE

(16T659)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

1

BREAKOUT MODULE PUMP 3 (24N527)

2

1 2 3 4 5

3

1 2 3 4

4

1 2 3 4 5

5

1 2 3 4 5

6

1 2 3 4 1 2 3 4

7

5 6 7 8

8

1 2 3 4

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 3

SEE DETAIL A OR B

TRANSDUCER PUMP TRANSDUCER PUMP

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

3 UP

MANIFOLD

MAC SERIES 46 (16P812 QTY

G3000

METER

PUMP 3

(EITHER, 239716,

258718,16M510,

OR 16M519)

GRND

SCREW

TWISTED PAIR CABLE (16W159)

Figure 17 Electrical Schematic, Sheet 2, Part 2

CONTINUED ON THE NEXT PAGE

+48V COM +48V COM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

1

BREAKOUT MODULE PUMP 4 (24N527)

2

1 2 3 4 5

3

1 2 3 4

4

1 2 3 4 5

5

1 2 3 4 5

6

1 2 3 4 1 2 3 4

7

5 6 7 8

8

1 2 3 4

+48V COM +48V COM

ENCODER/MOTOR

AND

WIRE HARNESS

PUMP 4

SEE DETAIL A OR B

TRANSDUCER PUMP TRANSDUCER PUMP

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

4 UP

MANIFOLD

MAC SERIES 46 (16P812 QTY

G3000

METER

PUMP 4

(EITHER, 239716,

258718,16M510,

OR 16M519)

GRND

SCREW

TWISTED PAIR CABLE (16W159)

38 333282B

FROM CAN IS BOARD (24M485) ON PAGE 2

Electrical Schematics

FROM CAN IS BOARD (24M485) ON PAGE 2

2

CABLE (15V206)

FLUSH

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

MANIFOLD

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

3

4

1

2

5

6

J8

1 2 3 4 5

COLOR

CHANGE

MODULE 1

(COLORS

1 THRU 8)

J9

6

3

4

1

2

5

6

J15 J16

4

3

6

5

2

1

4

3

6

5

2

1

3

4

1

2

5

6

J14 J10

1 2 3 4 5

4

3

6

5

2

1

*FLUSH

COLOR 9

COLOR 10

COLOR 11

COLOR 12

COLOR 13

COLOR 14

COLOR 15

COLOR 16

MANIFOLD

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

3

4

1

2

5

6

J8

1 2 3 4 5

COLOR

CHANGE

MODULE 2

(COLORS

9 THRU 16)

J9

6

3

4

1

2

5

6

J15 J16

4

3

6

5

2

1

4

3

6

5

2

1

3

4

1

2

5

6

J14 J10

1 2 3 4 5

4

3

6

5

2

1

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

MANIFOLD

DUMP

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

MANIFOLD

DUMP*

COLOR 9

COLOR 10

COLOR 11

COLOR 12

COLOR 13

COLOR 14

COLOR 15

COLOR 16

*FLUSH

COLOR 17

COLOR 18

COLOR 19

COLOR 20

COLOR 21

COLOR 22

COLOR 23

COLOR 24

MANIFOLD

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

3

4

1

2

5

6

1 2 3 4 5

COLOR

CHANGE

MODULE 3

(COLORS

17 THRU 24)

J8

3

4

1

2

5

6

J15

6

J9

J16 4

3

6

5

2

1

4

3

6

5

2

1

3

4

1

2

5

6

J14

5 4 3 2

J10

4

3

6

5

2

1

1

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

MANIFOLD

DUMP*

COLOR 17

COLOR 18

COLOR 19

COLOR 20

COLOR 21

COLOR 22

COLOR 23

COLOR 24

FLUSH

CATALYST 1

CATALYST 2

CATALYST 3

CATALYST 4

MANIFOLD

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

3

4

1

2

5

6

J8

CATALYST

CHANGE

MODULE 5

(CATALYST

1 THRU 4)

J9

6

4

3

6

5

2

1

3

4

1

2

5

6

J15 J16 4

3

6

5

2

1

3

4

1

2

5

6

J14 J10

1 2 3 4 5

4

3

6

5

2

1

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

MANIFOLD

DUMP

CATALYST 1

CATALYST 2

CATALYST 3

CATALYST 4

*FLUSH

COLOR 25

COLOR 26

COLOR 27

COLOR 28

COLOR 29

COLOR 30

MANIFOLD

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

3

4

1

2

5

6

1 2 3 4 5

COLOR

CHANGE

MODULE 4

(COLORS

25 THRU 32)

J8 J9

6

3

4

1

2

5

6

J15 J16 4

3

6

5

2

1

4

3

6

5

2

1

3

4

1

2

5

6

J14 J10

1 2 3 4 5

4

3

6

5

2

1

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

UNUSED

UNUSED

UNUSED

UNUSED

MANIFOLD

DUMP*

COLOR 25

COLOR 26

COLOR 27

COLOR 28

COLOR 29

COLOR 30

2

CABLE (15V206)

Figure 18 Electrical Schematic, Sheet 3

* May be unused in some configurations.

CONTINUED ON THE NEXT PAGE

333282B 39

Electrical Schematics

FLUSH

CATALYST 3

CATALYST 4

MANIFOLD

+12VDC

COM

+12VDC

COM

+12VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

4

5

6

1

2

3

4

1

2

J8

CATALYST

CHANGE

MODULE 6

(CATALYST

3 THRU 4)

J9

J15

6

J16

2

1

5

4

4

3

6

5

4

5

6

1

2

J14 J10

1 2 3 4 5

4

3

6

5

COM

+12VDC

+12VDC

COM

+12VDC

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

MANIFOLD

DUMP

CATALYST 3

CATALYST 4

FLUSH

CATALYST 1

CATALYST 2

MANIFOLD

+12VDC

COM

+12VDC

COM

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

4

5

6

1

2

4

5

6

1

2

J8

5 4 3 2 1

CATALYST

CHANGE

MODULE 5

(CATALYST

1 THRU 2)

J9

6

4

3

6

5

2

1

J15 J16 4

3

6

5

4

5

2

3

6

J14 J10

1 2 3 4 5

4

3

6

5

+12VDC

COM

COM

+12VDC

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

MANIFOLD

DUMP

CATALYST 1

CATALYST 2

Figure 19 Electrical Schematic, Sheet 3, Alternate

Configuration for Catalyst Change Control

CONTINUED ON THE NEXT PAGE

1 2 3 4 5

COLOR

CHANGE

MODULE 4

(COLORS

25 THRU 32)

40 333282B

Electrical Schematics

FROM CAN IS BOARD (24M485) ON PAGE 2

NON-HAZARDOUS LOCATION

HAZARDOUS LOCATION

COLOR FLUSH

COLOR 1

COLOR 2

COLOR 3

COLOR 4

COLOR 5

COLOR 6

COLOR 7

COLOR 8

MANIFOLD

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

4

5

2

3

6

1 2 3 4 5

COLOR

CHANGE

MODULE 7

(COLORS

33 THRU 40)

J8 J9

4

3

6

5

2

1

7

3

4

1

2

5

6

J15 J16

4

3

6

5

3

4

1

2

J14 J10 3

2

5

4

1

1 2 3 4 5

COM

+12VDC

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

MANIFOLD

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

MANIFOLD

+12VDC

COM

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

3

4

1

2

5

6

1 2 3 4 5

COLOR

CHANGE

MODULE 8

(COLORS

41 THRU 48)

J8 J9

7

3

4

1

2

J15 J16

4

3

6

5

2

1

4

3

6

5

2

1

3

4

1

2

5

6

J14

5 4 3 2

J10

1

4

3

6

5

2

1

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

COM

+12VDC

MANIFOLD

COLOR 22

COLOR 23

COLOR 24

COLOR 25

COLOR 26

COLOR 27

COLOR 28

COLOR 29

COLOR 30

5 4 3 2 1

BOOTH CONTROL

(24M731)

Figure 20 Electrical Schematic, Sheet 3, Hazardous

Location

333282B 41

Electrical Schematics

Optional Cables and Modules

NOTE: The total length of all cable used in the system must not exceed 150 ft (45 m). See the

Electrical Schematics, page 36

.

M12 CAN Cables, for Hazardous Locations

NOTE: The total length of cable used in the hazardous location must not exceed 120 ft (36 m).

Cable Part No.

Length ft (m)

16V423

16V424

2.0 (0.6)

3.0 (1.0)

16V425

16V426

16V427

16V428

16V429

16V430

6.0 (2.0)

10.0 (3.0)

15.0 (5.0)

25.0 (8.0)

50.0 (16.0)

100.0 (32.0)

15U531

15U532

15V205

15V206

15V207

15V208

15U533

15V213

M12 CAN Cables, for Non-Hazardous

Locations Only

2.0 (0.6)

3.0 (1.0)

6.0 (2.0)

10.0 (3.0)

15.0 (5.0)

25.0 (8.0)

50.0 (16.0)

100.0 (32.0)

CAN Cables, for Non-Hazardous

Locations Only

Cable Part No.

Length ft (m)

125306 1.0 (0.3)

123422

121000

121227

121001

1.3 (0.4)

1.6 (0.5)

2.0 (0.6)

3.0 (1.0)

121002

121003

120952

121201

121004

121228

5.0 (1.5)

10.0 (3.0)

13.0 (4.0)

20.0 (6.0)

25.0 (8.0)

50.0 (15.0)

16T659

25 Pin D-SUB Cables, for Non-Hazardous

Locations Only

2.5 (0.8)

16V659 6.0 (1.8)

Alternates for Communication Module 24R910, for Non-Hazardous Locations Only

Module Part No.

Module Part No.

CGMDN0*, DeviceNet CGMPB0*, Profibus

CGMEP0*, Ethernet IP CGMPN0*, Profinet

* You must purchase Map Token Kit 17C087 for use with these kits.

Alternates for Color Change Modules by Part Number (Factory Configuration), for

Non-Hazardous Locations Only, see page 61

Module Part No.

Description

24T557 2 color/2 catalyst

24T558

24T559

24T560

4 color/4 catalyst

6 color/6 catalyst

8 color/8 catalyst

Alternates for Color Change Modules by Part

Number (Factory Configuration), for Hazardous

24T571

Locations Only, see page 62

2 color/2 catalyst

24T572 4 color/2 catalyst

24T573

24T574

24T774

24T775

24T776

6 color/2 catalyst

8 color/2 catalyst, 13–24 color

12 color/2 catalyst

4 color/4 catalyst

6 color/4 catalyst

24T777

24T778

24T779

8 color/4 catalyst

12 color/4 catalyst, 13–30 color

13–18 color

42 333282B

Repair

Repair

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

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

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

NOTICE

To avoid damaging the circuit boards, wear Part

No. 112190 grounding strap on your wrist and ground appropriately.

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

Replace a Color Valve

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

Figure 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.

1. Flush and relieve pressure as described in your

PD2K operation manual.

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

Figure 22 Remove the Valve

NOTE: See manual 332454 to repair the valve.

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

5. Return the system to service.

333282B 43

Repair

Replace a Solenoid Replace the Color Change Board

Fuse

1. Remove electrical power from the system.

2. Remove air supply pressure from the system.

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

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

Electrical Schematics, page 36

.

5. Remove the solenoid (310) from the manifold

(309).

6. Install the new solenoid.

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

Electrical Schematics, page 36

.

8. Reinstall the cover.

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

Fuse

F1

Part No.

123690

Description

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.

44 333282B

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.

101

102

103

104

105

106

107

108

109

110

111

114

Part

No.

Description

24U237 BRACKET, mounting

◆ KIT, manifold, valve

100157 SCREW, cap, hex head;

1/4–20 x 0.375 in. (10 mm)

103195 SCREW, cap, hex head;

1/4–20 x 4.0 in. (101 mm)

100016 WASHER, lock; 1/4

100015 NUT, hex; 1/4–20

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

2.5 ft (0.76 m); ptfe

◆ KIT, module, control

15V206 CABLE, CAN; 5–pin female;

10 ft (3.05 m)

16V819 GROMMET, cable

24U236 TOOL, repair, valve (not shown)

◆ TOOL, installation, valve (not shown)

Low Pressure Non-IS Kits

Kit No.

24R915

24R916

24R917

24R918

24R919

24R920

24R921

24R922

Qty

4

4

4

2

1

2

4

1

1

1

1

1

Ref.

No.

115

120

121

122

123

Part

No.

Description

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

OD

222200 REGULATOR, back pressure; used on high pressure kits only (see detail drawing); see manual 307892

113070 NIPPLE; 3/8 npt x 1/4 npt; sst; used on high pressure kits only (see detail drawing)

110290 TEE; 1/4 npt(f); sst; used on high pressure kits only (see detail drawing)

112564 GAUGE, pressure, fluid; used on high pressure kits only (see detail drawing)

Qty

1

2

1

1

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

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)

2 color or 2 catalyst

Low Pressure Non-Circulating Color Change Kits

24T458 24T557 24U239

4 color or 4 catalyst

24T460 24T558 24U239

6 color

8 color

24T462

24T464

24T559

24T560

24U239

24U239

Low Pressure Circulating Color Change Kits

24T488 24T557 24U239 2 color

4 color

6 color

8 color

24T490

24T492

24T494

24T558

24T559

24T560

24U239

24U239

24U239

Tube Length

(115)

60 ft (18.3 m)

120 ft (36.6 m)

210 ft (64.05 m)

360 ft (109.8 m)

60 ft (18.3 m)

120 ft (36.6 m)

210 ft (64.05 m)

360 ft (109.8 m)

333282B 47

Parts

High Pressure Non-IS Kits

Kit No.

24R959

24R960

24R961

24R962

24T579

24T580

24R963

24R964

24R965

24R966

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)

2 color or 2 catalyst

High Pressure Non-Circulating Color Change Kits

24T648 24T557 24U240

4 color or 4 catalyst

24T650 24T558 24U240

6 color

8 color

24T652

24T654

24T559

24T560

24U240

24U240

High Pressure Acid Compatible Non-Circulating Catalyst Change Kits

2 catalyst 24U182 24T557 24U240

4 catalyst

2 color

4 color

6 color

8 color

24U183 24T558 24U240

High Pressure Circulating Color Change Kits

24T678 24T557 24U240

24T680

24T682

24T684

24T558

24T559

24T560

24U240

24U240

24U240

Tube Length

(115)

60 ft (18.3 m)

120 ft (36.6 m)

210 ft (64.05 m)

360 ft (109.8 m)

60 ft (18.3 m)

120 ft (36.6 m)

60 ft (18.3 m)

120 ft (36.6 m)

210 ft (64.05 m)

360 ft (109.8 m)

48 333282B

Notes

Parts

333282B 49

Parts

IS Color Change Kits

103

104

105

106

107

108

109

Ref.

No.

101

Part No.

Description

24V351

24N346

16W564

16W563

16Y954

100015

104429

113469

KIT, manifold, valve; . See

Valve Manifold Kits, page

53

for available kits.

MANIFOLD, mix, remote

HOSE, coupled, 2.5 ft.

HOSE, static mixer

Low Pressure

High Pressure

KIT, module, control

BRACKET, manifold

NUT, hex

SCREW, cap, hex

Low Pressure

High Pressure

1

2

4

4

1

2

1

Qty

2

Ref.

No.

110

111

112

113

114

Part No.

24U236

24R124

24U239

24U240

223547

100016

16V429

Description

TOOL, repair, color change valve, not shown

Low Pressure

High Pressure

TOOL, installation, color change valve, not shown

Low Pressure

High Pressure

WIRE, assembly, 25 ft.

WASHER, lock

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

Qty

1

1

2

4

1

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

50 333282B

Parts

24V157

24V158

24V159

24V160

24V161

24V162

24V331

24V332

24V333

24V334

24V335

24V343

24V344

24V345

24V346

24V337

24V338

24V339

24V340

24V347

24V348

24V349

24V350

24V166

24V167

24V308

24V309

24V326

24V327

24V336

Low Pressure IS Kits

Kit No.

Kit Description Standard Valve Manifold Kits (101) [see

Low Pressure Valve

Manifold Kits, page 53

for all available kits]

Low Pressure Non-Circulating Color Change Kits

1 color and 1 catalyst 24T457 (2)

2 colors and 1 catalyst

4 colors and 1 catalyst

6 colors and 1 catalyst

8 colors and 1 catalyst

24T458, 24T457

24T460, 24T457

24T462, 24T457

24T464, 24T457

12 colors and 1 catalyst 24T468, 24T369

2 colors and 2 catalysts 24T458 (2)

4 colors and 2 catalysts 24T460, 24T458

6 colors and 2 catalysts 24T462, 24T458

8 colors and 2 catalysts 24T464, 24T458

12 colors and 2 catalysts 24T468, 24T458

4 colors and 4 catalysts 24T460 (2)

6 colors and 4 catalysts 24T462, 24T460

8 colors and 4 catalysts 24T464, 24T460

12 colors and 4 catalysts 24T468, 24T460

Control Module

Kit (106) [see

IS Color Change Control

Modules, page 66

for parts]

24T571

24T571

24T572

24T573

24T574

24T774

24T571

24T572

24T573

24T574

24T774

24T775

24T776

24T777

24T778

Low Pressure Circulating Color Change Kits

1 color and 1 catalyst 24T487 (2)

2 colors and 1 catalyst

4 colors and 1 catalyst

6 colors and 1 catalyst

8 colors and 1 catalyst

24T488, 24T487

24T490, 24T487

24T492, 24T487

24T494, 24T487

12 colors and 1 catalyst 24T498, 24T487

2 colors and 2 catalysts 24T488 (2)

4 colors and 2 catalysts 24T490, 24T488

6 colors and 2 catalysts 24T492, 24T488

8 colors and 2 catalysts 24T494, 24T488

12 colors and 2 catalysts 24T498, 24T488

4 colors and 4 catalysts 24T490 (2)

6 colors and 4 catalysts 24T492, 24T490

8 colors and 4 catalysts 24T494, 24T490

12 colors and 4 catalysts 24T498, 24T490

24T571

24T571

24T572

24T573

24T574

24T774

24T571

24T572

24T573

24T574

24T774

24T775

24T776

24T777

24T778

333282B 51

Parts

24V359

24V360

24V361

24V362

24V363

24V364

24V381

24V382

24V383

24V384

24V385

24V396

24V397

24V398

24V399

24V390

24V391

24V392

24V393

24V402

24V403

24V404

24V405

24V369

24V370

24V371

24V372

24V373

24V374

24V389

High Pressure IS Kits

Kit No.

Kit Description Standard Valve Manifold Kits (101) [see

Low Pressure Valve

Manifold Kits, page 53

for all available kits]

High Pressure Non-Circulating Color Change Kits

1 color and 1 catalyst 24T647 (2)

2 colors and 1 catalyst

4 colors and 1 catalyst

6 colors and 1 catalyst

8 colors and 1 catalyst

24T648, 24T647

24T650, 24T647

24T652, 24T647

24T654, 24T647

12 colors and 1 catalyst 24T658, 24T647

2 colors and 2 catalysts 24T648 (2)

4 colors and 2 catalysts 24T650, 24T648

6 colors and 2 catalysts 24T652, 24T648

8 colors and 2 catalysts 24T654, 24T648

12 colors and 2 catalysts 24T658, 24T648

4 colors and 4 catalysts 24T650 (2)

6 colors and 4 catalysts 24T652, 24T650

8 colors and 4 catalysts 24T654, 24T650

12 colors and 4 catalysts 24T658, 24T650

Control Module

Kit (106) [see

IS Color Change Control

Modules, page 66

for parts]

24T571

24T571

24T572

24T573

24T574

24T774

24T571

24T572

24T573

24T574

24T774

24T775

24T776

24T777

24T778

High Pressure Circulating Color Change Kits

1 color and 1 catalyst 24T677(2)

2 colors and 1 catalyst

4 colors and 1 catalyst

6 colors and 1 catalyst

8 colors and 1 catalyst

24T678, 24T677

24T680, 24T677

24T682, 24T677

24T684, 24T677

12 colors and 1 catalyst 24T688, 24T677

2 colors and 2 catalysts 24T678 (2)

4 colors and 2 catalysts

6 colors and 2 catalysts

8 colors and 2 catalysts

24T680, 24T678

24T682, 24T678

24T684, 24T678

12 colors and 2 catalysts 24T688, 24T678

4 colors and 4 catalysts 24T680 (2)

6 colors and 4 catalysts

8 colors and 4 catalysts

24T682, 24T680

24T684, 24T680

12 colors and 4 catalysts 24T688, 24T680

24T571

24T571

24T572

24T573

24T574

24T774

24T571

24T572

24T573

24T574

24T774

24T775

24T776

24T777

24T778

52 333282B

Parts

Valve Manifold Kits

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

Low Pressure Valve Manifold Kits

Non-Circulating Valve Manifold Kits

24T467

24T468

24T469

24T470

24T471

24T472

24T473

24T474

24T475

24T476

Kit No.

24T457

24T458

24T459

24T460

24T461

24T462

24T463

24T464

24T465

24T466

24T477

24T478

24T479

24T480

24T481

24T482

24T483

24T484

24T485

24T486

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

Series

A

A

A

A

A

A

A

A

A

A

A

22 valves

23 valves

24 valves

25 valves

26 valves

27 valves

28 valves

29 valves

30 valves

31 valves

12 valves

13 valves

14 valves

15 valves

16 valves

17 valves

18 valves

19 valves

20 valves

21 valves

Kit Description

2 valves

3 valves

4 valves

5 valves

6 valves

7 valves

8 valves

9 valves

10 valves

11 valves

Circulating Valve Manifold Kits

24T497

24T498

24T499

24T500

24T501

24T502

24T503

24T504

24T505

24T506

Kit No.

24T487

24T488

24T489

24T490

24T491

24T492

24T493

24T494

24T495

24T496

24T507

24T508

24T509

24T510

24T511

24T512

24T513

24T514

24T515

24T516

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

Series

A

A

A

A

A

A

A

A

A

A

A

22 valves

23 valves

24 valves

25 valves

26 valves

27 valves

28 valves

29 valves

30 valves

31 valves

12 valves

13 valves

14 valves

15 valves

16 valves

17 valves

18 valves

19 valves

20 valves

21 valves

Kit Description

2 valves

3 valves

4 valves

5 valves

6 valves

7 valves

8 valves

9 valves

10 valves

11 valves

333282B 53

Parts

Valve Manifold Kit Parts

54 333282B

Parts

1

2

3

Ref.

No.

6

7

4

5

8

9

10

Part No.

16P259

111450

24T441

24T442

24R051

16N256

111457

24T521

24T522

157974

104092

Description

MANIFOLD

O-RING; chemically resistant

VALVE, for non-circulating kits; includes item 2

VALVE, for circulating kits; includes item 2

PLUG, cc valve

RETAINER, nut

O-RING; ptfe

PLATE, outlet, manifold

PLATE, end, manifold

WASHER, plain

SCREW, cap, socket head;

10–24 x 0.625 in. (16 mm)

NUT, hex; 10–24

Qty

Ref.

No.

12

13

14

15

16

17

18

19

Part No.

104893

24T523

111328

24T525

24T524

111504

557716

104644

Description

O-RING; ptfe

FITTING, fluid; 7/16–20 x 1/4 npt(m)

CONNECTOR, tube;

10–32(m) x 5/32 in. (4 mm) OD tube

ROD, connecting; 3 in. (76 mm)

ROD, connecting; 1.5 in. (38 mm)

O-RING; chemically resistant

PLUG; 7/16–20

PLUG, screw; 10–32 x 0.156

in. (4 mm)

Qty

11 100179

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

2

2

3

3

1

1

6

7

7

8

8

9

9

10

10

4

4

5

5

6

Low Pressure Non-Circulating Valve Manifold Kit Part Quantities

Kit No.

24T469

24T470

24T471

24T472

24T473

24T474

24T475

24T457

24T458

24T459

24T460

24T461

24T462

24T463

24T464

24T465

24T466

24T467

24T468

2

2

3

2

4 3 1

4

6

6

8

4

5

6

7

8 8

10 9

10 10 0

12 11 1

12 12 0

14 13 1

0

1

0

1

0

1

14 14 0

16 15 1

16 16 0

18 17 1

18 18 0

20 19 1

20 20 0

4

0

5

2

6

2

4 3 1

4

6

6

8

8 5

10 6

10 6

12 7

12 7

14 8

3

4

4

5

14 8

16 9

16 9 1

18 10 1

1

1

18 10 1

20 11 1

20 11 1

1

1

1

1

1

1

1

1

1

1

7

1

Reference Numbers

8 10 12 13 14 15 16 17 18 19

1 3 3 3 2 0 3 1 2 0

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

4 4 3 3 0

5

6

7

8

5

6

7

8

4

5

6

7

3

9 9 8

10 10 9

11 11 10 6

12 12 11 9

13 13 12 9

14 14 13 9

6

6

3

3

6

15 15 14 9 3

16 16 15 12 0

17 17 16 12 0

18 18 17 12 3

19 19 18 12 3

20 20 19 15 0

21 21 20 15 0

3

0

0

3

0

3

0

3

3

0

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

5 2

14 0

17 2

16 0

19 2

18 0

21 2

20 0

4

7

6

9

8 0

11 2

10 0

13 2

12 0

15 2

0

2

0

2

333282B 55

Parts

Kit No.

24T476

24T477

24T478

24T479

24T480

24T481

24T482

24T483

24T484

24T485

24T486

12

13

13

14

14

15

15

16

1

11

11

12

2 3 4

22 21 1

22 22 0

24 23 1

24 24 0

26 25 1

26 26 0

28 27 1

28 28 0

30 29 1

30 30 0

32 31 1

5 6 7

22 12 1

22 12 1

24 13 1

24 13 1

26 14 1

26 14 1

28 15 1

28 15 1

30 16 1

30 16 1

32 17 1

Reference Numbers

1

1

1

1

1

1

1

1

8

1

1

1

3

3

3

3

3

3

3

3

3

3

10 12 13 14 15 16 17 18 19

3 22 22 21 15 3 1 23 2

23 23 22 15 3

24 24 23 18 0

1

1

22 0

25 2

25

26

27

28

29

30

31

32

25

26

27

28

29

30

31

32

24

25

26

27

28

29

30

31

18

18

18

21

21

21

21

24

0

3

3

0

0

3

3

0

1

1

1

1

1

1

1

1

24

27

26

29

28

31

30

33

0

2

0

2

0

2

0

2

56 333282B

Parts

2

2

3

3

1

1

10

11

11

12

12

13

13

8

9

7

8

9

10

14

14

15

15

16

5

6

6

7

4

4

5

Low Pressure Circulating Valve Manifold Kit Part Quantities

Kit No.

24T500

24T501

24T502

24T503

24T504

24T505

24T506

24T507

24T508

24T509

24T510

24T511

24T512

24T513

24T514

24T515

24T516

24T487

24T488

24T489

24T490

24T491

24T492

24T493

24T494

24T495

24T496

24T497

24T498

24T499

2

2

3

2

4 3 1

4

6

6

8

4

5

6

7

8 8

10 9

10 10 0

12 11 1

12 12 0

14 13 1

14 14 0

0

1

0

1

0

1

16 15 1

16 16 0

18 17 1

18 18 0

20 19 1

20 20 0

22 21 1

22 22 0

24 23 1

24 24 0

26 25 1

26 26 0

28 27 1

28 28 0

30 29 1

30 30 0

32 31 1

4

0

5

2

6

2

4 3 1

20 11 1

22 12 1

22 12 1

24 13 1

24 13 1

26 14 1

26 14 1

28 15 1

28 15 1

30 16 1

30 16 1

32 17 1

4

6

6

8

3

4

4

5

8

10

5

6

10 6

12 7

12 7

14 8

14 8

16 9 1

16 9 1

18 10 1

18 10 1

20 11 1

1

1

1

1

1

1

1

1

1

1

1

7

1

Reference Numbers

8 10 12 13 14 15 16 17 18 19

1 3 5 5 2 0 3 1 0 0

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

7 7 3 3 0 1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

9

11

13

15

9

11

13

15

4

5

6

7

3

17 17 8

19 19 9

21 21 10 6

23 23 11 9

25 25 12 9

27 27 13 9

29 29 14 9

3

3

6

6

6

31 31 15 12 0

33 33 16 12 0

35 35 17 12 3

37 37 18 12 3

39 39 19 15 0

3

0

0

0

3

3

3

0

3

3

0

41 41 20 15 0

43 43 21 15 3

45 45 22 15 3

47 47 23 18 0

49 49 24 18 0

51 51 25 18 3

53 53 26 18 3

55 55 27 21 0

57 57 28 21 0

59 59 29 21 3

61 61 30 21 3

63 63 31 24 0

2

0

2

0

2

0

2

0

2

0

2

0

2

0

2

2

0

2

0

2

0

0

2

2

0

0

2

0

2

2

0

2

0

2

0

2

0

2

0

2

0

2

0

2

2

0

2

0

2

0

0

2

2

0

0

2

0

2

333282B 57

Parts

High Pressure Valve Manifold Kits

Non-Circulating Valve Manifold Kits

24T656

24T657

24T658

24T659

24T660

24T661

24T662

24T663

24T664

24T665

Kit No.

24T647

24T648

24T649

24T650

24T651

24T652

24T653

24T654

24T655

24T666

24T667

24T668

24T669

24T670

24T671

24T672

24T673

24T674

24T675

24T676

24T845 (acidcatalyzed)

24T846 (acidcatalyzed)

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

Series

A

A

A

A

A

A

A

A

A

A

A

A

A

A

21 valves

22 valves

23 valves

24 valves

25 valves

26 valves

27 valves

28 valves

29 valves

30 valves

31 valves

3 valves

11 valves

12 valves

13 valves

14 valves

15 valves

16 valves

17 valves

18 valves

19 valves

20 valves

Kit Description

2 valves

3 valves

4 valves

5 valves

6 valves

7 valves

8 valves

9 valves

10 valves

5 valves

Circulating Valve Manifold Kits

24T686

24T687

24T688

24T689

24T690

24T691

24T692

24T693

24T694

24T695

Kit No.

24T677

24T678

24T679

24T680

24T681

24T682

24T683

24T684

24T685

24T696

24T697

24T698

24T699

24T700

24T701

24T702

24T703

24T704

24T705

24T706

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

Series

A

A

A

A

A

A

A

A

A

A

A

A

A

21 valves

22 valves

23 valves

24 valves

25 valves

26 valves

27 valves

28 valves

29 valves

30 valves

31 valves

11 valves

12 valves

13 valves

14 valves

15 valves

16 valves

17 valves

18 valves

19 valves

20 valves

Kit Description

2 valves

3 valves

4 valves

5 valves

6 valves

7 valves

8 valves

9 valves

10 valves

58 333282B

Valve Manifold Kit Parts

Parts

333282B 59

Parts

Ref.

No.

1

2

3

4

5

6

7

8

10

12

Part No.

Description

16N271

111450 O-RING; chemically resistant

24T581 VALVE, for non-circulating kits; includes item 2

24T582

MANIFOLD, for circulating kits

24T583

24R052

16N269

111457

24T725

24T726

111820

104893

VALVE, for circulating kits; includes item 2

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

PLUG, cc valve

RETAINER, nut

O-RING; ptfe

PLATE, outlet, manifold

PLATE, end, manifold

SCREW, cap, socket head;

10–24 x 0.75 in. (19 mm)

O-RING; ptfe

Qty

Ref.

No.

13

14

15

16

18

19

Part No.

24T523

111328

24T729

24T728

557716

104644

Description

FITTING, fluid; 7/16–20 x

1/4 npt(m)

CONNECTOR, tube;

10–32(m) x 5/32 in. (4 mm) OD tube

ROD, connecting; 3.290 in.

(84 mm)

ROD, connecting; 1.645 in.

(42 mm)

PLUG; 7/16–20

PLUG, screw; 10–32 x 0.156

in. (4 mm)

Qty

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

2

2

3

3

1

1

8

8

9

6

7

7

4

4

5

5

6

High Pressure Non-Circulating Valve Manifold Kit Part Quantities

Kit No.

24T647

24T648

24T649

24T650

24T651

24T652

24T653

24T654

24T655

24T656

24T657

24T658

24T659

24T660

24T661

24T662

2

2

3

2

4 3 1

4

6

6

8

4

5

6

7

8 8

10 9

10 10 0

12 11 1

12 12 0

14 13 1

14 14 0

0

1

16 15 1

16 16 0

18 17 1

0

1

0

1

4

0

5

2

6

2

4 3 1

4

6

6

8

3

4

4

5

8

10

5

6

10 6

12 7

12 7

14 8

14 8

16 9 1

16 9 1

18 10 1

1

1

1

1

1

1

1

1

1

1

1

7

Reference Numbers

8 10 12

1 1 3 3

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

13

3

14 15

2 0

4 4 3 1

5

6

7

8

5

6

7

8

4

5

6

7

1

9 9 8

10 10 9

11 11 10 2

12 12 11 3

13 13 12 3

14 14 13 3

15 15 14 3

1

1

2

2

2

16 16 15 4

17 17 16 4

18 18 17 4

0

1

0

0

0

1

1

1

0

0

1

0

1

1

0

16

1

1

0

1

0

0

1

1

0

1

0

1

0

1

0

1

18

0

2

0

2

0

0

2

2

0

2

0

2

0

2

0

2

19

0

60 333282B

Kit No.

24T672

24T673

24T674

24T675

24T676

24T845

24T846

24T663

24T664

24T665

24T666

24T667

24T668

24T669

24T670

24T671

Parts

13

14

14

15

15

16

2

3

11

11

12

12

13

1

9

10

10

2 3 4

18 18 0

20 19 1

20 20 0

22 21 1

22 22 0

24 23 1

24 24 0

26 25 1

26 26 0

28 27 1

28 28 0

30 29 1

30 30 0

32 31 1

4 3 1

6 5 1

5 6 7

18 10 1

20 11 1

20 11 1

22 12 1

22 12 1

24 13 1

24 13 1

26 14 1

26 14 1

28 15 1

28 15 1

30 16 1

30 16 1

32 17 1

4 3 1

6 4 1

Reference Numbers

1

1

1

1

1

1

1

1

1

1

1

1

1

8

1

1

1

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

10

3

12 13 14 15 16

19 19 18 4 1

20 20 19 5

21 21 20 5

0

0

22 22 21 5

23 23 22 5

24 24 23 6

25 25 24 6

26 26 25 6

27 27 26 6

0

0

1

1

1

1

28 28 27 7

29 29 28 7

30 30 29 7

31 31 30 7

32 32 31 8

4 4 3 1

6 6 5 1

0

0

1

0

0

1

1

2

2

2

2

0

2

0

2

0

2

0

2

0

2

0

19

0

1

1

1

1

0

1

0

1

0

1

0

1

0

1

0

18

0

333282B 61

Parts

24T690

24T691

24T692

24T693

24T694

24T695

24T696

24T697

24T698

24T699

24T700

24T701

24T702

24T703

24T704

24T705

24T706

24T677

24T678

24T679

24T680

24T681

24T682

24T683

24T684

24T685

24T686

24T687

24T688

24T689

2

2

3

2

4 3 1

4

6

6

8

4

5

6

7

8 8

10 9

10 10 0

12 11 1

12 12 0

14 13 1

14 14 0

0

1

0

1

0

1

16 15 1

16 16 0

18 17 1

18 18 0

20 19 1

20 20 0

22 21 1

22 22 0

24 23 1

24 24 0

26 25 1

26 26 0

28 27 1

28 28 0

30 29 1

30 30 0

32 31 1

4

0

2

2

3

3

1

1

10

11

11

12

12

13

13

8

9

7

8

9

10

14

14

15

15

16

5

6

6

7

4

4

5

High Pressure Circulating Valve Manifold Kit Part Quantities

Kit No.

5

2

6

2

7

Reference Numbers

8 10 12

1 1 3 5

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

3

4 3 1

20 11 1

22 12 1

22 12 1

24 13 1

24 13 1

26 14 1

26 14 1

28 15 1

28 15 1

30 16 1

30 16 1

32 17 1

4

6

6

8

3

4

4

5

8

10

5

6

10 6

12 7

12 7

14 8

14 8

16 9 1

16 9 1

18 10 1

18 10 1

20 11 1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

13

5

14

2

7 7 3 1

9

11

13

15

9

11

13

15

4

5

6

7

1

17 17 8

19 19 9

21 21 10 2

23 23 11 3

25 25 12 3

27 27 13 3

29 29 14 3

1

1

2

2

2

31 31 15 4

33 33 16 4

35 35 17 4

37 37 18 4

39 39 19 5

41 41 20 5

43 43 21 5

45 45 22 5

47 47 23 6

49 49 24 6

51 51 25 6

53 53 26 6

55 55 27 7

57 57 28 7

59 59 29 7

61 61 30 7

63 63 31 8

15

0

2

0

2

0

2

0

2

0

2

0

2

0

2

0

2

2

0

2

0

2

0

0

2

2

0

0

2

0

2

19

0

0

0

1

1

0

0

0

0

1

1

0

1

0

0

1

1

1

0

1

0

0

0

1

1

1

0

1

1

0

16 18

1 0

2

0

2

0

2

0

2

0

2

0

2

0

2

0

2

2

0

2

0

2

0

0

2

2

0

0

2

0

2

62 333282B

Notes

Parts

333282B 63

Parts

Color Change Control Module Kits

Non-IS Color Change Control Modules

64 333282B

Parts

304

305

307

308

Ref.

No.

Part

No.

Description

— — — PANEL 301

302 24T566 BOARD, circuit

302a 123690 FUSE; 125 mA

303 112324 SCREW, machine, pan head;

4–40 x 0.25 in. (6 mm)

309

310

311

312

313

314

315

24T562 COVER

119162

116343

123691

CONNECTOR, 6–position

SCREW, ground; M5 x 0.8

HOLDER, fuse

24T563 MANIFOLD

16P316 SOLENOID

117831 SCREW, machine, pan head;

6–32 x 0.5 in. (13 mm)

103833 SCREW, machine, pan head;

10–32 x 0.375 in. (10 mm)

24T565 PLUG; 5/8–32; includes item

314

113418 O-RING; buna-N

100139 PLUG, pipe; 1/8 npt

Qty

1

1

1

2

4

1

6

1

1

8

14

3

Ref.

No.

316

317

318

319

320

321

322

324

332

Part

No.

Description

C06061 MUFFLER

115671 FITTING, connector; 1/8 npt(m) x 1/4 in. (6 mm) OD tube

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

(6 mm) OD tube

590332 TUBE; polyethylene; 1/4 in. (6 mm) OD

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

OD

— — — STRAP, tie

— — — FERRULE

114263 FITTING, connector; 1/8 npt(m) x 5/32 in. (4 mm) OD tube

151395 WASHER

Qty

2

1

2

1

1

4

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

Parts labeled — — — are not available separately.

Non-IS Control Module Part Quantities

Find your module kit no. in the left column and the desired reference number in the top row to find the part quantity used in your control module kit.

Kit No.

24T557

24T558

24T559

24T560

Kit

Description

2 color

4 color

6 color

8 color

6

6

2

4

6–Position

Connector

(305)

Solenoid

(310)

6

10

14

18

Plug (313) Tie Strap

(321)

12

8

4

0

4

4

4

4

Ferrule

(322)

12

20

28

36

Connector

Fitting

(324)

6

10

14

18

333282B 65

Parts

IS Color Change Control Modules

66 333282B

Parts

304

305

307

308

Ref.

No.

Part

No.

Description

— — — PANEL 301

302 24T566 BOARD, circuit

302a 123690 FUSE; 125 mA

303 112324 SCREW, machine, pan head;

4–40 x 0.25 in. (6 mm)

309

310

311

312

24U567 COVER

119162

116343

123691

CONNECTOR, 6–position

SCREW, ground; M5 x 0.8

HOLDER, fuse

15T636 MANIFOLD

121324 SOLENOID

16M00

7

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

103833 SCREW, machine, pan head;

10–32 x 0.375 in. (10 mm)

313

315

316

317

121628 SCREW, self-sealing; 4–40 x

0.25 in. (6 mm)

100139 PLUG, pipe; 1/8 npt

C06061 MUFFLER

115671 FITTING, connector; 1/8 npt(m) x 1/4 in. (6 mm) OD tube

Qty

1

1

1

6

2

4

1

6

1

1

4

Ref.

No.

318

319

320

321

322

324

331

332

333

334

335

Part

No.

Description

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

(6 mm) OD tube

590332 TUBE; polyethylene; 1/4 in. (6 mm) OD

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

OD

— — — STRAP, tie

— — — FERRULE

109193 ELBOW, connector; 10–32

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

16U743 SPACER

16U744 PLATE, non-conductive

16U745 PLATE, ground

16U746 SCREW, pan-head; 4–40

16W50

1

LABEL, instructions

102794 NUT, hex

101764 WASHER, lock

188773 WASHER, flat

Qty

2

1

1

1

3

6

1

1

2

3

2

1

339

340

341

7

7

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 in the top row to find the part quantity used in your control module kit.

Kit No.

24T571

24T572

24T573

24T574

24T774

24T775

Kit

Description

2 color and 2 catalyst

4 color and 2 catalyst

6 color and 2 catalyst

8 color and 2 catalyst

12 color and

2 catalyst;

13–24 color

4 color and 4 catalyst

Solenoid

(310)

6

8

10

12

16

10

Plug (313)

24

20

16

12

4

16

Tube (320) Ferrule (322) Connector

Fitting (324)

30 ft (9.1 m) 12 6

40 ft (12.2 m) 16

50 ft (15.2 m) 20

60 ft (18.3 m) 24

80 ft (24.4 m) 32

50 ft (15.2 m) 20

8

10

12

16

10

333282B 67

Parts

Kit No.

24T776

24T777

24T778

24T779

Kit

Description

6 color and 4 catalyst

8 color and 4 catalyst

12 color and

4 catalyst;

13–30 color

14

18

13–18 color 6

Solenoid

(310)

12

8

0

Plug (313)

12

Tube (320) Ferrule (322) Connector

Fitting (324)

60 ft (18.3 m) 24 12

70 ft (21.3 m) 28

90 ft (27.4 m) 36

14

18

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 High Pressure Expansion Kits

Kit No.

Without Manifold

24T443

Kit Description Kit No.

Without Manifold

24T584

Kit Description

24T444

One non-circulating valve

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

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

24T585

One non-circulating valve

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

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

With Manifold

24T445

With Manifold

24T586

24T446

24T447

24T448

Manifold with one non-circulating valve. Includes valve, plug, solenoid, fittings, and tubing.

Manifold with one circulating valve.

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

Manifold with two non-circulating valves. Includes valves, solenoids, fittings, and tubing.

Manifold with two circulating valves. Includes valves, solenoids, fittings, and tubing.

24T587

24T588

24T589

Manifold with one non-circulating valve. Includes valve, plug, solenoid, fittings, and tubing.

Manifold with one circulating valve.

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

Manifold with two non-circulating valves. Includes valves, solenoids, fittings, and tubing.

Manifold with two circulating valves. Includes valves, solenoids, fittings, and tubing.

High Pressure Acid-Compatible Expansion Kits

Kit No.

Without Manifold

24T590

Kit Description

One non-circulating acidcompatible valve (replaces a plug). Includes valve, solenoid, fittings, and tubing.

With Manifold

24T591

24T592

Manifold with one non-circulating acid-compatible valve. Includes valve, plug, solenoid, fittings, and tubing.

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 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 High Pressure Expansion Kits

Kit No.

Without Manifold

24T449

Kit Description Kit No.

Without Manifold

24T712

Kit Description

24T450

One non-circulating valve

(replaces a plug). Includes valve,

IS solenoid, fittings, and tubing.

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

24T713

One non-circulating valve

(replaces a plug). Includes valve,

IS solenoid, fittings, and tubing.

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

With Manifold

24T451

With Manifold

24T714

24T452

24T453

24T454

Manifold with one non-circulating valve. Includes valve, plug, IS solenoid, fittings, and tubing.

Manifold with one circulating valve.

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

Manifold with two non-circulating valves. Includes valves, IS solenoids, fittings, and tubing.

Manifold with two circulating valves. Includes valves, IS solenoids, fittings, and tubing.

24T715

24T716

24T717

Manifold with one non-circulating valve. Includes valve, plug, IS solenoid, fittings, and tubing.

Manifold with one circulating valve.

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

Manifold with two non-circulating valves. Includes valves, IS solenoids, fittings, and tubing.

Manifold with two circulating valves. Includes valves, IS solenoids, fittings, and tubing.

High Pressure Acid-Compatible Expansion Kits

Kit No.

Without Manifold

24T718

Kit Description

One non-circulating acidcompatible valve (replaces a plug). Includes valve, IS solenoid, fittings, and tubing.

With Manifold

24T719

24T720

Manifold with one non-circulating acid-compatible valve. Includes valve, plug, IS solenoid, fittings, and tubing.

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

A

11.30 in. (1478 mm)

B

7.67 in. (195 mm)

C D

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

E F

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

Figure 25 IS Control Module

A

16.57 in. (421 mm)

B

8.22 in. (209 mm)

C

15.07 in. (383 mm)

D

6.70 in. (170 mm)

E F

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

333282B 71

Dimensions

Figure 26 Manifold Mounting Bracket, Non-IS T

3.84 in. (98 mm)

U

11.44 in. (291 mm)

V

0.312 in. (8 mm) diameter

72 333282B

Dimensions

Figure 27 IS Valve Manifold Bracket

A

5.63 in (168 mm)

B C D E

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

F

0.65 in. (17 mm)

G H J K L M

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

N

4 x 0.28 in (7 mm)

P

2 x 0.41 in (10 mm)

333282B 73

Dimensions

Figure 28 Remote Mix Manifold Bracket

A B C D E F

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

G

1.25 in (32 mm)

H

0.11 (3 mm)

J

4 x 0.22 in (6 mm)

K

2 x 0.41 (10 mm)

74 333282B

Technical Data

Technical Data

Color Change Kits

Maximum fluid working pressure:

Low pressure kits

High pressure kits

Maximum working air pressure:

Air supply:

Viscosity range of fluid:

Fluid inlet size:

Fluid outlet size:

Air inlet size:

Wetted parts:

U.S.

300 psi

1500 psi

100 psi

85–100 psi

5/32 in. OD tube

Metric

2.1 MPa, 21 bar

10.5 MPa, 105 bar

0.7 MPa, 7.0 bar

0.6–0.7 MPa, 6.0–7.0 bar

20–5000 centipoise

1/4 npt(f)

1/4 npt(f)

4 mm OD tube

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

Valve See valve manual 332454.

333282B 75

Graco Standard Warranty

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.

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 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.

free of charge any defective parts. The equipment will be returned to the original purchaser transportation made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost

Any action for breach of warranty must be brought within two (2) years of the date of sale.

FOR GRACO CANADA CUSTOMERS drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

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

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

To place an order, contact your Graco Distributor or call to identify the nearest distributor.

Phone: 612-623-6921 or Toll Free: 1-800-328-0211 Fax: 612-378-3505

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

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

Original Instructions. This manual contains English. MM 333282

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

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

Copyright 2014, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revision B, September 2014

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